Mercedes Mbe 4000 Manual DDC SVC Man 0056

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
To the Operator experienced, trained personnel

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

DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATION
ii All information subject to change without notice. (Rev. 04/08)
TABLE OF CONTENTS
CAUTION SUMMARY .......................................................................... 1

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

TABLE OF CONTENTS
STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR A

LONG TIME ................................................................................. 26
MONITORING ENGINE OPERATION ............................................. 27
BATTERY CHARGE .................................................................... 27
OIL PRESSURE .......................................................................... 27
EXCESSIVE IDLING ................................................................... 28
CHANGING THE IDLE SPEED ....................................................... 28
SHUTTING DOWN THE ENGINE ................................................... 28
SHUTTING DOWN AFTER HIGH LOAD OPERATION ............... 28
EMERGENCY RUNNING MODE .................................................... 29
STOP ENGINE OVERRIDE OPTION .............................................. 29
COLD WEATHER OPERATION ...................................................... 30
WINTER FRONTS ....................................................................... 30
CLEANING AND STORAGE ............................................................... 31

CLEANING THE ENGINE ................................................................ 31
HIGH-PRESSURE CLEANING EQUIPMENT ............................. 31
CLEANING THE COOLING SYSTEM ............................................. 31
DEGREASING ............................................................................. 32
STORAGE ........................................................................................ 33
TROUBLESHOOTING ......................................................................... 34
EMERGENCY STARTING ............................................................... 34
TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM .......................................................................................... 34
GENERAL TROUBLESHOOTING ................................................... 35
SERVICE PRODUCTS ......................................................................... 48

DIESEL FUELS ................................................................................ 48
FLOW IMPROVERS .................................................................... 48
KEROSENE ................................................................................. 48
ENGINE OILS .................................................................................. 49
SYNTHETIC OILS ....................................................................... 49
COOLANT ........................................................................................ 50
FULLY-FORMULATED ANTIFREEZE ......................................... 50
WATER ........................................................................................ 50
COOLANT SPECIFICATIONS ..................................................... 51
COOLANT CONCENTRATION ................................................... 51
iv All information subject to change without notice. (Rev. 04/08)

SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY

FORMULATED COOLANT .......................................................... 52
DROPOUT ................................................................................... 52
NON-APPROVED COOLANTS ................................................... 52
RECYCLED ANTIFREEZE .......................................................... 53
CORROSION INHIBITORS ......................................................... 53
DISPOSAL ................................................................................... 54
COLD WEATHER PRODUCTS ....................................................... 54
WINTER-GRADE DIESEL FUEL ................................................. 54
LOW-VISCOSITY ENGINE OIL ................................................... 55
WINTER COOLANT ANTIFREEZE PROTECTION .................... 55
BATTERIES ................................................................................. 55
TECHNICAL DATA .............................................................................. 56

ENGINE DATA ................................................................................. 57
TESTING AND ADJUSTING VALUES ............................................. 58
MAINTENANCE ................................................................................... 60
SCHEDULED INTERVALS .............................................................. 60
MAINTENANCE SCHEDULE TYPES ......................................... 60
SEVERE SERVICE ................................................................. 60
SHORT-HAUL ......................................................................... 61
LONG-HAUL ........................................................................... 61
MAINTENANCE SCHEDULE AND INTERVAL
OPERATIONS ......................................................................... 61
MAINTENANCE INTERVALS .................................................. 61
MAINTENANCE OPERATION SETS ...................................... 61
SCHEDULE USE ......................................................................... 62
MAINTENANCE TABLES ................................................................ 63
REQUIRED MAINTENANCE OPERATIONS ................................... 69
ENGINE INSPECTING ................................................................ 69
VALVE LASH CHECKING AND ADJUSTING ............................. 69
GAINING ACCESS TO THE VALVES ..................................... 69
CHOOSING A METHOD ......................................................... 70
METHOD ONE ........................................................................ 71
METHOD TWO ....................................................................... 72
ADJUSTING VALVE LASH ...................................................... 73
RESTORING THE VEHICLE TO OPERATING CONDITION .. 73
All information subject to change without notice. (Rev. 04/08) v

TABLE OF CONTENTS
FUEL/WATER SEPARATOR PREFILTER ELEMENT

CLEANING .................................................................................. 74
FUEL PRO 382 FUEL/WATER SEPARATOR ELEMENT
REPLACEMENT .......................................................................... 75
MAIN FUEL FILTER ELEMENT CHANGING .............................. 76
ENGINE OIL AND FILTER CHANGING ...................................... 77
OPTIONAL OIL CENTRIFUGE ............................................... 80
COOLANT CONCENTRATION AND INHIBITOR LEVEL
CHECKING .................................................................................. 81
COOLANT INHIBITOR TEST INTERVALS ............................. 82
INHIBITOR LEVEL CHECKING .............................................. 84
COOLANT FLUSHING AND CHANGING ................................... 85
COOLING SYSTEM INSPECTING ............................................. 86
REAR ENGINE POWER TAKE-OFF (REPTO) .......................... 87
REPTO TORSIONAL DAMPER INSPECTION ....................... 87
REPTO TORSIONAL DAMPER CLEANING ........................... 87
CUSTOMER ASSISTANCE ................................................................. 89

WORKING WITH DDC SERVICE OUTLETS .................................. 93
STEP ONE ................................................................................... 93
STEP TWO .................................................................................. 93
STEP THREE .............................................................................. 94
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000

ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS ......... 95
TERMS OF COVERAGE ................................................................. 95
USES ........................................................................................... 95
DEFECTS .................................................................................... 95
REPAIRS ..................................................................................... 95
WARRANTY PERIOD .................................................................. 95
LIKE REPLACEMENT ENGINE .................................................. 96
SERVICE SUPPLIES .................................................................. 96
ENGINE REMOVAL AND REINSTALLATION ............................. 96
THIS WARRANTY DOES NOT COVER: ......................................... 97
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 97
FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000
KILOMETERS .............................................................................. 97
MAINTENANCE ........................................................................... 97
vi All information subject to change without notice. (Rev. 04/08)

INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 97

OTHER LIMITATIONS ................................................................. 97
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE

4000 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE
APPLICATIONS ................................................................................... 99
TERMS OF COVERAGE ................................................................. 99
USES ........................................................................................... 99
DEFECTS .................................................................................... 99
REPAIRS ..................................................................................... 99
WARRANTY PERIOD .................................................................. 99
LIKE REPLACEMENT ENGINE .................................................. 100
SERVICE SUPPLIES .................................................................. 100
ENGINE REMOVAL AND REINSTALLATION ............................. 100
THIS WARRANTY DOES NOT COVER: ......................................... 100
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 100
FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000
KILOMETERS .............................................................................. 100
MAINTENANCE ........................................................................... 101
INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 101
OTHER LIMITATIONS ................................................................. 101
All information subject to change without notice. (Rev. 04/08) vii

TABLE OF CONTENTS
viii All information subject to change without notice. (Rev. 04/08)

CAUTION SUMMARY
The following cautions must be

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

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
HOT OIL
of clothing and jewelry. Tie back
To avoid injury from hot oil, do or contain long hair that could
not operate the engine with the be caught in any moving part
rocker cover(s) removed. causing injury. The hydraulic fan
may start without warning.
PERSONAL INJURY
To avoid injury from slipping and HOT COOLANT
falling, immediately clean up any To avoid scalding from the
spilled liquids. 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
USED ENGINE OIL cap slowly to relieve pressure.
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
2 All information subject to change without notice. (Rev. 04/08)

PERSONAL INJURY FIRE

To avoid injury from the To avoid injury from combustion
projection of tools or other of heated lubricating-oil vapors,
objects that may fall on or behind stop the engine immediately if an
the vibration damper of an oil leak is detected.
engine, always check and remove
these items before starting the
engine.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
PERSONAL INJURY
working on an operating engine.
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
FIRE
prevents contact with rotating
parts. To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.

CAUTION SUMMARY
Electrical System
jump starting an engine, charging a Battery Explosion and Acid Burn
battery, or working with the vehicle To avoid injury from battery
electrical system. 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
PERSONAL INJURY
with battery acid:
To avoid injury from accidental
engine startup while servicing Flush your skin with water.
the engine, disconnect/disable Apply baking soda or lime to
the starting system. help neutralize the acid.
Flush your eyes with water.
Get medical attention

immediately.
Electrical Shock
To avoid injury from electrical
shock, use care when connecting
battery cables. The magnetic ELECTRICAL SHOCK
switch studs are at battery
voltage. To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.

Electrical Shock Hazard

High voltage can remain inside
the Electrostatic Oil Separator
after removal. Wait 30 minutes
after turning off the ignition
before removing the separator.
Never touch parts through
ventilation openings or impeller
opening with finger or conductive
items (e.g. screwdriver or wire).
High voltage can remain inside
the Electrostatic Oil Separator for
up to 12 hours after the ignition
is turned off.

CAUTION SUMMARY
Cooling System Air Intake System

Observe the following cautions when Observe the following cautions when
servicing the cooling system. working on the air intake system.
HOT COOLANT PERSONAL INJURY

To avoid scalding from the To avoid injury from hot surfaces,
expulsion of hot coolant, never wear protective gloves, or allow
remove the cooling system engine to cool before removing
pressure cap while the engine is any component.
cap slowly to relieve pressure.
PERSONAL INJURY
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
PERSONAL INJURY
air inlet screen shield over the
To avoid injury from slipping and turbocharger air inlet. The shield
falling, immediately clean up any prevents contact with rotating
spilled liquids. parts.

Fuel System
fueling the vehicle or working with FIRE
the fuel system. To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
resistance heating elements. Do
PERSONAL INJURY
To avoid injury from fuel spills,
do not overfill the fuel tank.
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
PERSONAL INJURY
To prevent the escape of high
pressure fuel that can penetrate
skin, ensure the engine has
been shut down for a minimum
of 10 minutes before servicing
any component within the high
pressure circuit. Residual high
fuel pressure may be present
within the circuit.

CAUTION SUMMARY
FIRE
To avoid injury from fire caused
by heated diesel-fuel vapors:
Keep those people who are not

directly involved in servicing
away from the engine.
Stop the engine immediately if

a fuel leak is detected.
Do not smoke or allow open

flames when working on an
operating engine.
Wear adequate protective

clothing (face shield,
insulated gloves and apron,
etc.).
To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.

Compressed Air
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 FIRE
pressure.
To avoid injury from fire from a
buildup of volatile vapors, keep
Lubricating Oil and Filters the engine area well ventilated
during operation.
replacing the engine lubricating oil
and filters.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.

IDENTIFICATION
IDENTIFICATION
The MBE 4000 engine is built in Agency (USEPA) and California Air
accordance with sound technological Resources Board (CARB) emission
principles and based on state-of-the-art standards. An emission label is
technology. It complies with all United attached to the cylinder head cover, as
States Environmental Protection required by law. See Figure 1.
Figure 1 Emission Label, MBE 4000

Despite this, the engine may constitute General View of the MBE
a risk of damage to property or 4000 Engine
injury to persons under the following
For a general view of the MBE 4000
conditions:
engine, showing major components,
It is not used for its intended see Figure 2 for the left-hand side, and
purpose. Figure 3 for the right-hand side.
It is modified or converted in an
incorrect manner.
The safety instructions included in
this manual are disregarded.
Personnel Requirements
Work on the engine should be carried
out only by skilled technicians who
have been instructed in the specific
skills necessary for the type of work
being performed.
Engine Conversions and

Modifications
The function and safety of the engine
could be affected if unauthorized
modifications are made to it. Detroit
Diesel will not accept responsibility
for any resulting damage.
Tampering with the fuel injection
system and engine electronics could
also affect the engine's power output or
exhaust emission levels. Compliance
with the manufacturer's settings
and with statutory environmental
protection regulations cannot then be
guaranteed.

IDENTIFICATION
1. EGR Outlet Pipe 8. Engine Trim Cover

2. Coolant Pump 9. Crankcase Breather
3. Thermostat Housing 10. Air Compressor
4. Modulated EGR Valve 11. Fuel Filter Housing
5. EGR Cooler 12. Oil Pan

6. EGR Shutoff Valve (hidden) 13. EGR Mixer
7. Air Intake Manifold 14. Air Conditioning Compressor
Figure 2 Major Engine Components, Left Side

1. Oil Filter 7. EGR Cooler

2. Air Solenoid Valve (Engine Brake) 8. Reed Valve Housing
3. Turbocharger 9. EGR Control Valve
4. EGR Hot Pipe 10. EGR Mixer
5. Exhaust Manifold 11. Alternator
6. EGR Shutoff Valve 12. Belt Tensioner
Figure 3 Major Engine Components, Right Side

IDENTIFICATION
Engine Type Plate

The engine type plate is used to
identify the engine. It is located on the
oil filter housing. See Figure 4.
Figure 5 Engine Type Plate
The last six numbers are the serial

numbers (745111 in see Figure 5).
NOTE:
Figure 4 Location of Engine Type
In addition to the fourteen digit number
Plate
etched on the crankcase, there is a
ten digit number used for warranty
Details on the Plate and service that is found on the
DDEC-ECU label. The ten digit
The engine type reference, OM 460
number is derived from the fourteen
LA, is the production code. The
digit number (see Figure 6).
first three numbers of the engine
serial number are the model number.
See Figure 5.
Figure 6 Engine Serial Number

Engine Features individual cylinder heads are made of

cast iron. The cylinder head gasket is
All MBE 4000 engines are
an adjustment-free seal with rubber
water-cooled, four-stroke,
sealing elements.
direct-injection inline diesel engines.
Each cylinder has a separate fuel The pistons are made of aluminum
injection pump (unit pump) with a alloy with ring carriers and a shallow
short injection line to the injection combustion chamber recess. The
nozzle, which is located in the center pistons are cooled by oil spray nozzles.
of the combustion chamber. The unit
The crankshaft is precision-forged
pumps are attached to the crankcase
with seven main bearings and eight
and are driven from the camshaft.
custom-forged counter weights, and a
Each cylinder has two intake valves
vibration damper at the front end.
and two exhaust valves.
The camshaft is made of
Charge-air cooling and an exhaust gas
induction-hardened steel and has
turbocharger are standard equipment.
seven cam bearings. Each cylinder
The engine has a fully electronic has cams for intake and exhaust valves
control system consisting of a and a unit pump.
DDEC-ECU (Engine Control Unit)
The valves are controlled by roller
and a DDEC-VCU (Vehicle Control
tappets, pushrods, and rocker arms.
Unit) connected by a proprietary
The intake and exhaust valves are
datalink. This system regulates the
opened and closed by a free-floating
injection quantity and timing using
valve bridge.
solenoid valves, allowing extremely
low-emission operation. There is a force-feed lubricating oil
circuit supplied by a gear-type oil
Standard engine braking is controlled
pump. This pump is positioned at the
by a pneumatically-operated
rear of the oil pan and driven by gears
exhaust brake on the turbocharger
from the crankshaft. The oil heat
and by a hydraulically-operated
exchanger is integrated with the oil
constant-throttle system. For greater
filter housing on the right-hand side.
braking power, an optional turbo
brake is available. The gear-type fuel pump is located
near the front of the crankcase on the
The cylinder block has integrated oil
left hand side. The pump is driven
and water channels. The upper section
from the forward end of the camshaft.
of the cylinder bore has a carbon
scraper ring seated in a groove on
the top part of the cylinder. The six

IDENTIFICATION
The air compressor, with a Exhaust

power-steering pump attached, Brake/Constant-Throttle
is driven by a gear on the camshaft. Valves
The engine is cooled by a closed To increase braking performance,
system using recirculated coolant; the engine is equipped with an
temperature is regulated automatically exhaust brake on the turbocharger
by a thermostat. in conjunction with constant-throttle
There are two main drive belts, each valves on the cylinder head.
with its own automatic belt tensioner. See Figure 7.
The alternator and coolant pump NOTE:

(and any other accessories) and the On EGR engines, the constant-throttle
refrigerant compressor are driven by a valves are activated by engine oil
main drive belt. The fan is driven by pressure.
its own drive belt
Electrical equipment includes a starter The exhaust back pressure is used by
and an alternator. the exhaust brake to increase braking
performance.
Figure 7 Constant-Throttle Activation (shown with EGR system removed)

The constant-throttle valves use the engine to provide very high braking
air that escapes through them on the horsepower.
compression stroke to provide braking
The turbo brake can be operated either
force. The constant throttles are small
manually or automatically, through
valves which are built into the cylinder
the cruise control function.
heads. When open, a link is created
between the combustion chamber and Because the charge air pressure is
the exhaust port. maintained at a high level during
braking, full throttle response is
The engine brake is activated by the
available immediately, if the operator
DDEC-VCU. In engine braking mode,
desires it, without any turbo lag.
an engine rpm range of up to 2,500
rpm can be used by the operator. The turbo brake is maintenance-free,
2,500 rpm, however, may never be highly reliable, and adds virtually no
exceeded. The engine is turned off weight to the engine.
automatically when the engine rpm is:
Below 900 rpm for Allison Exhaust Gas Recirculation
Automatic Transmissions The purpose of the Exhaust Gas
Below 1100 rpm for all other Recirculation (EGR) System is to
transmissions reduce engine exhaust gas emissions
in accordance with EPA regulations.
Also, the engine brake is automatically
turned off when the accelerator pedal The MBE 4000 engines for
is pressed. on-highway EPA 2004 regulation
applications use a cooled EGR system
NOTE: consisting of an EGR cooler, EGR
When in emergency running mode control valves, reed valves, and an
(constant rpm), the engine brake can EGR mixer.
be activated only when the engine is In the cooled EGR system, part of the
in overrun. When constant rpm has exhaust gasses from the front three
been attained, the engine brake is cylinders are routed from the exhaust
automatically turned off. manifold through the EGR cooler, past
control and reed valves, and are mixed
Turbo Brake, Optional with the intake manifold charge air.
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

IDENTIFICATION
The addition of cooled exhaust Electronic Engine Control

gasses back into the combustion System
airflow reduces the peak in cylinder
The engine is equipped with a fully
combustion temperature. Less oxides
electronic control system. See Figure
of nitrogen (NOx) are produced at
8.
lower combustion temperatures.
The recycled exhaust gases are cooled
before engine consumption in a tube
and shell engine water cooler.
Figure 8 Electronic Engine Control System
This system is composed of the and the DDEC-VCU (Vehicle Control

DDEC-ECU (Engine Control Unit) 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, the Nexiq
Diagnostic Data Reader (DDR) or
Detroit Diesel Diagnostic Link
(DDDL) PC software.
The DDEC-ECU monitors both Figure 9 DDEC-ECU
the engine and the datalink. When
a malfunction or other problem
These data are evaluated together
is detected, the system selects an
with the data from the sensors on
appropriate response; for example,
the engine, such as coolant and
the emergency running mode may
fuel temperature and oil and charge
be activated. For more information
pressure.
on the emergency running mode,
refer to the Emergency Running The data is then compared to the
Mode section under Operations. characteristic maps or lines stored in
the DDEC-ECU.
DDEC-ECU Engine-Resident From these data, quantity and timing
Control Unit of injection are calculated and the
The DDEC-ECU (see see Figure 9) unit pumps are actuated accordingly
is located on the left-hand side of the through the solenoid valves.
engine.
NOTE:
The DDEC-ECU processes the data To obtain a replacement DDEC-ECU,
received from the DDEC-VCU, for all the data given on the DDEC-ECU
example the position of the accelerator label are required.
pedal, engine brake, etc.
The DDEC-ECU data label has the 10
digit engine serial number (see Figure
6), the engine horse power and torque.

IDENTIFICATION
Vehicle Control Unit and transmitted to the DDEC-ECU via

the proprietary data link.
The DDEC-VCU, see Figure
10, communicates with the other The DDEC-VCU controls
electronic control units installed on various systems, for example,
the vehicle over the J1587 and J1939 communications with the datalink and
data link. the engine brake.
If the engine control system detects
a fault, the appropriate fault code is
broadcast on the datalink and can be
read using minidiag2, the Nexiq DDR
or DDDL PC software. Fault code
information may also be available on
the vehicle or equipment instrument
panel.
Sensor Locations
Use caution when handling the
Figure 10 DDEC-VCU sensors.
Sets of data for specific applications

are stored in the DDEC-VCU
including idle speed, maximum
running speed, and speed limitation. CHEMICAL BURNS
The DDEC-VCU receives data from To avoid injury from chemical

the following sources: burns, wear a face shield and
neoprene or PVC gloves when
The operator (accelerator pedal handling sensor hoses.
position, engine brake switch)
Other electronic control units (the
antilock brake system) The Engine Oil Pressure/Temperature
Sensor is located at the base of the oil
The DDEC-ECU (oil pressure and filter.
coolant temperature)
See Figure 11 for sensor locations on
From these data, instructions are the MBE 4000 engine.
computed for controlling the engine

1. Intake Air Pressure/Temperature 5. Engine Coolant Temperature

Sensor Sensor
2. EGR Temperature Sensor 6. Barometric Pressure Sensor
(Integrated into DDEC-ECU)
3. Camshaft Position Sensor 7. Supply Fuel Temperature Sensor
4. Crankshaft Position Sensor 8. Engine Oil Pressure/Temperature
Sensor
Figure 11 Sensor Location

OPERATION
OPERATION
Important: Before starting the the engine overheats, uses excessive

engine, carefully read all operating fuel or lubricating oil, vibrates,
instructions in this manual and do all misfires, makes unusual noises, or
the recommended pretrip inspections shows an unusual loss of power, turn
and daily maintenance. Check the the engine off as soon as possible and
engine oil and fuel levels, and drain determine the cause of the problem.
contaminants from the fuel/water Engine damage may be avoided by a
separator (optional). quick response to early indications of
problems.
Before Starting the Engine When starting the engine in cold
NOTE: weather, refer to the Service
If you drain the fuel/water separator Products section.
completely, you may have to prime the Checking the Batteries
fuel system. Use only batteries that have been
correctly filled and serviced. To
Be sure you are familiar with all of provide corrosion protection, apply
the instruments, gauges and controls dielectric grease, part number
which are needed to operate the 48-02349-000, liberally to the
engine. terminal pads. Approved suppliers are
Note especially the location and listed in Table 1.
function of the following:
Lubricant or
Oil pressure gauge Manufacturer
Part Number
Low oil pressure warning light No. 71032; No.
Shell Oil Co.
Coolant temperature gauge 71306
Texaco, Inc. No. 955
High coolant temperature warning
light Quaker State No. NYK-77
Water in fuel warning light Table 1 Approved Electrical

Tachometer Lubricants
Air restriction indicator
Watch for any signs of engine
problems when starting or driving. If

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:
Figure 12 Oil Dipstick
Flush your skin with water.
Apply baking soda or lime to 2. If necessary, top off by filling

help neutralize the acid. engine oil through the oil fill cap
Flush your eyes with water. (see Figure 13) to the maximum
fill level on the oil dipstick.
Get medical attention
immediately.
Checking the Oil Level

Check the oil level as follows:
1. Check the oil level using the oil
dipstick (see Figure 12).
Figure 13 Oil Fill Cap

PERSONAL INJURY
To avoid injury from slipping and For detailed procedures, refer to the
falling, immediately clean up any Maintenance section.
spilled liquids.

OPERATION
Checking the Coolant Level NOTICE:

(Cold Check)
Correct torque on the high pressure
Check coolant level as follows: lines is critical. Incorrect torques
1. Ensure that all coolant plugs in could result in leaks or lack of power
the bottom of the radiator and on due to restricted fuel flow.
the radiator outlet pipe are secure
and tight.
1. Make sure that all high-pressure
2. Check the coolant level. The and low-pressure lines are
cooling system is correctly filled securely tightened. For tightening
when the coolant is between the specifications, refer to the
maximum and minimum marks Technical Data section.
on the surge tank.
2. If equipped with a hand pump on
For more information, refer to the the fuel/water separator, work the
Maintenance section. hand pump 50 times.
Adding Fuel NOTE:

There should be a strong resistance
When adding fuel, pay attention to the in the hand pump, caused by the
following: pressure buildup within the fuel
Add winter or summer grade fuel system.
according to the season of the
year. 3. Crank the engine for 30 seconds
at a time, but no longer. Wait at
Work in the cleanest conditions least two minutes. The engine
possible. should start within four 30-second
Prevent water from entering the attempts.
fuel tank.
For further information, refer to the
Service Products section.
Priming the Fuel System

Prime the fuel system as follows:

Starting the Engine [b] Check the oil feed and return
lines at the turbocharger for
Before operating the engine, do the
tightness. Shut down the
work described under "Before Starting
engine and tighten them if
the Engine." Start the engine as
necessary.
follows:
4. Shut down the engine.
NOTICE: 5. Approximately five minutes after
shutdown, check the engine oil
Never attempt to start any
level. If necessary, add oil up to
Mercedes-Benz electronic engine
the maximum fill level on the oil
using ether or any other starting
dipstick.
fluid. Serious engine damage could
result. 6. Check all the mounting fasteners
on the engine for tightness.
Checking the Coolant Level (Hot

Check)
Check the coolant levels as follows:
PERSONAL INJURY
1. Allow the engine to run for
approximately five minutes at a
near or on an operating engine,
moderate speed.
remove loose items of clothing
and jewelry. Tie back or contain
long hair that could be caught in
any moving part causing injury.
1. Turn on the ignition switch.

2. With the accelerator pedal in the
idle position, start the engine.
3. Check the engine for leaks.
[a] Check all hoses, hose clamps,
and pipe unions on the engine
for tightness. Shut down the
engine and tighten them if
necessary.

OPERATION
Important: At outside temperatures

below 20C (4F), a coolant
HOT COOLANT preheater is recommended.
To avoid scalding from the 1. Chock the tires, place the

expulsion of hot coolant, never transmission in neutral, and set
remove the cooling system the parking brake.
pressure cap while the engine is 2. Turn on the ignition switch and
at operating temperature. Wear start the engine
(face shield, rubber gloves, 3. If the engine doesn't start after
apron, and boots). Remove the 20 seconds, stop. Try again after
cap slowly to relieve pressure. waiting about one minute.
NOTICE:
2. Then, with the coolant
temperature above 50C (122F), Do not rev the engine if the oil
recheck the coolant level. pressure gauge indicates no
oil pressure. To avoid engine
3. Add more coolant if necessary. damage, shut down the engine
Open the heater valves before within approximately ten seconds.
adding coolant. Check to determine the cause of the
4. Do not close the heater valves problem.
until the engine has been run
briefly and the coolant level
again checked and corrected as 4. Monitor the oil pressure gauge
necessary. immediately after starting the
engine.
Starting an Engine That Has Not
NOTE:
Been Run for a Long Time
Do not place the engine under full load
Before starting an engine which has until it reaches operating temperature.
not been run for a long time, certain
special work must be carried out.
Refer to the Cleaning and Storage
section.

Monitoring Engine
Operation
While the engine is operating, monitor FIRE
the battery charge indicator light, To avoid injury from fire, keep all
the oil pressure and avoid excessive potential ignition sources away
idling. from diesel fuel, including open
Battery Charge resistance heating elements. Do
The battery charge indicator light
(see Figure 14) must go out once the
engine starts. 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.
Oil Pressure
When the engine has reached its
Figure 14 Battery Charge Indicator normal operating temperature, the
Light engine oil pressure must not drop
below the following values:
If the indicator light comes on 36 psi (250 kPa) at rated speed
while the engine is running, do the
7 psi (50 kPa) at idling speed
following:
If oil pressure drops below these
1. Shut down the engine.
values, stop the engine and determine
2. Check the poly-V belt for the cause.
tightness.

OPERATION
Excessive Idling Engine power and rpm fall, even

though the accelerator pedal
Never allow the engine to idle for
remains steady.
more than 30 minutes. Excessive
idling can cause oil to leak from the The exhaust pipe gives off heavy
turbocharger. smoke.
The coolant and/or oil temperature
Changing the Idle Speed climb abnormally.
The rpm range of the MBE 4000 Abnormal sounds suddenly occur
engine is 600 to 850 rpm if the in the engine or turbocharger.
parameters in the DDEC-VCU are set
to the default range.
Shutting Down After High Load
Change the idle speed as follows: Operation
1. Turn the cruise control switch to After high load operation, do the
the OFF position. following:
2. To increase the idle speed, push
the "Resume" switch until the idle NOTICE:
is fast enough.
After high load operation, allow the
3. To decrease the idle speed, push engine to idle for one to two minutes
the "Decel" switch until the idle without load. Shutting down the
is slow enough. engine without idling may cause
damage to the turbocharger.
Shutting Down the Engine
If the engine has been running at full 1. If the engine has been running
output or the coolant temperature has at full output or the coolant
been high, allow the engine to idle temperature has been high, allow
for one to two minutes without load. the engine to idle for one to two
Then turn off the ignition key switch. minutes without load.
If any the following occur, shut down 2. Turn off the ignition switch and
the engine immediately. shut down the engine.
The oil pressure swings back and
forth or falls sharply.

Emergency Running Mode Stop Engine Override

The engine is equipped with the
Option
electronic engine control system, The Stop Engine Override Option is
which monitors the engine as it is used for a momentary override. The
running. DDEC-ECU will record the number
of times the override is activated after
As soon as a fault is detected, it is
a fault occurs.
evaluated and one of the following
measures is initiated. Momentary Override A Stop
Engine Override (SEO) switch is used
NOTICE: to override the shutdown sequence
(see Figure). This override resets the
To prevent possible serious engine
60 second (30 seconds for oil pressure)
damage, have any faults corrected
shutdown timer, restoring power to the
without delay by an authorized
level when the Red Stop Lamp (RSL)
dealer.
was illuminated. The switch must be
recycled after five seconds to obtain a
In conjunction with any dashboard subsequent override.
or instrument panel display, the
code for the electronic control
unit reporting the fault can be read
immediately on the display.
Complete fault codes are
transmitted and can be read
using minidiag2, the Nexiq DDR
or DDDL PC software.
If the fault is serious enough to
impair normal operation, the
electronic engine system switches
over to emergency running mode.
Figure 15 Typical SEO Switch and
When in emergency running
Warning Lamps
mode, the engine operates at a
constant 1300 rpm. This allows
NOTE:
you to move the vehicle to a
The operator has the responsibility to
service location.
take action to avoid engine damage.
For fault codes and their meanings,
see the vehicle service manual.

OPERATION
Cold Weather Operation

Special precautions must be taken
during cold weather. To protect your
engine, special cold weather handling
is required for fuel, engine oil, coolant,
and batteries.
Winter Fronts
A winter front may be used to improve
cab heating while idling. At least 25%
of the grill opening should remain
open in sectioned stripes that run
perpendicular to the charge air cooler
tube flow direction. This assures even
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).

CLEANING AND STORAGE
Special precautions should be taken Cleaning the Cooling

for a stored engine to protect the its System
interior and exterior.
Important: Collect the used coolant,
cleaning solutions, and washing
Cleaning the Engine liquids and dispose of them in an
Important: Observe all environmental environmentally responsible manner.
protection regulations. Clean as follows:
High-Pressure Cleaning NOTICE:

Equipment
Clean at moderate pressures only;
Information on suitable cleaning otherwise the fins of the radiator
and protective products is available grille could be damaged.
from any authorized dealer. Note the
equipment manufacturer's operating
instructions. 1. First remove debris (dust, insects,
etc.) from the fins of the radiator
grille.
NOTICE:
To prevent damage to engine
components, keep the water
moving at all times while cleaning. EYE INJURY
Never direct water onto electrical
To avoid injury from flying debris
components, plug connectors, seals
when using compressed air, wear
or flexible hoses.
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
Comply with the minimum working
pressure.
distance between the high-pressure
nozzle and the surface being cleaned:
2. Remove the debris by blowing
Approximately 28 inches (700
them through with compressed air
mm) for circular pattern jets
or spraying them out with water.
Approximately 12 inches (300 Work from the rear of the radiator
mm) for 25-degree flat jets and (in the opposite direction of the
dirt cutters normal cooling air flow).

CLEANING AND STORAGE
3. Drain the coolant when

the engine is cold. For
detailed procedures, see the HOT COOLANT
vehicle/chassis maintenance
manual. For types of coolant, To avoid scalding from the
refer to the Service Products expulsion of hot coolant, never
section. remove the cooling system
4. If the HVAC unit is connected at operating temperature. Wear
to the cooling system, open the adequate protective clothing
regulating valves all the way. (face shield, rubber gloves,
Degreasing cap slowly to relieve pressure.
Degrease as follows:
3. Drain all the cleaning solution.
1. Fill the cooling system with a 5%
solution (1.6 ounces per quart of 4. Flush the cleaning solution from
water50 grams per liter) of a the cooling system.
mildly alkaline cleaning agent,
[a] Immediately after draining
such as sodium carbonate.
the cleaning solution, flush
2. Run the engine at moderate speed the system with clean water.
until the thermostat starts to open,
[b] Once the clean water has
at an operating temperature of
drained, fill the system again
approximately 80C (176F).
with clean water.
Then run it for about five minutes
longer. Shut down the engine and [c] Run the engine. Allow
allow it to cool to approximately the engine to warm up to
50C (112F). approximately 80C (176F),
and then run it about five
minutes longer.
[d] Drain the hot water.
5. Fill the cooling system with new
coolant. For detailed procedures,
see the vehicle/chassis
maintenance manual. For
types of coolant, refer to the
Service Products section.

Storage If the engine is to be out of service

for over 12 months, or under
Required protective measures for the
extraordinary storage or transportation
MBE 4000 engine depend on the
conditions, then special protective
following:
measures are necessary. Information
The length of time that the engine is available from any authorized
will be out of service dealer. It is strongly recommended
that you request this information.
The climate and conditions where
the engine is stored
NOTE:
After cleaning, engines should, If the engine is to be out of service
whenever possible, be placed in a dry, for over 18 months, the oil must be
well-ventilated place. changed before the engine can be
brought back into service.
In all cases, protect the engine
against direct exposure to moisture
(rain/splash water).
If the engine is to be out of service
for 12 months or less, anticorrosion
measures are not necessary, provided
that the place of storage are dry and
well-ventilated as described above.

TROUBLESHOOTING
TROUBLESHOOTING
In addition to operating the engine

carefully and maintaining it properly,
make sure to correct any malfunction
promptly.
Emergency Starting
For emergency starting procedures
(jump starting), see the driver's
manual under the heading "Emergency
Starting With Jumper Cables."
Troubleshooting the
Electronic Engine Control
System
When the electronic engine control
system detects a fault, it broadcasts
a message on the datalink. The dash
display will show the code "ECU
128," indicating there is an engine
fault.
Important: To read the complete
fault code, bring the vehicle to an
authorized dealer. Complete fault
codes can be read using minidiag2, the
Nexiq DDR or DDDL PC software.
For fault codes and their meanings,
see the next section in this guide.

General Troubleshooting NOTE:

Remember to follow all cautions when
The tables that follow are designed
troubleshooting the engine.
to identify the causes of common
problems, suggest further checks and
appropriate remedies. When dealer
service is necessary, this is mentioned
in the table.
Problem - The Engine Will Not Crank

Cause Remedy
Test the batteries. Replace them, if
The batteries are damaged or weak.
needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged
Replace the battery cables.
and/or corroded.
Have an authorized dealer replace the
The starter is damaged and/or worn.
starter.
The clutch or transmission is Bring the vehicle to an authorized
damaged. dealer for service.
There is internal damage to the Bring the vehicle to an authorized
engine. dealer for service.

TROUBLESHOOTING
ProblemThe Engine Turns Over Slowly

Cause Remedy
needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged
Replace the battery cables.
and/or corroded
The starter is damaged and/or worn.
starter.
The engine oil does not meet the Change the engine oil, using the
correct specifications. correct type of oil.
The transmission fluid does not meet Change the transmission fluid, using
the correct specifications. the correct type of fluid.

ProblemThe Engine Cranks, But Won't Start

Cause Remedy
needed.
Bring the vehicle to an authorized
The cranking speed is not set correctly.
dealer for service.
No intake air preheater is installed,
Install an intake air preheater.
and it is too cold to start without one.
The intake air preheater is Check the intake air preheater, and
malfunctioning. replace it, if necessary.
Push both sensors into their holes as
The camshaft TDC sensor and/or the
far as they will go. If this does not
crank angle position sensor are out of
solve the problem, bring the vehicle to
adjustment.
an authorized dealer for service.
The camshaft TDC sensor and/or
the crank angle position sensor are
dealer for service.
damaged.
Check the fuel lines for air pockets.
There is air in the fuel system. Bleed the fuel system and start the
engine.
The air filter is clogged. Clean or replace the air filter.
The fuel filter is clogged. Replace the filter element.
The exhaust brake valve is Have an authorized dealer check the
malfunctioning. operation of the valve.
The valves are not adjusted properly. Check the valve lash.
There are other problems in the fuel Bring the vehicle to an authorized
system. dealer for service.

TROUBLESHOOTING
ProblemThe Engine Starts Only After Cranking for a Long Time

Cause Remedy
Add fuel and bleed the fuel system, if
The fuel tank is low or empty.
necessary.
Check the fuel lines for leaks and
There are leaks in the fuel lines.
repair them, if necessary.
Clean and bleed the system. Have
The fuel line, the fuel prefilter, or the
the fuel lines and filters checked by an
screen in the fuel tank is blocked.
authorized dealer.
adjustment.
dealer for service.
damaged.

ProblemThe Engine Starts, But Dies

Cause Remedy
Add fuel and bleed the fuel system, if
The fuel tank is low or empty.
necessary.
Clean and bleed the system. Have
The fuel line, the fuel prefilter, or the
the fuel lines and filters checked by an
screen in the fuel tank is blocked.
authorized dealer.
adjustment.
dealer for service.
damaged.
The constant-throttle valves are Bring the vehicle to an authorized
malfunctioning. dealer for service.
ProblemThe Engine Fan Doesn't Work

Cause Remedy
The fan hub is damaged. Replace the fan hub.
The fan wiring is damaged. Repair the fan wiring.
The parameter settings in the
Have an authorized dealer reprogram
DDEC-ECU or DDEC-VCU are
the control unit.
incorrect.

TROUBLESHOOTING
ProblemThe Engine Fan Is Constantly On

Cause Remedy
Check the operation of the fan override
The fan override switch is on.
switch.
The fan hub is damaged. Replace the fan hub
The parameter settings in the
Have an authorized dealer reprogram
DDEC-ECU or DDEC-VCU are
the control unit.
incorrect.
AC switch is damaged Check AC switch.
ProblemFuel Consumption Is Too High

Cause Remedy
The tires are not properly inflated. Check all tires for correct pressure.
Check the air restriction indicator.
The air filter and/or intake air system
Clean the intake air system and
is clogged.
replace the air filter if necessary.
The remedies are listed in "The Engine
The engine performs poorly, or does
Performs Poorly, Does Not Develop
not develop full power.
Full Power."

ProblemThe Engine Performs Poorly, Does Not

Develop Full Power
Cause Remedy
is clogged.
There are other problems with the fuel Bring the vehicle to an authorized
The valves are not adjusted properly Check the valve lash.
The coolant temperature sensor is Bring the vehicle to an authorized
damaged or reading incorrectly. dealer for service.
The fuel temperature sensor is Bring the vehicle to an authorized
The engine oil temperature sensor is Bring the vehicle to an authorized
The charge-air temperature sensor is Bring the vehicle to an authorized
There are problems with the Bring the vehicle to an authorized
DDEC-ECU or DDEC-VCU. dealer for service.

TROUBLESHOOTING
ProblemThe Engine Is in Emergency Running Mode

(constant speed 1,300 rpm)
Cause Remedy
The DDEC-ECU or DDEC-VCU is Bring the vehicle to an authorized
An incorrect parameter is in the dealer and have the parameter
DDEC-ECU or DDEC-VCU. settings reprogrammed in the
DDEC-ECU or DDEC-VCU.
ProblemThe Coolant Temperature Is Above Normal

Cause Remedy
Check for coolant leaks, and repair as
The coolant level is too low.
needed.
The poly-V belt is loose. Tighten or replace the poly-V belt.
The coolant temperature gauge and/or Bring the vehicle to an authorized
sensor is not reading correctly. dealer for service.
Clean the radiator. Repair or replace
The radiator is damaged or dirty.
the radiator if necessary.
The coolant pump is damaged.
coolant pump.
The thermostat is damaged.
coolant pump.
dealer and have the fan hub checked
The fan is not operating properly. or have the parameter settings
reprogrammed in the DDEC-ECU or
DDEC-VCU.

ProblemThe Coolant Temperature Is Below Normal

Cause Remedy
The coolant temperature gauge and/or Bring the vehicle to an authorized
sensor is not reading correctly. dealer for service.
The thermostat is damaged.
thermostat.
dealer and have the fan hub checked.
The fan is not operating properly.
dealer and have the parameter
settings reprogrammed in the
DDEC-ECU or DDEC-VCU.
ProblemThe Cooling System Is Losing Coolant

Cause Remedy
There is an external coolant leak. Repair the leaking component.
The radiator cap is leaking. Replace the radiator cap.
The air compressor head is damaged.
air compressor.
The cylinder head gasket is leaking.
head gasket.
ProblemThere Is Coolant in the Engine Oil

Cause Remedy
The cylinder head gasket is damaged.
head gasket.
The oil/water heat exchanger is Have an authorized dealer replace the
leaking. heat exchanger.
There is an internal coolant leak.
dealer for service.

TROUBLESHOOTING
ProblemThere 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
Change the oil.
the recommended interval.
The oil is not of the recommended
Change the oil.
quality.
ProblemThe Engine Oil Pressure Is Low

Cause Remedy
The oil pressure gauge and/or sensor Bring the vehicle to an authorized
is not reading correctly. dealer for service.
There is fuel in the oil.
dealer for service.
The oil filter is clogged. Replace the filter element.
The oil filter bypass valve is damaged. Replace the bypass valve.
The oil pump and/or relief valve is Have an authorized dealer replace the
damaged. oil pump.
ProblemThe Engine Exhaust Is White

Cause Remedy
The fuel is of poor quality. Add fuel of the right quality.
The intake air preheater is Check the intake air preheater, and
malfunctioning. replace it, if necessary.

ProblemThe Engine Exhaust Is Black

Cause Remedy
is clogged.
The intake air preheater is Check that the heater is not staying on
malfunctioning. all of the time.
There is damage to the fuel system:
the fuel pump, one or more fuel Bring the vehicle to an authorized
injectors, or one or more unit pumps dealer for service.
are damaged.
The charge-air temperature sensor is Bring the vehicle to an authorized
ProblemThe Engine Exhaust Is Blue

Cause Remedy
The engine oil level is too high Adjust the oil level, and then have the
(engine oil is reaching the combustion oil level checked by an authorized
chamber). dealer.
The turbocharger is leaking oil.
turbocharger
The valve stem seals are loose or Have an authorized dealer replace the
damaged. seals.
The piston rings are worn.
piston rings.

TROUBLESHOOTING
ProblemEngine Brake Performance Is Poor

Cause Remedy
The engine brake control switch is
Replace the switch
damaged.
The exhaust brake is not operating Have an authorized dealer check the
properly. operation of the valve.
The constant-throttle valves are Bring the vehicle to an authorized
malfunctioning. dealer for service.
Components of the DDEC-ECU and/or Bring the vehicle to an authorized
DDEC-VCU are damaged. dealer for service.
ProblemCruise Control Is Not Working

Cause Remedy
One or more of the cruise control
Replace the damaged switch.
switches are damaged.
Components of the DDEC-ECU and/or
DDEC-VCU are damaged or not
dealer for service.
working properly.
ProblemThe Battery Charge Indicator Light Does Not

Come On When the Engine Is Not Running
Cause Remedy
The bulb is damaged. Change the bulb.
The circuit is broken. Repair the break in the circuit.

ProblemThe Battery Charge Indicator Light Comes

On When the Engine is Running
Cause Remedy
Check the belt tension; if necessary,
The poly-V belt is too loose. have an authorized dealer replace the
belt tensioner.
The belt tensioner is damaged.
belt tensioner.
The poly-V belt is worn or damaged. Replace the belt.
The alternator is damaged (has a Have an authorized dealer replace the
damaged rectifier or voltage regulator). alternator.

SERVICE PRODUCTS
SERVICE PRODUCTS
Carefully match together the Always filter the fuel before adding
components of the engine with the it to the tank.
lubricants they need. Use only brands
For information about fuel in cold
which have been tested and approved
weather operation, see the heading
by DDC. Information is available
"Winter-Grade Diesel Fuel" later in
from any authorized dealer.
this chapter.
Do not use special lubricant additives.
None are needed, and the use of Flow Improvers
additives could affect warranty.
The effectiveness of flow improvers is
Important: Dispose of service not guaranteed with all fuels. Comply
products in an environmentally with the product manufacturer's
responsible manner. This includes any recommendations. Any authorized
parts which have been in contact with dealer can provide information on
them (for example, filters). Reclaim approved flow improvers.
them or recycle them, if possible,
and be sure to comply with all legal
Kerosene
disposal requirements.
Keep the quantity added as low as
Diesel Fuels possible, bearing in mind the outside
temperature.
Use only commercially available
vehicle diesel fuel. Grades such as The addition of five percent by
marine diesel fuel, heating oil, and volume of kerosene will improve
others are not permissible. the fuel's resistance to cold by about
1C (1.8F). Never add more than 50
Do not use fuel additives. Using fuel percent kerosene to the fuel.
additives could affect your warranty.
If using diesel fuel with a high sulphur
content, exceeding 0.5 percent by
weight, change the engine oil at
shorter intervals.
Fuel added from drums or cans could
be contaminated. This could lead
to malfunctions in the fuel system.

NOTICE:
For safety reasons, add the
kerosene to the diesel only in the
fuel tank. Add the kerosene first,
then the diesel. Run the engine for
a short time to allow the mixture to
reach all parts of the fuel system.
Engine Oils
The engine is delivered from the Figure 16 API Lubricant Service
factory filled with an approved engine Mark
oil.
When maintenance work is performed,
NOTICE: record engine oil changes including
details of the brand used, the
The use of non-approved engine
quality category, and the Society
oils could affect warranty rights, and
of Automotive Engineers (SAE)
cause engine damage.
viscosity rating of the oil. When
topping off, use only engine oils of
Only multigrade oils of American the correct API designation and SAE
Petroleum Institute (API) service rating.
designation CI-4 will achieve proper For information about oil in cold
performance for the cooled EGR weather operation, see the heading
engines. Look for the service "Low-Viscosity Engine Oil" later in
mark printed on the oil container. this chapter.
See Figure 16.
Synthetic Oils
Synthetic oil may be used in MBE
4000 engines, provided they are of the
correct API designation and viscosity,
as required for non-synthetic oil.

SERVICE PRODUCTS
Synthetic oil offers improved containing glycol compounds and

low-temperature flow properties corrosion inhibitors is known as
and high-temperature resistance to fully-formulated antifreeze.
oxidation. However, it is generally
more costly than non-synthetic oil. NOTICE:
Review carefully the product Do not use propylene glycol.
information published by the synthetic
oil manufacturer. Performance
Fully-formulated antifreeze has the
additive systems often respond
following properties:
differently in synthetic oil. Use of
synthetic oil does not change the It protects the radiator and engine
recommended oil change service from freezing.
interval.
It provides protection against
corrosion and cavitation for all
Coolant components in the cooling system.
Coolant is a mixture of water and It raises the boiling point of the
antifreeze. Under normal conditions, coolant. This slows the rate of
it is a mixture of 50 percent water evaporation, avoiding coolant loss
and 50 percent antifreeze, but under at high temperatures.
extreme cold weather conditions, as
much as 60 percent antifreeze can be
Water
added. For reasons of anticorrosion
protection and to raise the boiling Water containing no additives is
point, the coolant must remain in the not suitable as a coolant, even if no
cooling system all year round. antifreeze protection is needed.
Regardless of mileage, replace The water used in the coolant must
the coolant every two years since comply with certain requirements,
the degree of corrosion protection which are not always satisfied by
gradually drops with time. drinking water. If water quality is
inadequate, the water must undergo
Fully-Formulated Antifreeze suitable treatment.
Antifreeze approved for use in the The following types of water are
MBE 4000 engine is a mixture of preferred for use in coolant:
glycol compound (ethylene glycol), Distilled water
and corrosion inhibitors. Antifreeze
Water purified by reverse osmosis

De-ionized water the requirements of the Truck

Maintenance Council (TMC). Coolant
specifications are listed in Table 2.
NOTICE:
In some areas, tap water can Coolant Concentration
contain high levels of dissolved
chlorides, sulfates, magnesium, and When topping off the cooling system
calcium, causing scale deposits, after a drop in the coolant level, the
sludge deposits and/or corrosion. concentration of corrosion-inhibiting
These deposits can damage the antifreeze in the coolant must be
coolant pump and allow the engine 50 percent by volume. This affords
to overheat. protection down to a temperature of
37C (34F). The cooling mixing
ratio is listed in Table 3.
Coolant Specifications
NOTE:
To avoid damage to the cooling If the concentration is too low, there
system, use only an approved is risk of corrosion/cavitation in the
corrosion-inhibiting antifreeze. cooling system.
Approved antifreeze must be
fully-formulated and comply with
Type of Coolant Requirement

Fully-Formulated Ethylene Glycol TMC RP-329 Type "A"
Temperature Must Not Fall Below
Water plus Corrosion Inhibitors
0C (32F)
Table 2 Coolant Specifications
Antifreeze Protection Water % Corrosion - Inhibiting

Down to C (F) by Volume Antifreeze % by Volume
37 (34) 50 50
52 (62) 40 The cooling mix ratio is Max. 60
Table 3 Coolant Mixing Ratio

SERVICE PRODUCTS
For information about coolant in Water-softening to deter formation

cold weather operation, see the of mineral deposits
heading "Winter Coolant Antifreeze
Cavitation protection to protect
Protection" later in this chapter.
wet sleeve cylinder liners
Supplemental Coolant Additives

Dropout
for Fully Formulated Coolant
Excessive amounts of some corrosion
The concentrations of some inhibitors
inhibitors can cause a gel or crystalline
will gradually deplete during normal
deposit that reduces both heat transfer
engine operation. SCAs replenish
and coolant flow. This deposit is
the protection for cooling system
called "dropout."
components. The coolant must
be maintained with the proper Dropout takes the color of the coolant
concentration of SCA. Detroit Diesel when wet, but becomes a white or gray
Power Cool maintenance SCAs are powder when dry. It can pick up solid
recommended. particles in the coolant and become
gritty. It will cause premature wear
of the coolant pump seals and other
NOTICE: components of the cooling system.
Failure to properly maintain coolant
The wet gel can be removed using an
with SCA can result in damage
alkaline (non-acid) cleaner containing
to the cooling system and its
either sodium nitrite or sodium
related components. Conversely,
tetraborate.
over-concentration of SCA inhibitor
can result in poor heat transfer, If the gel is allowed to dry, it is
leading to engine damage. necessary to disassemble the engine
Always maintain concentrations at and clean it with a caustic solution,
recommended levels. Do not use or physically clean the individual
traditional SCAs with OAT coolant. components.
Non-Approved Coolants
The proper application of SCA will
provide: The following types of coolant are
not approved for use in MBE 4000
pH control engines:
Restored inhibitor levels to prevent Antifreeze or coolant containing
corrosion phosphate can cause dropout,

overheating, and damage to Corrosion Inhibitors

coolant pump seals.
Automotive coolants offer no NOTICE:
protection against liner pitting,
Do not mix types of corrosion
and generally contain high levels
inhibitors. Do not add additional
of phosphate and silicate.
inhibitors to new, fully-formulated
Antifreeze based on methyl alcohol antifreeze, or coolant containing
can damage the non-metallic new, fully-formulated antifreeze.
components of the cooling system. This can cause deposits or dropout
They are not suitable for use with in the cooling system.
diesel engines because of their
low boiling point.
The following types of corrosion
Antifreeze based on methoxy
inhibitors are approved for use in
propanol is not compatible with
MBE 4000 engines:
the fluoroelastomer seals used in
the cooling system. Supplemental Coolant Additives
(SCAs)
Glycol-based HVAC coolants
contain phosphates which can Organic Acid Technology (OAT)
deposit on hot internal engine Inhibitors
surfaces and reduce heat transfer.
Corrosion inhibitors are very
important in maintaining engine
Recycled Antifreeze life. All corrosion inhibitors protect
Recycled antifreeze that complies with against corrosion caused by acid,
TMC RP-329 Type "A" (for ethylene and cavitation of wet cylinder liners.
glycol) is approved for use in MBE SCAs also protect against mineral
4000 engines. The antifreeze must deposits.
be recycled by distillation, reverse The concentrations of some inhibitors
osmosis, or ion exchange. will gradually diminish during normal
Other recycled antifreeze, especially engine operation. To protect the
any antifreeze recycled by means of engine, nitrite concentration must
filtration processes, is not approved. be checked at regular intervals, and
inhibitors added as necessary. The
intervals are longer if OAT inhibitors
are used.

SERVICE PRODUCTS
NOTICE: Cold Weather Products

Always maintain inhibitor at the Special precautions must be taken
recommended level. Failure to during cold weather. To protect your
properly maintain coolant with SCA engine, take the following special
can result in damage to the cooling measures in cold weather.
system and related components. Use the recommended cold
Over-concentration of SCA inhibitor weather fuel and engine oil.
can result in poor heating transfer
and lead to engine damage. Check the concentration of
antifreeze in your coolant.
Take special care of the batteries to
The following types of inhibitor must ensure proper cranking amperage
not be used in MBE 4000 engines:
Soluble oil additives cause poor Winter-Grade Diesel Fuel
heat transfer and lead to engine
damage. At low outside temperatures, paraffin
may separate from the diesel and
Chromate additives can lead to affect its ability to flow freely. Avoid
the build-up of "green slime" breakdowns caused by this problem
(chromium dioxide) in the engine, (for example, blocked filters) by using
leading to engine damage. cold-resistant winter-grade diesel
fuel with improved low-temperature
Disposal flow characteristics. In most cases,
winter-grade fuel can be used without
Coolants are biologically degradable problems at cold outside temperatures.
substances.
If using summer-grade fuel or a less
When disposing of used coolant, cold-resistant winter grade, a flow
comply with local legal requirements improver or kerosene can be added.
and waste water regulations. The amount needed depends on the
Consult the local water supply outside temperature.
authorities to determine the best Flow improver or petroleum spirit
method of disposal. must be mixed with diesel fuel
A modern engine coolant has complex before its flow characteristics have
tasks to perform. Do not allow any been adversely affected by paraffin
form of "reprocessing" which consists separation.
only of mechanical purification.

If changes have already been caused volume (this gives the maximum
by paraffin separation, they can be antifreeze protection). Further
corrected only by heating the entire increases in the mixing ratio would
fuel system. reduce the level of antifreeze
protection and adversely affect the
Do not add anything to cold-resistant
coolant's ability to dissipate heat.
winter-grade diesel fuels. The fuel's
low-temperature flow characteristics
could actually deteriorate with
additives.
FIRE
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
Figure 17 Engine Oil Temperature

Low-Viscosity Engine Oil Ranges
When changing the engine oil,
estimate the interval before your Batteries
next oil change. Choose an oil
from the SAE viscosity class Batteries should receive more
which corresponds to the outside frequent maintenance and recharging
temperatures anticipated during this during the cold season of the year.
period of operation. See Figure 17. Careful maintenance and low current
consumption will help to maintain the
full battery charge. Starting capacity
Winter Coolant Antifreeze
drops severely in cold weather. At
Protection
10C (14F) starting capacity is
Before the temperature dips below about 60 percent of normal. If the
freezing, check the concentration of engine is shut down or out of use
antifreeze in the coolant. If necessary, for an extended period of time, store
increase it. the batteries out of the vehicle in a
heated area if possible. Ensure good
Do not increase the proportion
ventilation when recharging.
(mixing ratio) of corrosion-inhibiting
antifreeze beyond 55 percent by

TECHNICAL DATA
TECHNICAL DATA
General technical information is

listed in Table 4.
Description MBE 4000 Engine

Vertical, inline cylinder block with
Engine Type
turbocharger and charge-air cooler
Cooling System Liquid Circuit
Combustion Principle 4-Stroke direct-injection diesel
Number of Cylinders 6
Bore 128 mm (5.04 in.)
Stroke 166 mm (6.54 in.)
Displacement (total) 12.816 liters (782 in)
Compression Ratio 17.75:1
Starting Speed Approximately 100 rpm
Direction of Engine Rotation (viewed
Counterclockwise
from flywheel)
Starter Electric Motor
Table 4 General Technical Information

Engine Data Dimension Size

The engine weights are listed in Table 1338.7 mm
Length (A)
5. The engine dimensions (ready (53.1 in.)
for shipment) are listed in Table 6. 1069.3 mm
Also see Figure 18 and Figure 19. Width (B)
(42.1 in.)
Coolant capacities are listed in Table
7. Lubricating oil capacities 1130.3 mm
Height (C)
(44.5 in.)
arelisted in Table 8.
Table 6 Engine Dimensions
Engine Dry
Engine
Weight
6-Cylinder 960 kg (2117 lb)
Table 5 Engine Weights
Figure 18 Side View Figure 19 Front View
Description MBE 4000 Engine

Coolant Capacity* Max. 70 L (74 qt)
*Does not include capacity of cooling system.
Table 7 Coolant Capacity

TECHNICAL DATA
Oil System Fill

Description Oil Pan Capacity
Capacity
EGR engines w/front
36 L (38 qts) 39.5 L (41.7 qts)
Sump *
Non-EGR Engines
w/front Sump & Right
36 L (38 qts) 39.5 L (41.7 qts)
Hand Drive Export
Applications *
Rear Sump Applications 40.0 L (42.3 qts) 43.5 L (46.0 qts)
Non-EGR Engines
w/front Sump & Left 40.0 L (42.3 qts) 43.5 L (46.0 qts)
Hand Drive Applications
Front Sump Engine s/n
40.0 L (42.3 qts) 43.5 L (46.0 qts)
833529 and below
* Engine s/n 833530 and above
Including oil filter.
Table 8 Lubricating Oil Capacity
Testing and Adjusting Pressure is listed in Table 10.

Values Coolant thermostat conditions are
listed in Table 11. Injector pressures
Valve lash checking and adjustments
are listed in Table 12.
are listed in Table 9. Engine Oil
Valve Type Check For: Adjust To:

mm (in.) mm (in.)
Intake 0.30 to 0.60 (0.012 to 0.024) 0.40 (0.016)
Exhaust 0.50 to 0.80 (0.020 to 0.032) 0.60 (0.024)
Table 9 Valve Lash Checking and Adjustment

Engine Speed Minimum Pressure

At idling rpm 50 kPa (7 psi)
At maximum rpm 250 kPa (36 psi)
Table 10 Engine Oil Pressure
Condition Specification
Starts to open 81 to 85C (177 to 185F)
Fully open 95C (203F)
Minimum lift 8 mm (0.3 in.)
Table 11 Coolant Thermostat
Opening Pressure Value in kPa (Psi)

Minimum opening pressure 25500 (3698)
Maximum opening pressure 27000 (3916)
Table 12 Injector Pressures

MAINTENANCE
MAINTENANCE
When performed on a regular basis, Important: If the engine is stored for

changing the engine oil and filters is more than 18 months, the oil must
the least costly way of obtaining safe be changed before the engine can be
and reliable vehicle operation. Added brought into service.
benefits and savings occur when you
check that the valves, fuel injectors, Maintenance Schedule Types
and oil and cooling circuits are in good
working order during oil changes. There are three types of maintenance
schedule:
The maintenance section of this
manual explains when you should Schedule I (Severe Service)
change your oil and what to look for Schedule II (Short Haul)
when checking for wear or damage.
Schedule III (Long Haul)
For additional information, please
contact Detroit Diesel Technical To determine which schedule to use,
Service. find the distance traveled by the
vehicle in a year, regardless of vehicle
type.
Scheduled Intervals
All service intervals and maintenance Severe Service Applies to
operations are based on the parts and vehicles that annually travel up to
accessories expressly approved for 6000 miles (10,000 kilometers) or
your engine. that operate under severe conditions.
The scope and frequency of Examples of Severe Service usage
maintenance work are determined include: operation on extremely poor
by the engine's operating conditions: roads or where there is heavy dust
severe duty, short haul, or long haul. accumulation; constant exposure
to extreme hot, cold, salt-air, or
Evidence of regular maintenance is other extreme climates; frequent
essential if a warranty claim has to be short-distance travel; construction-site
submitted. operation; city operation (fire truck,
If optional equipment is installed, be garbage truck); or farm operation.
sure to comply with the maintenance
requirements for these extra items.

Short-Haul Applies to vehicles Maintenance Intervals The

that annually travel up to 60,000 miles three maintenance interval tables show
(100,000 kilometers) and operate which maintenance operation must
under normal conditions. Examples be performed at the actual distances
of Short-Haul usage are: operation (in miles or kilometers) for each
primarily in cities and densely maintenance operation. The schedule
populated areas; local transport with of actual distances is based on the
infrequent freeway travel; or high intervals given in the Maintenance
percentage of stop-and-go travel. Schedule Table (Table 13).
The three maintenance interval tables
Long-Haul Long Haul are:
(over-the-road transport) is for
vehicles that annually travel more than Maintenance Interval Table,
60,000 miles (100,000 kilometers), Severe Service (Table 14)
with minimal city or stop-and-go Maintenance Interval Table, Short
operation. Examples of Long-Haul Haul (Table 15)
usage are: regional delivery that
is mostly freeway miles; interstate Maintenance Interval Table, Long
transport; or any road operation with Haul ( Table 16)
high annual mileage.
Maintenance Operation Sets
Maintenance Schedule and Each Maintenance Operations
Interval Operations The three Sets Table (M1 through M4) lists the
different schedules of vehicle usage descriptions of only those maintenance
(severe, short haul, and long haul) are operations that must be performed at
listed in Table 13. For each schedule, that maintenance operation set. Each
the appropriate distance interval maintenance operation set is listed in
(in miles and kilometers) is given a separate Maintenance Operations
for performing and repeating each Table.
maintenance operation. The descriptions of all maintenance
The descriptions of all maintenance operations, and the maintenance
operations, indicating all maintenance operation sets at which each operation
operation sets at which each operation must be performed are listed in Table
must be performed are listed in Table 17 and Table 18.
14, Table 15, and Table 16.

MAINTENANCE
Schedule Use Complete each Maintenance

Operation Set at the required interval.
Before placing your new vehicle
For example, when you have
in service, determine the correct
completed Maintenance Operation
maintenance intervals that apply to
Set M3 under the 16th maintenance
your intended use of the vehicle. Refer
number listed in the Maintenance
to the Maintenance Schedule Table
Interval Table, repeat the pattern. For
to determine the distance interval at
the 17th maintenance, do Maintenance
which each maintenance operation
Operation Set M1, under the first
must be performed to comply with
maintenance number listed in the
your vehicle's schedule.
Maintenance Interval Table.
When the vehicle reaches the actual
distance given for an interval, refer NOTE:
to the Maintenance Interval Tables For Severe Service, the pattern
to find the Maintenance Operation repeats after 15 maintenance
Set that applies to that interval. Then numbers, not 16 (as for Short Haul
perform the maintenance operations and Long Haul).
listed in the applicable Maintenance
Interval Operation Table.

Maintenance Tables
Maintenance Maintenance Intervals

Maintenance
Interval
Schedule Frequency Miles Km
Operation
Maintenance 1 (M1) every 10,000 17,000
Schedule I Optional oil
(Severe Service) centrifuge every 20,000 32,000
vehicles that (change rotor)
annually travel
up to 6,000 miles
(10,000 km) first 20,000 32,000
Maintenance 3 (M3)
then every 40,000 68,000
Maintenance 1 (M1) every 15,000 25 000
Schedule II Optional oil

(Short Haul) centrifuge every 20,000 32,000
vehicles that (change rotor)
annually Maintenance 2 (M2) every 30,000 50,000
travel up to
60,000 miles first 30,000 50 000
Maintenance 3 (M3)
(100,000 km) then every 60,000 100,000
Optional oil
centrifuge every 20,000 32,000
Schedule III (change rotor)
(Long Haul)
vehicles that Maintenance 1 (M1) every 25,000 42,000
annually travel Maintenance 2 (M2) every 50,000 84,000
more than
60,000 miles first 50,000 84,000
Maintenance 3 (M3)
(100,000 km) then every 100,000 167,000
Table 13 Maintenance Schedule Table

MAINTENANCE
Maintenance
Maint. No Miles Km
Interval
1 M1 10,000 17,000
2 M1, M2 and M3 20,000 32,000
3 M1 30,000 50,000
4 M1 and M2 40,000 67,000
5 M1 50,000 84, 000
6 M1, M2 and M3 60,000 100, 000
7 M1 70,000 117,000
8 M1 and M2 80,000 134,000
9 M1 90,000 150,000
10 M1, M2 and M3 100,000 167,000
11 M1 110,000 184,000
12 M1 and M2 120,000 200,000
13 M1 130,000 217,000
14 M1, M2 and M3 140,000 234,000
15 M1 150,000 250,000
16 M1 and M2 160,000 267,000
Table 14 Maintenance Intervals for Schedule I, Severe Service

Maintenance
Maint. No. Miles Km
Interval
1 M1 15,000 25 000
2 M1, M2, and M3 30,000 50,000
3 M1 45,000 75,000
4 M1, M2 and M4 60,000 100,000
5 M1 75,000 125,000
6 M1, M2 and M3 90,000 150,000
7 M1 105,000 120,000
8 M1 and M2 120,000 200,000
9 M1 135,000 225,000
10 M1, M2, and M3 150,000 250,000
11 M1 165,000 275,000
12 M1, M2 and M4 180,000 300,000
13 M1 195,000 325,000
14 M1 and M2 210,000 350,000
15 M1 225,000 375,000
16 M1, M2 and M3 240,000 400,000
Table 15 Maintenance Intervals for Schedule II, Short Haul

MAINTENANCE
Maintenance
Maint. No Miles Km
Interval
1 M1 25,000 42,000
M1, M2, M3
2 50,000 84,000
and M4
3 M1 75,000 125,000
4 M1 and M2 100,000 167,000
5 M1 125,000 209,000
6 M1, M2, and M3 150,000 250 000
7 M1 175,000 292,000
8 M1 and M2 200,000 334,000
9 M1 225,000 375,000
M1, M2, M3
10 250,000 417,000
and M4
11 M1 275,000 459,000
12 M1 and M2 300,000 500,000
13 M1 325,000 542,000
14 M1, M2, and M3 350,000 584,000
15 M1 375,000 625,000
16 M1 and M2 400,000 667,000
Table 16 Maintenance Intervals for Schedule III, Long Haul

Operation Description M1 M2 M3
Engine Inspecting
Valve Lash Checking and Adjusting
Fuel /Water Separator Prefilter Element Cleaning
Main Fuel Filter Element Changing
Engine Oil and Filter Changing
Coolant Concentration and Inhibitor Level Checking
Coolant Flushing and Changing*
Cooling System Inspecting
* Coolant flushing and changing must be done at least every two years.
Table 17 Required Maintenance Operations Sets, Schedule I

MAINTENANCE
Maintenance Operation Description M1 M2 M3 M4

Engine Inspecting
Valve Lash Checking and Adjusting
Fuel /Water Separator Prefilter Element Cleaning
Main Fuel Filter Element Changing
Coolant Concentration and Inhibitor Level
Checking
Coolant Flushing and Changing*
Rear Engine Power Take-Off (REPTO) torsional

damper checking
* Coolant flushing and changing must be done at least every two years.
For Schedule II and III, the valve lash checking and adjusting must be
done first at 60,000 miles and then every M4.
For Schedule II, the REPTO torsional damper checking must be done
first at 60,000 miles or 3000 hours and then every 30,000 miles or
1500 hours.
Table 18 Required Maintenance Operations Sets, Schedule II and III

Required Maintenance Gaining Access To The Valves

Operations Gain access to the valves as follows:
The following sections describe the
NOTE:
required maintenance operations
Clean the cylinder head covers before
listed in Table 17 and listed in Table
removing it.
18.
1. Remove the cylinder head covers.
Engine Inspecting See Figure 20.
Inspect engine as follows:
1. Visually check the engine for
signs of leakage. A slight
dampness at the sealing points is
no cause for concern.
NOTE:
More severe leaks, combined with a
continual loss of oil, must be corrected
without delay.
2. Visually inspect all lines and

hoses. Listen for any sound of
leaking. Make sure all pipes and
hoses are undamaged, correctly
positioned to avoid chafing, and
properly secured.
Valve Lash Checking and

Adjusting
A special engine cranking tool (J
46167) is required for this procedure.
Figure 20 Cylinder Head Cover
NOTE:
Adjust the valve lash when the engine 2. Remove the inspection cover on
is cold. Wait at least 30 minutes after the flywheel housing.
shutdown, even if the engine ran only
a short time.

MAINTENANCE
3. Fit the cranking tool into the See Figure 22 for the cylinder and
inspection hole on the timing valve layout on the MBE 4000 engine.
case. See Figure 21.
Figure 21 Placing Cranking Tool
Choosing A Method Select a

method for adjusting the valve lash.
There are two acceptable methods for
adjusting valve lash: Figure 22 Cylinder and Valve
Layout
In order, according to the timing
sequence used for fuel injection
(see "Method OneAdjust Each
Cylinder In Firing Order")
By type of valve, depending on
crankshaft position (see "Method
TwoAdjust All Valves Using
Two Crankshaft Positions").

Method One Method one allows NOTE:

you to adjust each cylinder in the When the piston in cylinder #1 is at
order in which fuel is injected. The ignition TDC, the valves of cylinder #6
crankshaft must be repositioned will overlap, meaning that both intake
after each cylinder is adjusted as and exhaust valves are partially open,
listed in Table 19. and show no measurable play when
tested with a feeler gauge.
1. For each cylinder, use the
cranking tool to turn over the
2. Check each valve and adjust it (if
crankshaft until the piston is
necessary), using the procedures
exactly at top dead center (TDC)
under the headings "Checking
in the compression stroke. The
Valve Lash" and "Adjusting Valve
valves must be closed and it must
Lash."
be possible to turn the push rods
without effort.
Engine Crankshaft Position Cylinders

Ignition TDC 1 5 3 6 2 4
MBE 4000
Valve Overlap 6 2 4 1 5 3
Table 19 Valve Adjustment Method One

MAINTENANCE
Method Two Method two allows 3. Using the cranking tool, turn the
you to adjust all the valves using just crankshaft until cylinder #6 is
two crankshaft positions. at the ignition TDC position (all
valves are closed) and cylinder
1. Using the cranking tool, turn the
#1 is at the valve overlap position
crankshaft until cylinder #1 is
(all valves are open).
at the ignition TDC position (all
valves are closed) and cylinder 4. Using the same procedure, check
#6 is at the valve overlap position the valves listed in Table 20 in the
(all valves are open). "Valve Overlap" row and adjust
them (if necessary), using the
2. Check the valves listed in Table
procedures under the headings
20 in the "Ignition TDC" row of
"Checking Valve Lash" and
and adjust them (if necessary),
"Adjusting Valve Lash."
using the procedures under the
headings "Checking Valve Lash"
and "Adjusting Valve Lash."
Cylinder #1 Crankshaft Cylinder Valve Types*

Engine
Position 1 2 3 4 5 6
Ignition TDC I/E I E I E
MBE 4000
Valve Overlap E I E I I/E
*I = Intake Valve, E = Exhaust Valve
Table 20 Valve Adjustment Method Two

Adjusting Valve Lash Adjust NOTE:

valve lash as follows: When adjusting the valves, adjust to
the exact setting. Use the range only
1. If adjustment is needed, loosen
for checking adjustment.
the locknut. See Figure 23.
3. Tighten the locknut 50 Nm (37
lbft).
4. Check the valve lash again.
Adjust again if necessary.
Restoring The Vehicle To

Operating Condition Restore
the vehicle to operation condition as
follows:
1. Install the cylinder head covers.
2. Remove the cranking tool from
Figure 23 Valve Lash Adjustment
the inspection hole in the flywheel
housing.
2. Turn the adjusting screw until
3. Replace the end cover on the
the valve lash is correct. Use the
inspection hole and tighten the
exact settings listed in Table 21.
bolts 25 Nm (18 lbft).
Check For : Adjust To:

Valve Type
(mm (in.) (mm (in.)
Intake 0.30 to 0.60 (0.012 to 0.024) 0.40 ( 0.016)
Exhaust 0.50 to 0.80 (0.020 to 0.032) 0.60 (0.024)
Table 21 Valve Lash Adjustment

MAINTENANCE
Fuel/Water Separator Prefilter tighten firmly, using hands

Element Cleaning only.
Clean the prefilter element as follows:
1. Loosen the bleed screw.
See Figure 24.
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.
6. Assemble the sight bowl and the
prefilter element.
[a] Lubricate one O-ring with a
light coating of engine oil and
insert it into the sight bowl.
[b] Screw the prefilter element
and sight bowl together.
7. Assemble the prefilter element
and the separator head.
[a] Lubricate the other O-ring
with a light coating of engine
oil and insert it into the open
end of the prefilter element.
[b] Screw the prefilter element Figure 24 Fuel/Water Separator
onto the separator head and

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 50 times.
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. The engine should
start within four 30 second
attempts.
Fuel Pro 382 Fuel/Water

Separator Element Replacement
Replace the fuel/water separator
element as follows:
Figure 25 Fuel Pro 382

Fuel/Water Separator

MAINTENANCE
1. Remove the vent cap, open the 10. Start the engine and raise the rpm
drain valve and drain fuel into for one minute to purge the air.
approved container, until level is After the air is purged stop the
below the collar. See Figure 25. engine, loosen the vent cap until
the fuel level lowers to just above
2. Using a collar wrench remove
the collar. Tighten the vent cap
collar and cover.
by hand. Check for leaks.
3. Remove the filter element from
the separator head and discard Main Fuel Filter Element
filter and O-rings. Dispose of Changing
filter properly.
Change the main fuel filter element as
4. Clean the cover and the mounting follows:
surface on the body.
1. Open the fuel tank fill cap to
5. Install the filter element with release pressure in the fuel
bottom grommet, new cover system. Replace and tighten the
O-ring, cover and collar. Hand cap.
tighten only.
2. Clean the outside of the fuel filter
6. Fill cover half-way with clean housing (see Figure 26).
fuel through the vent cap opening.
7. Replace O-ring on the vent cap
and install in cover. Hand tighten
only.
NOTE:
Do not use tools to tighten the collar
or vent cap.
8. Tighten the drain plug.

9. Crank the engine for 30 seconds
at a time, but no longer. Before
cranking the engine again, wait
at least two minutes. The engine
should start within four, 30
second attempts.
Figure 26 Main Fuel Filter

3. Using a 36-mm socket, unscrew 9. Install a new O-ring on the filter

the cap on the main fuel filter cap and screw the cap onto the
housing. Remove the cap and lift filter housing. Tighten the cap to
the filter element a short distance 25 Nm (18 lbft).
within the filter housing allowing
10. If equipped with a hand pump on
the fuel to drain off the filter.
the fuel/water separator, work the
4. Remove the filter element from hand pump until resistance is felt.
the cap and clean the filter cap.
Discard the filter element and the NOTE:
O-ring from the cap. There should be a strong resistance
in the hand pump, caused by the
NOTICE: pressure build-up within the fuel
system.
To prevent damage to the filter
housing, do not allow dirt to get into
11. Crank the engine for 30 seconds
the filter housing.
at a time, but no longer. Before
cranking again, wait at least two
5. Clean the filter housing cap. minutes, then crank again. The
engine should start within four
6. Replace the O-ring.
30-second attempts.
7. Lubricate the filter element rubber
12. Once the engine starts allow it to
seal with a light coat of fuel oil
idle for at least one minute or until
and insert it into the filter housing.
idle is smooth before applying
Push down and rotate the filter
the throttle. Check the fuel filter
element while installing to ensure
housing for leaks.
it is seated properly at the base of
the housing.
NOTE: Select the SAE class (viscosity) on the
A properly seated filter element will basis of the average air temperature
hold the fuel in the filter housing and for the season (see Figure 27).
prevent it from draining back to the
tank. If the fuel does not stay in the NOTE:
housing the element is not seated Continued use of a single SAE class
properly, repeat steps 1 and 2. will result in frequent oil changes. For
this reason, view the temperature
8. Fill fuel filter housing with clean ranges for the various SAE classes.
fuel oil.

MAINTENANCE
Figure 27 Engine Oil Temperature Figure 28 Oil Filter Cap

Ranges
To ensure the engine is protected

and the oil stays clean until the next FIRE
oil change, use only oils of API To avoid injury from fire, keep
classification CI-4. open flames, sparks, electrical
Drain oil as follows: resistance heating elements, or
other potential ignition sources
1. Chock the tires, place the away when draining lubrication
transmission in neutral, and set oil. Do not smoke when draining
the parking brake. lubricating oil.
NOTE:
Change the engine oil only when 3. Drain the oil.
the engine is at a temperature of
approximately 60C (140F). [a] Place a suitable receptacle
beneath the oil drain plug on
2. Using a 36-mm socket, unscrew the underside of the oil pan.
the oil filter cap (see Figure 28). [b] Carefully unscrew the oil
drain plug on the oil pan and
allow the oil to drain out
(see Figure 29).

NOTICE:
To prevent damage to the filter
housing, ensure that no foreign
objects get inside it. Do not wipe
clean the filter housing.
5. Replace the O-ring on the cap

(see Figure 30).
6. Install the new filter into the cap.
Figure 29 Engine Oil Drain Plug,
Make sure the filter element is
Oil Pan
securely in place.
7. Screw the cap onto the oil filter
[c] Discard the O-ring on the oil housing. Tighten the cap 45 Nm
drain plug. (33 lbft).
4. Remove both the filter cap and 8. Install the oil drain plug, using a
the filter element. To release the new O-ring. Tighten the plug 80
filter element, twist the lower Nm (60 lbft).
edge of the filter element to the
side (see Figure 30).
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
9. Add new engine oil through the

oil fill (see Figure 31) until the
maximum fill level on the oil
dipstick has been reached. Engine
Figure 30 Cap with Oil Filter fill capacity is 44 L (46 qts).
Element

MAINTENANCE
11. Check the filter and oil drain plug

for signs of leakage.
12. Stop the engine. Check the oil
level again after approximately
five minutes. If necessary, add oil
up to the maximum fill level on
the oil dipstick.
Optional Oil Centrifuge Every

Figure 31 Oil Fill 20,000 miles (32,000 km) change the
oil centrifuge rotor as follows:
1. Remove the cover of the oil
centrifuge.
2. Lift out the dirty rotor and replace
it with a clean one (see Figure
near or on an operating engine,
32).
remove loose items of clothing,
jewelry, tie back or contain long
hair that could be caught in any
moving part causing injury.
10. Start the engine with the

accelerator pedal in the idle
position. Monitor the oil pressure
gauge.
NOTICE:
Keep the engine running at idling Figure 32 Rotor
speed until an oil pressure reading is
obtained. If no oil pressure is shown 3. Replace the centrifuge cover.
after approximately 10 seconds,
stop the engine and determine the
cause. Failure to do so could result
in engine damage.

Coolant Concentration and NOTE:

Inhibitor Level Checking Check and correct the coolant level
only when the coolant temperature is
Check the coolant concentration as
below 50C (122F).
follows:
1. Open the cap on the surge tank
slowly, to allow excess pressure
to escape. Set the cap aside.
HOT COOLANT 2. Before adding coolant,
To avoid scalding from the use a suitable tester to
expulsion of hot coolant, never check the concentration of
remove the cooling system corrosion-inhibiting antifreeze.
pressure cap while the engine is If the concentration is lower
at operating temperature. Wear than 50 percent by volume,
adequate protective clothing drain coolant/add antifreeze until
(face shield, rubber gloves, the concentration is correct.
apron, and boots). Remove the The coolant mixing ratio is
cap slowly to relieve pressure. listed in Table 22.
Corrosion-Inhibiting
Antifreeze
Water Percentage Antifreeze
Protection Down
by Volume Percentage by
to C (F)
Volume
37 (34) 50 50
52 (62) 40 Maximum 60*
*Concentrations of 60 percent affords the maximum antifreeze protection.
Higher concentrations adversely affect heat dissipation.
Table 22 Coolant Mixing Ratio

MAINTENANCE
NOTE: Check the nitrite concentration at

When topping off, use only a regular intervals as listed in Table 24
pre-prepared coolant mixture with a POWER Trac 3Way Test
containing a 50 percent concentration Strip. Nitrite levels must be within
by volume of corrosion-inhibiting 8002400 PPM. Additional SCA
antifreeze. must be added to the coolant when
it becomes depleted, as indicated by
a nitrite concentration of 800 PPM
NOTICE:
or less. If the nitrite concentration
If the concentration of antifreeze is is greater than 800 PPM, do not
too low, there is a risk of corrosion add additional SCA. If the nitrite
or cavitation in the cooling system. concentration is above 2400 PPM, the
system is over-inhibited and should
be partially drained and filled with a
3. Check the coolant level and add 50/50 mix of water and EG.
more coolant if necessary.
NOTE:
Coolant Inhibitor Test Drain intervals listed in Table 24 are
Intervals Coolant inhibitor dependent on proper maintenance.
level should be checked at the
intervals listed in Table 23.
If topping off is needed, add coolant
which is identical to the initial fill
coolant.
Service Application Inhibitor Test Interval

On-highway Trucks and Motor 20,000 Miles (32,000 Kilometers
Coaches
City Transit Coaches, Pick-up and 6,000 Miles (9,600 Kilometers) or
Delivery Short Trip, and Emergency three months, whichever comes first
Vehicles
Industrial, Continuous Duty Generator 500 Hours or three months, whichever
Set, and all Other Applications comes first
Standby Generator Set 200 Hours or yearly, whichever comes
first
Table 23 Required Coolant Inhibitor Test Intervals

Coolant Maintenance Interval Action
A. 20,000 miles (32,000 km) Test nitrite concentration

Antifreeze/Water or 3 months with test strip, add SCA or
+ SCA Inhibitor B. 500 hours or 3 months dilute coolant as needed.
(DDC Power
Cool) A. 300,000 miles (480,000 km)
Drain and clean system.
or 2 years
Replace with new coolant.
B. 2 years or 4,000 hours
A. 20,000 miles (32,000 km)
or 3 months
Ethylene Replace with new coolant.
B. 500 hours or 3 months
Glycol/Water +
SCA Inhibitor A. 300,000 miles (480,000 km) Drain and clean system.
B. 2 years or 4,000 hours Replace with new coolant.
A. 300,000 miles (480,000 km)

Add Power Cool Plus
or 2 years
Ethylene Extender
B. 5,000 hours
Glycol/Water +
A. 600,000 miles (960,000 km)
OAT Inhibitor Drain and clean system.
or 4 years
A. 20,000 miles (32,000 km)
or 3 months
Water Only + B. 500 hours or 3 months
SCA Inhibitor A. 300,000 miles
(480,000 km) or 2 years
A. 300,000 miles
Add Power Cool Plus
(480,000 km) or 2 years
Extender
Water Only + B. 5,000 hours
OAT Inhibitor A. 600,000 miles
(960,000 km) or 4 years
A = On-highway trucks and motor coaches, city transit coaches, pickup
and delivery, short trip, and emergency vehicles.
B = Industrial, generator set, and other applications
Table 24 Nitrite Interval Checks

MAINTENANCE
Inhibitor Level Checking Use 3. Sixty seconds (one minute) after

Detroit Diesel POWER Trac3way dipping, compare the nitrite
Coolant Test Strips to measure pad to the color chart on the
nitrite and glycol concentrations. container to determine the nitrite
Cavitation/corrosion protection is concentration.
indicated on the strip by the level of
4. If the additive indicator (middle
nitrite concentration. Freeze/boil-over
pad) shows any color change,
protection is determined by glycol
this indicates the presence of an
concentration.
unauthorized inhibitor.
Check the inhibitor level as follows:
5. If there is any doubt about the
quality of the coolant, change the
coolant.
6. After each use, replace and
HOT COOLANT tighten the cap on the test strip
To avoid scalding from the container. Discard any test strips
expulsion of hot coolant, never that have turned light pink or tan
remove the cooling system in color.
7. Close and tighten the cap on the
surge tank.
1. Dip the test strip into the coolant

for one second, then remove it.
Shake the strip vigorously to
remove excess liquid.
2. Immediately compare the end
pad to the color chart on the
container to determine the glycol
concentration.

Coolant Flushing and Changing

Flush and change the coolant as
follows:
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
at operating temperature. Wear Figure 33 Coolant Drain Plug
(face shield, rubber gloves, NOTICE:
cap slowly to relieve pressure. Do not apply more than 20 psi (140
kPa) air pressure for a radiator
flush; more pressure could damage
1. Open the cap on the surge tank the radiator or heater core.
slowly, to allow excess pressure
to escape. Set the cap aside.
4. Start radiator flushing by
2. Open the water regulating valve attaching a flushing gun nozzle to
for the heating system. the radiator outlet and run water
3. Place a large receptacle in until the radiator is full.
underneath the coolant drain
plug and open the coolant drain
plug on the bottom of the radiator.
See Figure 33.
NOTE:
Make sure the coolant can flow
unobstructed into the receptacle.

MAINTENANCE
EYE INJURY NOTE:

Before doing this inspection, do either
To avoid injury from flying debris "Coolant Concentration Checking," or
when using compressed air, wear "Coolant Flushing and Changing."
shield or safety goggles) and do Inspect the cooling system as follows:
not exceed 276 kPa (40 psi) air
pressure.
5. Apply no more than 140 kPa (20 HOT COOLANT

psi) air pressure intermittently to
To avoid scalding from the
help dislodge sediment buildup in
expulsion of hot coolant, never
the core.
6. Drain the radiator, and flush the pressure cap while the engine is
radiator until clean water flows at operating temperature. Wear
from the radiator. Remove the adequate protective clothing
flushing gun. (face shield, rubber gloves,
7. When the coolant has drained,
install the coolant drain plug on
the radiator.
8. Add coolant in the specified 1. Inspect the radiator, condenser,
concentration until the maximum coolant pump, engine oil cooler,
mark on the surge tank is reached. freeze plugs, and heat exchanger
for damage and leaks.
9. Start the engine and run it for
about one minute at varying 2. Check all cooling system pipes
speeds to release air pockets in and hoses for damage and leaks;
the cooling system. Ensure the ensure they are positioned to
heater valve is still open. Check avoid chafing, and are securely
the coolant level and add more fastened.
coolant if necessary. 3. Check the outside of the radiator
10. Shut down the engine, close and and condenser for blockage.
tighten the cap on the surge tank. Check fins for damage; straighten
them if necessary.

Rear Engine Power Take-Off replace the damper. Regardless

(REPTO) of the condition, the torsional
coupling must be replaced at
The REPTO accessory drive is an
normal engine overhaul.
option on the MBE 4000 engine. The
drive provides continuous live power 2. Inspect the torsional damper
anytime the engine is operating. The rubber element as follows:
REPTO is driven by the camshaft gear
[a] Check the rubber element for
and is an integral part of a unique
bulges or cracks. If damage is
SAE#1 flywheel housing. All REPTO
found replace the damper.
installations require a torsional
coupling installed at the flange of [b] Inspect the rubber element
the drive unit (i.e. hydraulic pump). teeth for wear. If the teeth
The torsional coupling incorporates a are worn to less than one-half
rubber element designed to reduce the of the new part length (11.0
unwanted stresses from reaching the mm [0.433 in.]), replace the
engine. See Figure 34. torsional damper. See Figure
35.
Figure 34 MBE 4000 REPTO

Connection Illustration Figure 35 REPTO Torsional
Damper
REPTO Torsional Damper
Inspection Inspect the REPTO REPTO Torsional Damper
torsional damper as follows: Cleaning Clean the REPTO
torsional damper as follows:
1. Inspect the outer casing of the
torsional damper for dents or
bulges. If damage is found

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.

CUSTOMER ASSISTANCE
The satisfaction and good will of the Corporation and its distributor/dealer
owners of Detroit Diesel engines are organizations.
of primary concern to Detroit Diesel

CUSTOMER ASSISTANCE
DDC NORTH AMERICAN NAFTA ON-HIGHWAY OFFICES

EASTERN REGION 1 EASTERN REGION 2
Suwanee, Georgia Detroit, Michigan
3325 Paddocks Parkway 13400 Outer Drive West
Suwanee, GA 30024 Detroit, MI 48239-4001
Telephone: 678-341-6100 Telephone: 313-592-5420
Fax: 678-341-6150 Fax: 313-592-5887
WESTERN REGION 1 WESTERN REGION 2
Irvine, California Irvine, California
7700 Irvine Center, Suite 275 7700 Irvine Center, Suite 275
Irvine, CA 92618 Irvine, CA 92618
Telephone: 949-753-7710 Telephone: 949-753-7710
Fax: 949-753-7711 Fax: 949-753-7711
CANADIAN REGION
London, Ontario
Detroit Diesel of Canada, Ltd.
150 Dufferin Ave., Suite 701
London, ON N5A 5N6
Phone: 519-661-0149
Fax: 519-661-0171

MTU DETROIT DIESEL OFF-HIGHWAY SALES AND

CUSTOMER ASSURANCE CENTERS
CONSTRUCTION, INDUSTRIAL MARINE SALES (BX6)
AND MINING SALES (BX7) 13400 Outer Drive, West
13400 Outer Drive, West Detroit, MI 48239-4001
Detroit, MI 48239-4001 Phone: 313-592-7806
Phone: 313-592-5608 Fax: 313-592-5137
Fax: 313-592-5625
POWERGEN AND OIL FIELD SALES GOVERNMENT SALES (BX9)
(BX11) 13400 Outer Drive, West
13400 Outer Drive, West Detroit, MI 48239-4001
Detroit, MI 48239-4001 Phone: 313-592-5875
Phone: 313-592-5708 Fax: 313-592-5158
Fax: 313-592-5158
CUSTOMER ASSURANCE (M24)
13400 Outer Drive, West
Detroit, MI 48239-4001
Phone: 313-592-5550
Fax: 313-592-5717

CUSTOMER ASSISTANCE
DDC INTERNATIONAL REGIONAL OFFICE LOCATIONS
DETROIT DIESEL DISTRIBUTION LATIN AMERICAN REGION

CENTER B.V.(On/Off-Highway) (Off-Highway)
The Netherlands Miami, Florida
Ridderpoort 9 2277 N.W. 14th Street
2984 Ridderkerk Latin America Building
The Netherlands Miami, FL 33125-0068
Phone: (31) 180-442-900 Phone: 305-637-1555
Fax: (31) 180-462-062 Fax: 305-637-1580
MTU DETROIT DIESEL AUSTRALIA MTU ASIA PTE. LTD. (Off-Highway)

PTY. LTD.(On/Off-Highway) Singapore
Victoria Melbourne No. 1 Benoi Place
488 Blackshaws Road Singapore 629923
Altona North,Victoria 3205 Phone: (65) 6861-5922
Australia Fax: (65) 6861-3615 Sales Marine,
Phone: (61) 3 9243-9292 Rail, C & I, Electronics
Fax: (61) 3 9243-9271 Fax: (65) 6860-9959 Sales PowerGen,
Defense
MEXICO (On/Off-Highway)
Detroit Diesel Allison de Mexico, S.A.
Av. Santa Rosa 58
Col. Ampliacion Norte
54160 Tlalnepantla
Edo. de Mexico
MEXICO
Phone: 52 55-5333-1803
Fax: 52 55-5333-1875

Working with DDC Service Step One

Outlets Discuss your problem with a member
As the owner of a Detroit Diesel of management from the authorized
product you have a complete network service outlet. Frequently, complaints
of over 1,000 Detroit Diesel service are the result of a breakdown in
outlets in the U.S. and Canada, plus communication and can quickly be
many outlets worldwide that are resolved by a member of management.
prepared to meet your parts and If you have already discussed the
service needs: problem with the Sales or Service
Manager, contact the General
Service by trained personnel
Manager. If your complaint originates
Sales teams to help determine your with a dealer, explain the matter
specific power requirements to a management member of the
distributorship with whom the dealer
In many areas, emergency service
has his service agreement.
24 hours a day
Complete parts support including Step Two
reliabilt remanufactured parts
When it appears that your problem
Product information and literature cannot readily be resolved at the
We recognize however, that despite distributor level without additional
the best intentions of everyone assistance, contact the Detroit
concerned, misunderstandings may Diesel Regional Product Support or
occur. Normally, any situation Operations Manager responsible for
that arises in connection with the your local distributor. You will be
sale, operation, or service of your assisted by a member of the Manager's
product will be handled by the staff, depending upon the nature of
authorized service outlet in your area your problem.
(in the U.S. and Canada check the Prior to this contact, have the
Yellow Pages or service locator at following information available:
www.detroitdiesel.com for the Detroit
Diesel service outlet nearest you). Engine model and serial number
To further assure your complete Name and location of authorized

satisfaction, we have developed the service outlet
following procedure to use if you have Type and make of equipment
a problem that has not been handled
satisfactorily.

CUSTOMER ASSISTANCE
Engine delivery date and

accumulated miles or hours
of operation
Nature of problem
Chronological summary of
engine's history
Step Three
If you are still not satisfied, present the
entire matter in writing or by phone to:
Sr. Vice President, Parts, Service

and Customer Support
Detroit Diesel Corporation
13400 Outer Drive, West
Detroit, Michigan 482394001
Phone: 3135925000
Fax: 3135927244
When contacting the regional or

home office, please keep in mind that
ultimately your problem will likely
be resolved at the distributorship or
dealership, utilizing their facilities,
equipment, and personnel. Therefore,
it is suggested that you follow
the previously mentioned steps
in sequence when experiencing a
problem.

LIMITED WARRANTY ON NEW DETROIT DIESEL

MBE 4000 ENGINES USED IN ON-HIGHWAY VEHICLE
APPLICATIONS
Terms of Coverage approved by DDC will be used. DDC

may, at its discretion, replace rather
Uses than repair components. A reasonable
time must be allowed to perform
This warranty applies to the first the warranty repair after taking the
retail purchaser and subsequent engine to the authorized service outlet.
owners during the WARRANTY The owner is responsible for the
PERIOD of new Detroit Diesel percentage of repair costs shown in
MBE 4000 Engines (referred to as the warranty period chart. Repairs will
Engine) manufactured by Detroit be performed during normal business
Diesel Corporation and/or supplied hours.
by Detroit Diesel Corporation or
Detroit Diesel of Canada Limited
Warranty Period
(which are collectively referred to as
DDC) for use in on-highway vehicle The WARRANTY PERIOD begins
applications operated in the United on the date the engine is delivered to
States or Canada. the first retail purchaser or put in use
prior to sale at retail, whichever date
Defects occurs first, and ends at the time or
mileage/kilometer limits shown in the
This warranty covers Engine WARRANTY PERIOD chart.
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
new genuine parts or remanufactured
parts or components supplied or

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES
USED IN ON-HIGHWAY VEHICLE APPLICATIONS
Warranty Period
Warranty Limitations Repair Charges to be
(Whichever Occurs First) Paid by Owner
Item
Miles/
Months Parts Labor
Kilometers
No
Engine 0-24 Unlimited No Charge
Charge
0-100,000 mi No
Accessories 0-24 No Charge
0-160,000 km Charge
Upon expiration of the 24 month warranty coverage,
but within 500,000 mi/8000,000 km of use, the warranty
continues to apply as follows:
100% of service
Major Com- 0-500,000 mi No
25-60 outlet's normal
ponents* 0-800,000 km Charge
charge
* Cylinder Block/Head, Crankshaft, Camshaft, Main Bearing Bolts,
Flywheel Housing, Connecting Rod Assemblies, Oil Cooler Housing,
Water Pump Housing and Air Inlet Housing.
Table 25 Warranty Period Chart On-highway Vehicle Applications
Like Replacement Engine Engine Removal and

Reinstallation
Engine(s) supplied by DDC as a
replacement for an engine still under Reasonable labor costs for engine
warranty will assume the identity removal and reinstallation, when
of the engine being replaced and be necessary to make a warranty repair,
entitled to the remaining warranty are covered by this warranty.
coverage.
Service Supplies
The cost of service supplies such
as coolant, oil and filters which are
not reusable due to needed warranty
repairs is covered by this warranty.

This Warranty Does Not Incidental or Consequential

Cover: Damages
Detroit Diesel Corporation is
Repairs Due to Accidents, not responsible for incidental or
Misuse, Storage Damage, consequential costs or expenses which
Negligence or Certain the owner may incur as a result of
Modifications a malfunction or failure covered by
Repairs due to an accident, misuse, this warranty, such as communication
misapplication, storage damage, expenses, meals, lodging, loss of use
negligence or modification exceeding of the engine or vehicle (downtime),
DDC specifications are not covered by loss of time, inconveniences, cargo
this warranty. loss or damage, and other similar costs
and experiences.
Fuel Injection System After
100,000 Miles/160, 000 Other Limitations
Kilometers Performance of REPAIRS is the
The repair or replacement of fuel exclusive Owner's remedy under this
injection pump, high pressure warranty. Detroit Diesel Corporation
lines and nozzles after 100,000 does not authorize ant person to
miles/160,000 kilometers of operation assume or create for it any other
is not covered by this warranty. obligation or liability in connection
with the engine or the accessories.
Maintenance
DDC is not responsible for the
cost of maintenance or repairs
due to lack of performance of
required maintenance services as
recommended by DDC, or the
failure to use fuel, oil, lubricants and
coolant meeting DDC-recommended
specifications. Performance of the
required maintenance and use of
proper fuel, oil, lubricants and coolant
are the responsibility of the owner.
Refer to the Engine Operators Guide
for details.

USED IN ON-HIGHWAY VEHICLE APPLICATIONS
THIS WARRANTY AND

THE EMISSIONS CONTROL
WARRANTY ARE THE ONLY
WARRANTIES APPLICABLE
TO THE ENGINE AS USED
IN ON-HIGHWAY VEHICLE
APPLICATIONS. DETROIT DIESEL
CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS
OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR
PURPOSE. DETROIT DIESEL
CORPORATION SHALL NOT BE
LIABLE FOR ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES
AS DESCRIBED ABOVE.
Some states do not allow the limitation
of how long this warranty may last
or the limitation or exclusion of
incidental or consequential damages,
so the above may not apply to you.
This warranty gives you special legal
rights, and you may also have other
rights which may vary from state to
state.

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE

4000 ENGINES USED IN FIRE TRUCK OR CRASH
VEHICLE APPLICATIONS
Terms of Coverage approved by DDC will be used. DDC

may, at its discretion, replace rather
Uses than repair components. A reasonable
time must be allowed to perform
This warranty applies to the first the warranty repair after taking the
retail purchaser and subsequent engine to the authorized service outlet.
owners during the WARRANTY The owner is responsible for the
PERIOD of new Detroit Diesel percentage of repair costs shown in
MBE 4000 Engines (referred to as the warranty period chart. Repairs will
Engine) manufactured by Detroit be performed during normal business
Diesel Corporation and/or supplied by hours.
Detroit Diesel Corporation or Detroit
Diesel of Canada Limited (which
Warranty Period
are collectively referred to as DDC)
for use in fire truck or crash vehicle The WARRANTY PERIOD begins
applications operated in the United on the date the engine is delivered to
States or Canada. the first retail purchaser or put in use
prior to sale at retail, whichever date
Defects occurs first, and ends at the time or
mileage/kilometer limits shown in the
This warranty covers Engine WARRANTY PERIOD chart.
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
new genuine parts or remanufactured
parts or components supplied or

USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS
Warranty Period
Warranty Limitations Repair Charges to be
(Whichever Occurs First) Paid by Owner
Item
Miles/
Months Parts Labor
Kilometers
0-100,000 mi
Engine 0-60 No Charge No Charge
0-160,000 km
0-100,000 mi
Accessories 0-24 No Charge No Charge
0-160,000 km
Table 26 Warranty Period Chart On-highway Vehicle Applications
Like Replacement Engine This Warranty Does Not

Engine(s) supplied by DDC as a
Cover:
replacement for an engine still under
warranty will assume the identity Repairs Due to Accidents,
of the engine being replaced and be Misuse, Storage Damage,
entitled to the remaining warranty Negligence or Certain
coverage. Modifications
Repairs due to an accident, misuse,
Service Supplies misapplication, storage damage,
negligence or modification exceeding
The cost of service supplies such
DDC specifications are not covered by
as coolant, oil and filters which are
this warranty.
not reusable due to needed warranty
repairs is covered by this warranty.
Fuel Injection System After
100,000 Miles/160, 000
Engine Removal and
Kilometers
Reinstallation
The repair or replacement of fuel
Reasonable labor costs for engine
injection pump, high pressure
removal and reinstallation, when
lines and nozzles after 100,000
necessary to make a warranty repair,
miles/160,000 kilometers of operation
are covered by this warranty.
is not covered by this warranty.

Maintenance obligation or liability in connection

with the engine or the accessories.
DDC is not responsible for the
cost of maintenance or repairs THIS WARRANTY AND
due to lack of performance of THE EMISSIONS CONTROL
required maintenance services as WARRANTY ARE THE ONLY
recommended by DDC, or the WARRANTIES APPLICABLE
failure to use fuel, oil, lubricants and TO THE ENGINE AS USED
coolant meeting DDC-recommended IN ON-HIGHWAY VEHICLE
specifications. Performance of the APPLICATIONS. DETROIT DIESEL
required maintenance and use of CORPORATION MAKES NO
proper fuel, oil, lubricants and coolant OTHER WARRANTIES EXPRESS
are the responsibility of the owner. OR IMPLIED, INCLUDING
Refer to the Engine Operators Guide ANY IMPLIED WARRANTY
for details. OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR
Incidental or Consequential PURPOSE. DETROIT DIESEL
Damages CORPORATION SHALL NOT BE
LIABLE FOR ANY INCIDENTAL
Detroit Diesel Corporation is OR CONSEQUENTIAL DAMAGES
not responsible for incidental or AS DESCRIBED ABOVE.
consequential costs or expenses which
the owner may incur as a result of Some states do not allow the limitation
a malfunction or failure covered by of how long this warranty may last
this warranty, such as communication or the limitation or exclusion of
expenses, meals, lodging, loss of use incidental or consequential damages,
of the engine or vehicle (downtime), so the above may not apply to you.
loss of time, inconveniences, cargo This warranty gives you special legal
loss or damage, and other similar costs rights, and you may also have other
and experiences. rights which may vary from state to
state.
Other Limitations
Performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. Detroit Diesel Corporation
does not authorize ant person to
assume or create for it any other


Mercedes Mbe 4000 Manual DDC SVC Man 0056

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EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

To the Operator experienced, trained personnel

All information subject to change without notice. (Rev. 04/08) i

CAUTION SUMMARY .......................................................................... 1

All information subject to change without notice. (Rev. 04/08) iii

STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR A

CLEANING AND STORAGE ............................................................... 31

SERVICE PRODUCTS ......................................................................... 48

iv All information subject to change without notice. (Rev. 04/08)

SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY

TECHNICAL DATA .............................................................................. 56

All information subject to change without notice. (Rev. 04/08) v

FUEL/WATER SEPARATOR PREFILTER ELEMENT

CUSTOMER ASSISTANCE ................................................................. 89

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000

vi All information subject to change without notice. (Rev. 04/08)

INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 97

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE

All information subject to change without notice. (Rev. 04/08) vii

viii All information subject to change without notice. (Rev. 04/08)

The following cautions must be

All information subject to change without notice. (Rev. 04/08) 1

2 All information subject to change without notice. (Rev. 04/08)

PERSONAL INJURY FIRE

All information subject to change without notice. (Rev. 04/08) 3

Flush your eyes with water.

Get medical attention

4 All information subject to change without notice. (Rev. 04/08)

Electrical Shock Hazard

All information subject to change without notice. (Rev. 04/08) 5

Cooling System Air Intake System

HOT COOLANT PERSONAL INJURY

6 All information subject to change without notice. (Rev. 04/08)

All information subject to change without notice. (Rev. 04/08) 7

Keep those people who are not

Stop the engine immediately if

Do not smoke or allow open

Wear adequate protective

8 All information subject to change without notice. (Rev. 04/08)

All information subject to change without notice. (Rev. 04/08) 9

Figure 1 Emission Label, MBE 4000

10 All information subject to change without notice. (Rev. 04/08)

Engine Conversions and

All information subject to change without notice. (Rev. 04/08) 11

1. EGR Outlet Pipe 8. Engine Trim Cover

5. EGR Cooler 12. Oil Pan

Figure 2 Major Engine Components, Left Side

12 All information subject to change without notice. (Rev. 04/08)

1. Oil Filter 7. EGR Cooler

Figure 3 Major Engine Components, Right Side

All information subject to change without notice. (Rev. 04/08) 13

Engine Type Plate

Figure 5 Engine Type Plate

The last six numbers are the serial

Figure 6 Engine Serial Number

14 All information subject to change without notice. (Rev. 04/08)

Engine Features individual cylinder heads are made of

All information subject to change without notice. (Rev. 04/08) 15

The air compressor, with a Exhaust

The alternator and coolant pump NOTE:

Figure 7 Constant-Throttle Activation (shown with EGR system removed)

16 All information subject to change without notice. (Rev. 04/08)

All information subject to change without notice. (Rev. 04/08) 17