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EPA98 04 MBE 4000 Operators Manual (DDC-SVC-MAN-0056)

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1 Caution Summary
- 1.1 Engine Operation
- 1.2 Preventive Maintenance
- 1.3 Electrical System
- 1.4 Cooling System
- 1.5 Air Intake System
- 1.6 Fuel System
- 1.7 Compressed Air
- 1.8 Lubricating Oil and Filters
2 Identification
- 2.1 Personnel Requirements
- 2.2 Engine Conversions and Modifications
- 2.3 General View of the Mbe4000 Engine
- 2.4 Engine Type Plate
  - 2.4.1 Details on the Plate
- 2.5 Engine Features
- 2.6 Exhaust Brake/Constant-Throttle Valves
- 2.7 Turbo Brake, Optional
- 2.8 Exhaust Gas Recirculation
- 2.9 Electronic Engine Control System
  - 2.9.1 DDEC-ECU — Engine-Resident Control Unit
  - 2.9.2 Vehicle Control Unit
  - 2.9.3 Sensor Locations
3 Operation
- 3.1 Before Starting the Engine
  - 3.1.1 Checking the Batteries
  - 3.1.2 Checking the Oil Level
  - 3.1.3 Checking the Coolant Level (Cold Check)
  - 3.1.4 Adding Fuel
  - 3.1.5 Priming the Fuel System
- 3.2 Starting the Engine
  - 3.2.1 Checking the Coolant Level (Hot Check)
  - 3.2.2 Starting an Engine That Has Not Been Run for a Long Time
- 3.3 Monitoring Engine Operation
  - 3.3.1 Battery Charge
  - 3.3.2 Oil Pressure
  - 3.3.3 Excessive Idling
- 3.4 Changing the Idle Speed
- 3.5 Shutting Down the Engine
  - 3.5.1 Shutting Down After High Load Operation
- 3.6 Emergency Running Mode
- 3.7 Stop Engine Override Option
- 3.8 Cold Weather Operation
  - 3.8.1 Winter Fronts
4 Cleaning and Storage
- 4.1 Cleaning the Engine
  - 4.1.1 High-Pressure Cleaning Equipment
- 4.2 Cleaning the Cooling System
  - 4.2.1 Degreasing
- 4.3 Storage
5 Troubleshooting
- 5.1 Emergency Starting
- 5.2 Troubleshooting the Electronic Engine Control System
- 5.3 General Troubleshooting
6 Service Products
- 6.1 Diesel Fuels
  - 6.1.1 Flow Improvers
  - 6.1.2 Kerosene
- 6.2 Engine Oils
  - 6.2.1 Synthetic Oils
- 6.3 Coolant
  - 6.3.1 Fully-Formulated Antifreeze
  - 6.3.2 Water
  - 6.3.3 Coolant Specifications
  - 6.3.4 Coolant Concentration
  - 6.3.5 Supplemental Coolant Additives for Fully Formulated Coolant
  - 6.3.6 Dropout
  - 6.3.7 Non-Approved Coolants
  - 6.3.8 Recycled Antifreeze
  - 6.3.9 Corrosion Inhibitors
  - 6.3.10 Disposal
- 6.4 Cold Weather Products
  - 6.4.1 Winter-Grade Diesel Fuel
  - 6.4.2 Low-Viscosity Engine Oil
  - 6.4.3 Winter Coolant Antifreeze Protection
  - 6.4.4 Batteries
7 Technical Data
- 7.1 Engine Data
- 7.2 Testing and Adjusting Values
8 Maintenance
- 8.1 Scheduled Intervals
  - 8.1.1 Maintenance Schedule Types
    - 8.1.1.1 Severe Service
    - 8.1.1.2 Short-Haul
    - 8.1.1.3 Long-Haul
    - 8.1.1.4 Maintenance Schedule and Interval Operations
    - 8.1.1.5 Maintenance Intervals
    - 8.1.1.6 Maintenance Operation Sets
  - 8.1.2 Schedule Use
- 8.2 Maintenance Tables
- 8.3 Required Maintenance Operations
  - 8.3.1 Engine Inspecting
  - 8.3.2 Valve Lash Checking and Adjusting
    - 8.3.2.1 Gaining Access To The Valves
    - 8.3.2.2 Choosing A Method
    - 8.3.2.3 Method One
    - 8.3.2.4 Method Two
    - 8.3.2.5 Adjusting Valve Lash
    - 8.3.2.6 Restoring The Vehicle To Operating Condition
  - 8.3.3 Fuel/Water Separator Prefilter Element Cleaning
  - 8.3.4 Fuel Pro® 382 Fuel/Water Separator Element Replacement
  - 8.3.5 Main Fuel Filter Element Changing
  - 8.3.6 Engine Oil and Filter Changing
    - 8.3.6.1 Optional Oil Centrifuge
  - 8.3.7 Coolant Concentration and Inhibitor Level Checking
    - 8.3.7.1 Coolant Inhibitor Test Intervals
    - 8.3.7.2 Inhibitor Level Checking
  - 8.3.8 Coolant Flushing and Changing
  - 8.3.9 Cooling System Inspecting
  - 8.3.10 Rear Engine Power Take-Off (REPTO)
    - 8.3.10.1 REPTO Torsional Damper Inspection
    - 8.3.10.2 REPTO Torsional Damper Cleaning
9 Customer Assistance
- 9.1 Working With Ddc Service Outlets
  - 9.1.1 Step One
  - 9.1.2 Step Two
  - 9.1.3 Step Three
10 Limited Warranty On New Detroit Diesel Mbe 4000 Engines Used in On-Highway Vehicle Applications
- 10.1 Terms of Coverage
  - 10.1.1 Uses
  - 10.1.2 Defects
  - 10.1.3 Repairs
  - 10.1.4 Warranty Period
  - 10.1.5 Like Replacement Engine
  - 10.1.6 Service Supplies
  - 10.1.7 Engine Removal and Reinstallation
- 10.2 This Warranty Does Not Cover:
  - 10.2.1 Repairs Due to Accidents, Misuse, Storage Damage, Negligence or Certain Modifications
  - 10.2.2 Fuel Injection System After 100,000 Miles/160, 000 Kilometers
  - 10.2.3 Maintenance
  - 10.2.4 Incidental or Consequential Damages
  - 10.2.5 Other Limitations
11 Limited Warranty On New Detroit Diesel Mbe 4000 Engines Used in Fire Truck or Crash Vehicle Applications
- 11.1 Terms of Coverage
  - 11.1.1 Uses
  - 11.1.2 Defects
  - 11.1.3 Repairs
  - 11.1.4 Warranty Period
  - 11.1.5 Like Replacement Engine
  - 11.1.6 Service Supplies
  - 11.1.7 Engine Removal and Reinstallation
- 11.2 This Warranty Does Not Cover:
  - 11.2.1 Repairs Due to Accidents, Misuse, Storage Damage, Negligence or Certain Modifications
  - 11.2.2 Fuel Injection System After 100,000 Miles/160, 000 Kilometers
  - 11.2.3 Maintenance
  - 11.2.4 Incidental or Consequential Damages
  - 11.2.5 Other Limitations

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