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To The Operator

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EPA04 MBE 4000 ENGINE OPERATOR'S GUIDETo the OperatorThis guide contains instructions onthe safe operation and preventivemaintenance of your Detroit DieselMBE 4000 engine. Maintenanceinstructions cover routine engineservices such as lube oil and filterchanges in enough detail to permitself-servicing if desired.The operator should become familiarwith the contents of this guide beforeoperating the engine or carrying outmaintenance procedures.Power-driven equipment is onlyas safe as the person operating thecontrols. You are urged, as theoperator of this diesel engine, to keepfingers and clothing away from therevolving belts, drive shafts, etc. onengine installation.Throughout this guide CAUTIONSregarding personal safety andNOTICES regarding engineperformance or service life willappear. To avoid personal injury andensure long engine service life, alwaysheed these instructions.Whenever possible, it will benefityou to rely on an authorized DetroitDiesel service outlet for all yourservice needs from maintenance tomajor parts replacement. Authorizedservice outlets worldwide stockfactory original parts and havethe specialized equipment andAll information subject to change without notice. (Rev. 04/08)experienced, trained personnelto provide prompt preventivemaintenance and skilled enginerepairs.The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel serviceoutlet for information on the latestrevision. The right is reserved tomake changes at any time withoutobligation.NOTICE:Coolant must be inhibited withthe recommended SupplementalCoolant Additives (SCA) listed inthis guide. In addition, the enginecan be equipped with a coolantfilter/inhibitor system as an installedoption or as an after-sale item.Failure to check and maintain SCAlevels at required concentrations willresult in severe damage corrosionto the engine cooling system andrelated components.Trademark InformationDetroit Diesel , DDEC , andDiagnostic Link are registeredtrademarks of Detroit DieselCorporation. Nexiq is a trademarkof Nexiq Technologies, Inc. All othertrademarks are the property of theirrespective owners.DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATIONi

iiAll information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDETABLE OF CONTENTSCAUTION SUMMARY .ENGINE OPERATION .PREVENTIVE MAINTENANCE .ELECTRICAL SYSTEM .COOLING SYSTEM .AIR INTAKE SYSTEM .FUEL SYSTEM .COMPRESSED AIR .LUBRICATING OIL AND FILTERS .112466799IDENTIFICATION .PERSONNEL REQUIREMENTS .ENGINE CONVERSIONS AND MODIFICATIONS .GENERAL VIEW OF THE MBE 4000 ENGINE .ENGINE TYPE PLATE .DETAILS ON THE PLATE .ENGINE FEATURES .EXHAUST BRAKE/CONSTANT-THROTTLE VALVES .TURBO BRAKE, OPTIONAL .EXHAUST GAS RECIRCULATION .ELECTRONIC ENGINE CONTROL SYSTEM .DDEC-ECU — ENGINE-RESIDENT CONTROL UNIT .VEHICLE CONTROL UNIT .SENSOR LOCATIONS .1011111114141516171718192020OPERATION .BEFORE STARTING THE ENGINE .CHECKING THE BATTERIES .CHECKING THE OIL LEVEL .CHECKING THE COOLANT LEVEL (COLD CHECK) .ADDING FUEL .PRIMING THE FUEL SYSTEM .STARTING THE ENGINE .CHECKING THE COOLANT LEVEL (HOT CHECK) .222222232424242525All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATIONiii

TABLE OF CONTENTSSTARTING AN ENGINE THAT HAS NOT BEEN RUN FOR ALONG TIME .MONITORING ENGINE OPERATION .BATTERY CHARGE .OIL PRESSURE .EXCESSIVE IDLING .CHANGING THE IDLE SPEED .SHUTTING DOWN THE ENGINE .SHUTTING DOWN AFTER HIGH LOAD OPERATION .EMERGENCY RUNNING MODE .STOP ENGINE OVERRIDE OPTION .COLD WEATHER OPERATION .WINTER FRONTS .262727272828282829293030CLEANING AND STORAGE .CLEANING THE ENGINE .HIGH-PRESSURE CLEANING EQUIPMENT .CLEANING THE COOLING SYSTEM .DEGREASING .STORAGE .313131313233TROUBLESHOOTING .EMERGENCY STARTING .TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROLSYSTEM .GENERAL TROUBLESHOOTING .34343435SERVICE PRODUCTS .DIESEL FUELS .FLOW IMPROVERS .KEROSENE .ENGINE OILS .SYNTHETIC OILS .COOLANT .FULLY-FORMULATED ANTIFREEZE .WATER .COOLANT SPECIFICATIONS .COOLANT CONCENTRATION .4848484849495050505151ivAll information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDESUPPLEMENTAL COOLANT ADDITIVES FOR FULLYFORMULATED COOLANT .DROPOUT .NON-APPROVED COOLANTS .RECYCLED ANTIFREEZE .CORROSION INHIBITORS .DISPOSAL .COLD WEATHER PRODUCTS .WINTER-GRADE DIESEL FUEL .LOW-VISCOSITY ENGINE OIL .WINTER COOLANT ANTIFREEZE PROTECTION .BATTERIES .5252525353545454555555TECHNICAL DATA . 56ENGINE DATA . 57TESTING AND ADJUSTING VALUES . 58MAINTENANCE .SCHEDULED INTERVALS .MAINTENANCE SCHEDULE TYPES .SEVERE SERVICE .SHORT-HAUL .LONG-HAUL .MAINTENANCE SCHEDULE AND INTERVALOPERATIONS .MAINTENANCE INTERVALS .MAINTENANCE OPERATION SETS .SCHEDULE USE .MAINTENANCE TABLES .REQUIRED MAINTENANCE OPERATIONS .ENGINE INSPECTING .VALVE LASH CHECKING AND ADJUSTING .GAINING ACCESS TO THE VALVES .CHOOSING A METHOD .METHOD ONE .METHOD TWO .ADJUSTING VALVE LASH .RESTORING THE VEHICLE TO OPERATING CONDITION .All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL 3v

TABLE OF CONTENTSFUEL/WATER SEPARATOR PREFILTER ELEMENTCLEANING .FUEL PRO 382 FUEL/WATER SEPARATOR ELEMENTREPLACEMENT .MAIN FUEL FILTER ELEMENT CHANGING .ENGINE OIL AND FILTER CHANGING .OPTIONAL OIL CENTRIFUGE .COOLANT CONCENTRATION AND INHIBITOR LEVELCHECKING .COOLANT INHIBITOR TEST INTERVALS .INHIBITOR LEVEL CHECKING .COOLANT FLUSHING AND CHANGING .COOLING SYSTEM INSPECTING .REAR ENGINE POWER TAKE-OFF (REPTO) .REPTO TORSIONAL DAMPER INSPECTION .REPTO TORSIONAL DAMPER CLEANING .8182848586878787CUSTOMER ASSISTANCE .WORKING WITH DDC SERVICE OUTLETS .STEP ONE .STEP TWO .STEP THREE .89939393947475767780LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS . 95TERMS OF COVERAGE . 95USES . 95DEFECTS . 95REPAIRS . 95WARRANTY PERIOD . 95LIKE REPLACEMENT ENGINE . 96SERVICE SUPPLIES . 96ENGINE REMOVAL AND REINSTALLATION . 96THIS WARRANTY DOES NOT COVER: . 97REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS . 97FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000KILOMETERS . 97MAINTENANCE . 97viAll information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDEINCIDENTAL OR CONSEQUENTIAL DAMAGES . 97OTHER LIMITATIONS . 97LIMITED WARRANTY ON NEW DETROIT DIESEL MBE4000 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLEAPPLICATIONS . 99TERMS OF COVERAGE . 99USES . 99DEFECTS . 99REPAIRS . 99WARRANTY PERIOD . 99LIKE REPLACEMENT ENGINE . 100SERVICE SUPPLIES . 100ENGINE REMOVAL AND REINSTALLATION . 100THIS WARRANTY DOES NOT COVER: . 100REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS . 100FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000KILOMETERS . 100MAINTENANCE . 101INCIDENTAL OR CONSEQUENTIAL DAMAGES . 101OTHER LIMITATIONS . 101All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATIONvii

TABLE OF CONTENTSviiiAll information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDECAUTION SUMMARYThe following cautions must beobserved by the operator of thevehicle or equipment in which thisengine is installed and/or by thoseperforming basic engine preventivemaintenance. Failure to read and heedthese cautions and exercise reasonablecare for personal safety and thesafety of others when operating thevehicle/equipment or performing basicengine preventive maintenance mayresult in personal injury and engineand/or vehicle/equipment damage.Engine OperationObserve the following cautions whenoperating the engine.PERSONAL INJURYDiesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm. Always start and operate anengine in a well ventilatedarea. If operating an engine inan enclosed area, vent theexhaust to the outside. Do not modify or tamperwith the exhaust system oremission control system.FIRETo avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, including openflames, sparks, and electricalresistance heating elements. Donot smoke when refueling.All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATION1

CAUTION SUMMARYPreventive MaintenanceObserve the following cautions whenperforming preventative maintenance.HOT OILTo avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.PERSONAL INJURYTo avoid injury when workingnear or on an operating engineequipped with an hydraulicclutch fan, remove loose itemsof clothing and jewelry. Tie backor contain long hair that couldbe caught in any moving partcausing injury. The hydraulic fanmay start without warning.PERSONAL INJURYTo avoid injury from slipping andfalling, immediately clean up anyspilled liquids.USED ENGINE OILHOT COOLANTTo avoid scalding from theexpulsion of hot coolant, neverremove the cooling systempressure cap while the engine isat operating temperature. Wearadequate protective clothing(face shield, rubber gloves,apron, and boots). Remove thecap slowly to relieve pressure.To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.2All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDEPERSONAL INJURYFIRETo avoid injury from theprojection of tools or otherobjects that may fall on or behindthe vibration damper of anengine, always check and removethese items before starting theengine.To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.FIREPERSONAL INJURYTo avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.FIRETo avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.PERSONAL INJURYTo avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright 2008 DETROIT DIESEL CORPORATION3

CAUTION SUMMARYElectrical SystemObserve the following cautions whenjump starting an engine, charging abattery, or working with the vehicleelectrical system.PERSONAL INJURYTo avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.Battery Explosion and Acid BurnTo avoid injury from batteryexplosion or contact with batteryacid, work in a well ventilatedarea, wear protective clothing,and avoid sparks or flames nearthe battery. If you come in contactwith battery acid: Flush your skin with water. Apply baking soda or lim

authorized Detroit Diesel service outlet for information on the latest revision. The right is reserved to make changes at any time without obligation. NOTICE: Coolant must be inhibited with the recommended Supplemental Coolant Additives (SCA) listed in this guide. In addition, the engine can be equipped with a coolant filter/inhibitor system .