Mercedes-Benz Detroit Diesel MBE 4000 EPA 04 Official Operator’s Manual
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This is the COMPLETE Official Operator’s Manual for the Detroit Diesel Engine.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
This Manual contains information and data to this model. has specs, diagrams and schemes, which give you complete step by step
operations technical maintenance & troubleshooting procedures for your machine. this manual offers information you need for Operate your machine.
the information in this manual will enable you to understand how to maintain your machine without going into service.
all pages are printable, so run off what you need and take it with you into the garage or workshop.
Table Of Contents :
CAUTION SUMMARY ……………………………………………………………….. 1
ENGINE OPERATION …………………………………………………………… 1
PREVENTIVE MAINTENANCE ………………………………………………. 2
ELECTRICAL SYSTEM …………………………………………………………. 4
COOLING SYSTEM ………………………………………………………………. 5
AIR INTAKE SYSTEM ……………………………………………………………. 5
FUEL SYSTEM …………………………………………………………………….. 7
COMPRESSED AIR ………………………………………………………………. 8
LUBRICATING OIL AND FILTERS ………………………………………….. 8
IDENTIFICATION ……………………………………………………………………… 9
PERSONNEL REQUIREMENTS …………………………………………….. 10
ENGINE CONVERSIONS AND MODIFICATIONS …………………….. 10
GENERAL VIEW OF THE MBE4000 ENGINE ………………………….. 10
ENGINE TYPE PLATE …………………………………………………………… 13
DETAILS ON THE PLATE …………………………………………………. 13
ENGINE FEATURES …………………………………………………………….. 14
EXHAUST BRAKE/CONSTANT-THROTTLE VALVES ……………….. 15
TURBO BRAKE, OPTIONAL ………………………………………………….. 16
EXHAUST GAS RECIRCULATION …………………………………………. 16
ELECTRONIC ENGINE CONTROL SYSTEM …………………………… 17
DDEC-ECU — ENGINE-RESIDENT CONTROL UNIT …………… 18
VEHICLE CONTROL UNIT ………………………………………………… 19
SENSOR LOCATIONS ………………………………………………………. 19
OPERATION ……………………………………………………………………………. 21
BEFORE STARTING THE ENGINE ………………………………………… 21
CHECKING THE BATTERIES …………………………………………….. 21
CHECKING THE OIL LEVEL ………………………………………………. 22
CHECKING THE COOLANT LEVEL (COLD CHECK) ……………. 23
ADDING FUEL ………………………………………………………………….. 23
PRIMING THE FUEL SYSTEM …………………………………………… 23
STARTING THE ENGINE ………………………………………………………. 24
CHECKING THE COOLANT LEVEL (HOT CHECK) ……………… 24
STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR A
LONG TIME ……………………………………………………………………… 25
MONITORING ENGINE OPERATION ……………………………………… 26
BATTERY CHARGE ………………………………………………………….. 26
OIL PRESSURE ……………………………………………………………….. 26
EXCESSIVE IDLING …………………………………………………………. 27
CHANGING THE IDLE SPEED ………………………………………………. 27
SHUTTING DOWN THE ENGINE …………………………………………… 27
SHUTTING DOWN AFTER HIGH LOAD OPERATION …………… 27
EMERGENCY RUNNING MODE ……………………………………………. 28
STOP ENGINE OVERRIDE OPTION ………………………………………. 28
COLD WEATHER OPERATION ……………………………………………… 29
WINTER FRONTS …………………………………………………………….. 29
CLEANING AND STORAGE ……………………………………………………… 30
CLEANING THE ENGINE ………………………………………………………. 30
HIGH-PRESSURE CLEANING EQUIPMENT ……………………….. 30
CLEANING THE COOLING SYSTEM ……………………………………… 30
DEGREASING ………………………………………………………………….. 31
STORAGE ……………………………………………………………………………. 32
TROUBLESHOOTING ………………………………………………………………. 33
EMERGENCY STARTING ……………………………………………………… 33
TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM ……………………………………………………………………………… 33
GENERAL TROUBLESHOOTING …………………………………………… 34
SERVICE PRODUCTS ………………………………………………………………. 47
DIESEL FUELS …………………………………………………………………….. 47
FLOW IMPROVERS ………………………………………………………….. 47
KEROSENE ……………………………………………………………………… 47
ENGINE OILS ………………………………………………………………………. 48
SYNTHETIC OILS …………………………………………………………….. 48
COOLANT ……………………………………………………………………………. 49
FULLY-FORMULATED ANTIFREEZE ………………………………….. 49
WATER ……………………………………………………………………………. 49
COOLANT SPECIFICATIONS …………………………………………….. 50
COOLANT CONCENTRATION …………………………………………… 50
SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY
FORMULATED COOLANT …………………………………………………. 51
DROPOUT ……………………………………………………………………….. 51
NON-APPROVED COOLANTS …………………………………………… 51
RECYCLED ANTIFREEZE …………………………………………………. 52
CORROSION INHIBITORS ………………………………………………… 52
DISPOSAL ……………………………………………………………………….. 53
COLD WEATHER PRODUCTS ………………………………………………. 53
WINTER-GRADE DIESEL FUEL …………………………………………. 53
LOW-VISCOSITY ENGINE OIL …………………………………………… 54
WINTER COOLANT ANTIFREEZE PROTECTION ……………….. 54
BATTERIES ……………………………………………………………………… 54
TECHNICAL DATA …………………………………………………………………… 55
ENGINE DATA ……………………………………………………………………… 56
TESTING AND ADJUSTING VALUES ……………………………………… 57
MAINTENANCE ……………………………………………………………………….. 59
SCHEDULED INTERVALS …………………………………………………….. 59
MAINTENANCE SCHEDULE TYPES ………………………………….. 59
SEVERE SERVICE ……………………………………………………….. 59
SHORT-HAUL ………………………………………………………………. 60
LONG-HAUL ………………………………………………………………… 60
MAINTENANCE SCHEDULE AND INTERVAL
OPERATIONS ………………………………………………………………. 60
MAINTENANCE INTERVALS ………………………………………….. 60
MAINTENANCE OPERATION SETS ……………………………….. 60
SCHEDULE USE ………………………………………………………………. 61
MAINTENANCE TABLES ………………………………………………………. 62
REQUIRED MAINTENANCE OPERATIONS …………………………….. 68
ENGINE INSPECTING ………………………………………………………. 68
VALVE LASH CHECKING AND ADJUSTING ……………………….. 68
GAINING ACCESS TO THE VALVES ………………………………. 68
CHOOSING A METHOD ………………………………………………… 69
METHOD ONE ……………………………………………………………… 70
METHOD TWO …………………………………………………………….. 71
ADJUSTING VALVE LASH ……………………………………………… 72
RESTORING THE VEHICLE TO OPERATING CONDITION .. 72
FUEL/WATER SEPARATOR PREFILTER ELEMENT
CLEANING ………………………………………………………………………. 73
FUEL PRO® 382 FUEL/WATER SEPARATOR ELEMENT
REPLACEMENT ……………………………………………………………….. 74
MAIN FUEL FILTER ELEMENT CHANGING ………………………… 75
ENGINE OIL AND FILTER CHANGING ……………………………….. 76
OPTIONAL OIL CENTRIFUGE ……………………………………….. 79
COOLANT CONCENTRATION AND INHIBITOR LEVEL
CHECKING ………………………………………………………………………. 80
COOLANT INHIBITOR TEST INTERVALS ……………………….. 81
INHIBITOR LEVEL CHECKING ………………………………………. 83
COOLANT FLUSHING AND CHANGING …………………………….. 84
COOLING SYSTEM INSPECTING ……………………………………… 85
REAR ENGINE POWER TAKE-OFF (REPTO) …………………….. 86
REPTO TORSIONAL DAMPER INSPECTION ………………….. 86
REPTO TORSIONAL DAMPER CLEANING ……………………… 86
CUSTOMER ASSISTANCE ……………………………………………………….. 88
WORKING WITH DDC SERVICE OUTLETS ……………………………. 92
STEP ONE ……………………………………………………………………….. 92
STEP TWO ………………………………………………………………………. 92
STEP THREE …………………………………………………………………… 93
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000
ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS ……… 94
TERMS OF COVERAGE ……………………………………………………….. 94
USES ………………………………………………………………………………. 94
DEFECTS ………………………………………………………………………… 94
REPAIRS …………………………………………………………………………. 94
WARRANTY PERIOD ………………………………………………………… 94
LIKE REPLACEMENT ENGINE ………………………………………….. 95
SERVICE SUPPLIES ………………………………………………………… 95
ENGINE REMOVAL AND REINSTALLATION ……………………….. 95
THIS WARRANTY DOES NOT COVER: ………………………………….. 96
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ……………………. 96
FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000
KILOMETERS …………………………………………………………………… 96
MAINTENANCE ………………………………………………………………… 96
INCIDENTAL OR CONSEQUENTIAL DAMAGES …………………. 96
OTHER LIMITATIONS ……………………………………………………….. 96
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE
4000 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE
APPLICATIONS ……………………………………………………………………….. 98
TERMS OF COVERAGE ……………………………………………………….. 98
USES ………………………………………………………………………………. 98
DEFECTS ………………………………………………………………………… 98
REPAIRS …………………………………………………………………………. 98
WARRANTY PERIOD ………………………………………………………… 98
LIKE REPLACEMENT ENGINE ………………………………………….. 99
SERVICE SUPPLIES ………………………………………………………… 99
ENGINE REMOVAL AND REINSTALLATION ……………………….. 99
THIS WARRANTY DOES NOT COVER: ………………………………….. 99
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ……………………. 99
FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000
KILOMETERS …………………………………………………………………… 99
MAINTENANCE ………………………………………………………………… 100
INCIDENTAL OR CONSEQUENTIAL DAMAGES …………………. 100
OTHER LIMITATIONS ……………………………………………………….. 100
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