EPA07 MBE 4000 OPERATOR'S MANUAL - Chudovmanuals.chudov.com/Freightliner/DDC-SVC-MAN-0041.pdf ·...

EPA07 MBE 4000 OPERATOR'S MANUAL

To the Operator

This guide contains instructions onthe safe operation and preventivemaintenance of your DetroitDiesel EPA07 MBE 4000 engine.Maintenance instructions coverroutine engine services such as lubeoil and filter changes in enough detailto permit self-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 and

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.

The MBE 4000 engine is built inaccordance with sound technologicalprinciples and based on state-of-the-arttechnology.

Despite this, the engine may constitutea risk of damage to property or injuryto persons if it is not used for itsintended purpose.

The engine should not be modified orconverted in an incorrect manner orthe safety instructions included in thismanual disregarded.

All information subject to change without notice. iDDC-SVC-MAN-0041 Copyright © 2009 DETROIT DIESEL CORPORATION

NOTICE:Coolant must be inhibited with therecommended SCAs (supplementalcoolant additives) listed in theHow To section of this engineoperator's guide. In addition, theengine can be equipped with acoolant filter/inhibitor system as aninstalled option or as an after-saleitem. Failure to check andmaintain SCA levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.

WARRANTYThe applicable engine warranty iscontained in the booklet “WarrantyInformation for MBE 4000 Engines,”available from authorized DetroitDiesel service outlets.

Keep this Operator's Guidewith the engine installation atall times. It contains importantoperating, maintenance, and safetyinstructions.

Trademark Information

DDC®, Detroit Diesel®, DDEC®,Optimized Idle®, Diagnostic Link®,reliabilt®, POWER Trac®, POWERCOOL®, and POWER GUARD®

are registered trademarks of DetroitDiesel Corporation. Delco Remy®is a registered trademark of DelcoRemy America, Inc. Bosch® isa registered trademark of RobertBosch Company N.A. Fuel Pro®isa registered trademarks of DavcoManufacturing, L.L.C. Nexiq™ isa trademark of Nexiq Technologies,Inc. PowerBand® is a registeredtrademark of Gates Rubber Company.Tectyl® is a registered trademark ofDaubert Chemical Company, Inc.Biobor® is a registered trademark ofUnited States Borax and ChemicalCorporation. DuPont® is a registeredtrademark of E.I. DuPont de Nemoursand Company, Inc. All othertrademarks used are the property oftheir respective owners.

ii All information subject to change without notice.DDC-SVC-MAN-0041 Copyright © 2009 DETROIT DIESEL CORPORATION


TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1PERSONNEL REQUIREMENTS ..................................................... 2ENGINE CONVERSIONS AND MODIFICATIONS .......................... 2

CAUTION SUMMARY .......................................................................... 3ENGINE OPERATION ..................................................................... 3PREVENTIVE MAINTENANCE ....................................................... 4ELECTRICAL SYSTEM ................................................................... 6COOLING SYSTEM ......................................................................... 7AIR INTAKE SYSTEM ...................................................................... 7FUEL SYSTEM ................................................................................ 8STARTING AIDS .............................................................................. 8COMPRESSED AIR ......................................................................... 9LUBRICATING OIL AND FILTERS .................................................. 9AFTERTREATMENT SYSTEM ........................................................ 9

ENGINE IDENTIFICATION .................................................................. 11ENGINE COMPONENTS ................................................................. 11ENGINE MODEL AND SERIAL NUMBER DESIGNATION ............. 16

DETAILS ON THE PLATE .......................................................... 16CERTIFICATION LABELS ............................................................... 17

OPERATING INSTRUCTIONS FOR STARTING THE ENGINE .......... 18FIRST TIME START PREPARATION .............................................. 18SYSTEM CHECKS .......................................................................... 18

COOLING SYSTEM CHECKS .................................................... 18LUBRICATION SYSTEM CHECKS ............................................. 19

CHECKING THE OIL LEVEL .................................................. 19EXTENDED STORAGE .......................................................... 20

FUEL SYSTEM CHECKS ............................................................ 20ADDING FUEL ........................................................................ 22PRIMING THE FUEL SYSTEM ............................................... 22

OTHER CHECKS ........................................................................ 22STARTING THE ENGINE-FOR THE FIRST TIME ...................... 24

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ELECTRIC STARTER ............................................................. 25RUNNING THE ENGINE ................................................................. 26

OIL PRESSURE .......................................................................... 26WARM-UP ................................................................................... 26INSPECTION ............................................................................... 26

TRANSMISSION ..................................................................... 26FLUID LEAKS ......................................................................... 26CRANKCASE .......................................................................... 26TURBOCHARGER .................................................................. 26

AVOID UNNECESSARY IDLING ................................................. 27STOPPING THE ENGINE ................................................................ 27EMERGENCY JUMP STARTING .................................................... 27ROUTINE ENGINE START .............................................................. 28

STARTING THE ENGINE-ROUTINE ........................................... 29CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 30CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 30

MONITORING ENGINE OPERATION ............................................. 31BATTERY CHARGE .................................................................... 31OIL PRESSURE .......................................................................... 32EXCESSIVE IDLING ................................................................... 32

CHANGING THE IDLE SPEED ....................................................... 32SHUTTING DOWN THE ENGINE ................................................... 32

SHUTTING DOWN AFTER HIGH LOAD OPERATION ............... 33EMERGENCY RUNNING MODE .................................................... 34STOP ENGINE OVERRIDE OPTION .............................................. 34COLD WEATHER OPERATION ...................................................... 35

WINTER FRONTS ....................................................................... 35

DDEC VI SYSTEM ............................................................................... 36MOTOR CONTROL MODULE ......................................................... 36COMMON POWERTRAIN CONTROLLER ..................................... 37DDEC FEATURES ........................................................................... 38

CRUISE CONTROL ..................................................................... 38DATA RECORDING CAPABILITY ............................................... 40ENGINE BRAKES ....................................................................... 40ENGINE PROTECTION .............................................................. 41CALIFORNIA ENGINE IDLE LIMITING ....................................... 41IDLE SHUTDOWN TIMER .......................................................... 42

DDEC VI OPERATION ..................................................................... 42

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STOP ENGINE OVERRIDE SWITCH ......................................... 43IMMEDIATE SPEED REDUCTION ............................................. 44RED STOP LAMP ........................................................................ 44DIAGNOSTIC TOOL .................................................................... 44

FLASHING MALFUNCTION CODES ...................................... 44

DDEC VI ENGINE DRIVING TIPS ....................................................... 47ACCELERATING THE VEHICLE ..................................................... 47CRUISE CONTROL ......................................................................... 47ENGINE BRAKES AND CRUISE CONTROL .................................. 49SHIFTING ........................................................................................ 49IDLING ............................................................................................. 50

ENGINE BRAKE SYSTEM .................................................................. 51EXHAUST BRAKE/CONSTANT-THROTTLE VALVES .................... 51ANTI-LOCK BRAKING SYSTEMS ................................................... 53DRIVING ON FLAT, DRY PAVEMENT ............................................. 53DESCENDING A LONG, STEEP GRADE ....................................... 54DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 55

ENGINE SYSTEMS ............................................................................. 57FUEL SYSTEM ................................................................................ 57LUBRICATION SYSTEM ................................................................. 57AIR SYSTEM ................................................................................... 57COOLING SYSTEM ......................................................................... 57ELECTRICAL SYSTEM ................................................................... 58EXHAUST SYSTEM ........................................................................ 58EXHAUST GAS RECIRCULATION SYSTEM .................................. 58

AFTERTREATMENT SYSTEM ............................................................ 59OPERATING REQUIREMENTS ...................................................... 60PARKED REGENERATION PROCEDURE ..................................... 60

HAZARDOUS APPLICATIONS ................................................... 61DPF STATIONARY REGEN ONLY = 0-DISABLED ................ 62DPF STATIONARY REGEN ONLY = 1-ENABLED ................. 62

SERVICE RECORD ......................................................................... 62MAINTENANCE ............................................................................... 62

DRIVER ACTIONS ............................................................................... 63

INSTRUMENT PANEL LAMPS ........................................................... 65

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MAINTENANCE ................................................................................... 67SCHEDULED INTERVALS .............................................................. 67

MAINTENANCE SCHEDULE TYPES ......................................... 67SEVERE SERVICE ................................................................. 67SHORT-HAUL ......................................................................... 68LONG-HAUL ........................................................................... 68MAINTENANCE INTERVALS .................................................. 68

SCHEDULE USE ......................................................................... 68MAINTENANCE TABLES ................................................................ 69PREVENTIVE MAINTENANCE INTERVALS .................................. 73

ITEM 1 – LUBRICATING OIL FILTER ......................................... 73ITEM 2 – COOLING SYSTEM ..................................................... 74ITEM 3 – VALVE LASH CHECKING AND ADJUSTMENT .......... 75ITEM 4 – DRIVE BELTS .............................................................. 75ITEM 5 – FUEL/WATER SEPARATOR ........................................ 76ITEM 6 – FUEL FILTERS ............................................................ 76ITEM 7– AIR SYSTEM ................................................................ 77ITEM 8– EXHAUST SYSTEM ..................................................... 78ITEM 9 – AIR COMPRESSOR .................................................... 78ITEM 10 – AFTERTREATMENT SYSTEM (ATS) ........................ 78ITEM 11 – VIBRATION DAMPER ................................................ 78ITEM 12 – REPTO TORSIONAL DAMPER CHECKING ............. 79

REPTO TORSIONAL DAMPER INSPECTION ....................... 79REPTO TORSIONAL DAMPER CLEANING ........................... 79

REQUIRED MAINTENANCE OPERATIONS ................................... 80ENGINE INSPECTING ................................................................ 80

HOW-TO SECTION .............................................................................. 81HOW TO SELECT LUBRICATING OIL ............................................ 81

LUBRICANT REQUIREMENTS .................................................. 81COLD WEATHER STARTING ..................................................... 81SYNTHETIC OILS ....................................................................... 82THE USE OF SUPPLEMENTAL ADDITIVES .............................. 83WHEN TO CHANGE OIL ............................................................. 83

DISPOSING OF WASTE OIL .................................................. 84HOW TO REPLACE THE LUBE OIL AND FILTER ......................... 84

REPLACE LUBRICATING OIL AND FILTER ............................... 84HOW TO SELECT DIESEL FUEL ................................................... 87

QUALITY ..................................................................................... 87

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FUEL CONTAMINATION ............................................................. 87BIODIESEL ............................................................................. 88

PROHIBITED ADDITIVES ........................................................... 88USED LUBRICATING OIL ....................................................... 88FUEL ADDITIVES WITH SULFUR OR SULFATED ASH ........ 88GASOLINE .............................................................................. 89

HOW TO REPLACE THE FUEL FILTERS ....................................... 89REPLACE MAIN FUEL FILTER ELEMENT ................................. 89FUEL/WATER SEPARATOR PREFILTER ELEMENTCLEANING .................................................................................. 91REPLACE DAVCO 382 FUEL PRO®FUEL/WATER SEPARATORELEMENT .................................................................................... 92REPLACE DAVCO 382/382E FUEL PRO® FUEL FILTERELEMENT .................................................................................... 93

ENGINE OUT OF FUEL — HOW TO RESTART ............................. 96ENGINES WITH FUEL PRO FILTERS ........................................ 96ENGINE MOUNTED FUEL FILTER ............................................ 96

HOW TO CLEAN THE ENGINE ...................................................... 97HIGH-PRESSURE CLEANING EQUIPMENT ............................. 97

HOW TO CLEAN THE COOLING SYSTEM .................................... 97DEGREASING ............................................................................. 98

HOW TO SELECT COOLANT ......................................................... 99DEFINITIONS .............................................................................. 99APPROVED COOLANTS ............................................................ 100

ETHYLENE GLYCOL / WATER + CONVENTIONALCORROSION INHIBITOR, PROPYLENE GLYCOL / WATER+ CONVENTIONAL CORROSION INHIBITOR ....................... 101MIXING EG OR PG ANTIFREEZE AND WATER ................... 102RECYCLED ANTIFREEZE .................................................... 103ETHYLENE GLYCOL / WATER + OAT INHIBITOR,PROPYLENE GLYCOL / WATER + OAT INHIBITOR ............. 103WATER ONLY + SCA, WATER ONLY + OAT INHIBITOR ..... 104WATER REQUIREMENTS ...................................................... 105

COOLANTS NOT RECOMMENDED .......................................... 105ALL ANTIFREEZES AND COOLANTS CONTAININGPHOSPHATE ........................................................................... 105AUTOMOTIVE TYPE COOLANTS .......................................... 106METHYL ALCOHOL-BASED ANTIFREEZE ........................... 106

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GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... 106ADDITIVES NOT RECOMMENDED ........................................... 106

SOLUBLE OILS ....................................................................... 106CHROMATES .......................................................................... 106

COOLANT INHIBITOR TEST INTERVALS ................................. 107SUPPLEMENTAL COOLANT ADDITIVES FOR FULLYFORMULATED COOLANT ...................................................... 107MAINTENANCE INTERVALS .................................................. 108

SCA TEST PROCEDURES ......................................................... 110NEED RELEASE COOLANT FILTERS (NON-OAT SYSTEMS) . 111DROPOUT ................................................................................... 112COOLANT EXTENDER INHIBITOR ADDITIVE FOR “OAT”COOLANT ................................................................................... 112

OAT COOLANT DRAIN INTERVAL ........................................ 113CHRONIC COOLANT SYSTEM PROBLEMS ............................. 113DETROIT DIESEL COOLING SYSTEM MAINTENANCEPRODUCTS ................................................................................. 113

POWER COOL SCAS ............................................................. 113POWER COOL COOLANT FILTER ELEMENTS .................... 113POWER COOL CLEANERS ................................................... 113

SUMMARY OF COOLANT RECOMMENDATIONS .................... 114COOLANT LIFE OF GLYCOL COOLANT ............................... 115COOLANT LIFE OF OAT COOLANT ...................................... 115COOLANT LIFE OF OTHER COOLANTS .............................. 115

COOLANT FLUSHING AND CHANGING ................................... 116COOLING SYSTEM INSPECTING ............................................. 117

TROUBLESHOOTING ......................................................................... 118

ENGINE STORAGE ............................................................................. 131PREPARING ENGINE FOR STORAGE .......................................... 131

TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 131EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 132PROCEDURE FOR RESTORING TO SERVICE AN ENGINETHAT HAS BEEN IN EXTENDED STORAGE ............................. 135

CUSTOMER ASSISTANCE ................................................................. 137ROAD SERVICE IN THE U.S. OR CANADA ................................... 139WORKING WITH DETROIT DIESEL SERVICE OUTLETS ............ 139

viii All information subject to change without notice.DDC-SVC-MAN-0041 Copyright © 2009 DETROIT DIESEL CORPORATION


STEP ONE ................................................................................... 140STEP TWO .................................................................................. 140STEP THREE .............................................................................. 140

SPECIFICATIONS ................................................................................ 141FUEL AND LUBRICATING OIL FILTERS ........................................ 141

OIL PAN CAPACITY .................................................................... 141POWER COOL ENGINE PRODUCTS ............................................ 141

POWER COOL FULLY FORMULATED IEG COOLANT ............. 141POWER COOL 2000 AND 3000 SUPPLEMENTAL COOLANTADDITIVE .................................................................................... 142POWER COOL 3000 SUPPLEMENTAL ADDITIVE COOLANTFILTERS ...................................................................................... 143POWER COOL SUPPLEMENTAL ADDITIVE NEED RELEASECOOLANT FILTERS .................................................................... 143POWER COOL PLUS EXTENDED LIFE OAT COOLANT .......... 144POWER COOL PLUS EXTENDER FOR USE WITH POWERCOOL PLUS OAT COOLANT ...................................................... 144POWER COOL COOLING SYSTEM CLEANERS ...................... 144POWER TRAC COOLANT TESTING AND ANALYSISPRODUCTS ................................................................................. 145

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TABLE OF CONTENTS

x All information subject to change without notice.DDC-SVC-MAN-0041 Copyright © 2009 DETROIT DIESEL CORPORATION


INTRODUCTION

This guide is intended for useby the operator of an MBE 4000diesel engine used in the followingapplications:

□ On-Highway Vehicles

□ Fire Truck or Crash/RescueVehicles

Non-Genuine and RebuiltComponent Quality AlertElectronic engine controls havebeen instrumental in aiding enginemanufacturers in meeting the stringentemission requirements of the U.S.Environmental Protection Agency(U.S. EPA) and the California AirResources Board (CARB) andalso in meeting the ever-increasingperformance demands of the customer.

Maintenance procedures mustbe followed in order to continuesatisfactory performance anddurability and to ensure coverage ofthe engine under the manufacturer'swarranty. Many of these maintenanceprocedures also ensure that theengine continues to comply withapplicable emissions standards.Proper maintenance procedures, usingspecific components engineered tocomply with emissions regulations,may be performed by an authorizedDetroit Diesel distributor or dealer,an independent outlet or the operator

or owner. The owner is responsiblefor determining the suitability ofcomponents to maintain emissionscompliance during the engine's usefulemission life.

Detroit Diesel cautions that theindiscriminate rebuilding of precisioncomponents, without the benefit ofspecifications, specialized equipment,and knowledge of the electronicoperating system, will jeopardizeperformance or lead to more seriousproblems, and can take the engineoutside of compliance with U.S. EPAor CARB emissions standards.

There are other components inan engine, such as turbocharger,camshaft, piston, etc., whichare specifically designed andmanufactured to exacting standardsfor emissions compliance. It isimportant that these components, ifreplaced, modified or substituted, canbe verified to ensure that the engineremains in compliance with emissionsstandards. The use of inadequatelyengineered, manufactured or testedcomponents in repair or rebuild ofthe engine may be in violation of thefederal Clean Air Act and applicableU.S. EPA or CARB regulations.

All information subject to change without notice. 1DDC-SVC-MAN-0041 Copyright © 2009 DETROIT DIESEL CORPORATION

INTRODUCTION

Furthermore, modern engines exhibitoperating parameters which requirethe use of proper fluids, such asfuel, coolant and lubricating oil, tomaintain long engine life. The use offluids that do not meet Detroit Dieselspecifications may result in early wearout or engine failure.

Personnel RequirementsWork on the engine should be carriedout only by skilled technicians whohave been instructed in the specificskills necessary for the type of workbeing performed.

Engine Conversions andModificationsThe function and safety of the enginecould be affected if unauthorizedmodifications are made to it. DetroitDiesel will not accept responsibilityfor any resulting damage.

Tampering with the fuel injectionsystem and engine electronics couldalso affect the engine's power output orexhaust emission levels. Compliancewith the manufacturer's settingsand with statutory environmentalprotection regulations cannot then beguaranteed.

2 All information subject to change without notice.DDC-SVC-MAN-0041 Copyright © 2009 DETROIT DIESEL CORPORATION


CAUTION SUMMARY

The 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 andheed these cautions and exercisereasonable care for personal safetyand the safety of others whenoperating the vehicle/equipmentor performing basic enginepreventive maintenance may resultin personal injury and engineand/or vehicle/equipment damage..

Engine OperationObserve the following cautions whenoperating the engine.

FIRE

To avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, including openflames, sparks, and electricalresistance heating elements. Donot smoke when refueling.

HOT EXHAUST

During parked regeneration theexhaust gases will be extremelyHOT and could cause a fireif directed at combustiblematerials. The vehicle must beparked outside.

PERSONAL INJURY

Diesel 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.


CAUTION SUMMARY

Preventive MaintenanceObserve the following cautions whenperforming preventative maintenance.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

PERSONAL INJURY

To avoid injury from slipping andfalling, immediately clean up anyspilled liquids.

USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

PERSONAL INJURY

To 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.

HOT COOLANT

To 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.



PERSONAL INJURY

To 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.

PERSONAL INJURY

To 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.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.


CAUTION SUMMARY

Electrical SystemObserve the following cautions whenjump starting an engine, charging abattery, or working with the vehicleelectrical system.

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

Electrical Shock

To avoid injury from electricalshock, use care when connectingbattery cables. The magneticswitch studs are at batteryvoltage.

Battery Explosion and Acid Burn

To 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 lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.

ELECTRICAL SHOCK

To avoid injury from electricalshock, do not touch batteryterminals, alternator terminals, orwiring cables while the engine isoperating.



Cooling SystemObserve the following cautions whenservicing the cooling system.

HOT COOLANT


PERSONAL INJURY


Air Intake SystemObserve the following cautions whenworking on the air intake system.

PERSONAL INJURY

To avoid injury from hot surfaces,wear protective gloves, or allowengine to cool before removingany component.

PERSONAL INJURY

To 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.


CAUTION SUMMARY

Fuel SystemObserve the following cautions whenfueling the vehicle or working withthe fuel system.

PERSONAL INJURY

To avoid injury from fuel spills,do not overfill the fuel tank.

FIRE

To avoid injury from fire, containand eliminate leaks of flammablefluids as they occur. Failure toeliminate leaks could result infire.

FIRE


FIRE

To avoid injury from fire causedby heated diesel-fuel vapors:

□ Keep those people who are notdirectly involved in servicingaway from the engine.

□ Stop the engine immediately ifa fuel leak is detected.

□ Do not smoke or allow openflames when working on anoperating engine.

□ Wear adequate protectiveclothing (face shield,insulated gloves and apron,etc.).

□ To prevent a buildup ofpotentially volatile vapors,keep the engine area wellventilated during operation.

Starting Aids



Compressed AirObserve the following cautions whenusing compressed air.

EYE INJURY

To avoid injury from flying debriswhen using compressed air, wearadequate eye protection (faceshield or safety goggles) and donot exceed 276 kPa (40 psi) airpressure.

Lubricating Oil and FiltersObserve the following cautions whenreplacing the engine lubricating oiland filters.

PERSONAL INJURY


FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.

Aftertreatment SystemObserve the following cautions whenservicing the A·ertreatment System(ATS). Be advised that these two labelsare attached to the AftertreatmentDevice (ATD).


CAUTION SUMMARY

Figure 1 Hot Surfaces External and Internal Caution

Figure 2 Heavy Aftertreatment Device Caution



ENGINE IDENTIFICATION

The MBE 4000 engine has acertification label, engine model andserial number for identification.

Engine ComponentsFor a general view of the MBE 4000engine, showing major components,see Figure 3 for the left-hand side,and Figure 4 for the right-hand side.See Figure 5 for left side sensorlocations and see Figure 6 for rightside sensor locations.



1. Fuel Pump 9. Air Intake Manifold

2. Intake Throttle Valve 10. Fuel Filter Bracket

3. Air Intake Elbow 11. Fuel Filter and Lines

4. Alternator & A/C Mounting Bracket 12. Doser Block Assembly

5. Gas Mixer Housing 13. Engine Harness

6. Smart Injector Adaptor Frame(Internal)

14. MCM

7. Constant Throttle Valve (Internal) 15. Dipstick and Oil Fill

8. Electrostatic Crankcase Breather

Figure 3 Major Engine Components, Left Side



1. Air Intake Elbow 8. EGR Cooler Bracket

2. Turbocharger 9. Grid Heater

3. Fuel Doser Valve 10. EGR Valve

4. Flywheel Housing 11. EGR Coolant Return

5. Hot EGR Cooler Pipe 12. Coolant Outlet

6. Exhaust Manifold 13. Coolant Inlet

7. EGR Cooler 14. Front Mount

Figure 4 Major Engine Components, Right Side



1. Fuel Temperature Sensor 5. Fuel Compensation PressureSensor

2. Intake Throttle Valve 6. Fuel Cut-off

3. Intake Manifold Pressure/Temper-ature Sensor

7. Fuel Line Pressure Sensor

4. Doser Block Asembly

Figure 5 Left Side Sensor Locations



1. EPV-1 4. EGR Delta-P Sensorr

2. Wastegate Actuator 5. Oil Pressure/Temperature Sensor

3. Turbocharger Pressure/Tempera-ture Sensor

Figure 6 Right Side Sensor Locations



Engine Model And SerialNumber DesignationThe fourteen-digit engine model andserial number is located on the leftfront of the engine cylinder block, onthe DDEC-MCM label and on the oilfilter housing on the right-hand side ofthe engine. See Figure 7.

Figure 7 Location of Engine TypePlate

Details on the Plate

The engine type reference, OM 460LA, is the production code. The firstthree numbers of the engine serialnumber are the engine series number,the next three number are the enginemodel number. See Figure 8.

The engine type reference and thecomplete engine model and serialnumber appears beside the nameof the manufacturer. The enginetype reference, OM 460 LA is theproduction code. The engine model

and serial number contains the typereference followed by a sequentialmanufacturing number. The last sixdigits of the engine model and serialnumber is the serial number for theengine. See Figure 8.

Figure 8 Engine Type Plate



Certification LabelsThe MBE 4000 engine complieswith all United States EnvironmentalProtection Agency (USEPA) andCalifornia Air Resources Board

(CARB) emission standards. Anemission label is attached to thecylinder head cover, as required bylaw. See Figure 9.

Figure 9 Emission Label, MBE 4000


OPERATING INSTRUCTIONS FOR STARTING THE ENGINE

OPERATING INSTRUCTIONS FOR STARTING THEENGINE

Following are instructions for startingthe engine.

First Time StartPreparationWhen preparing to start a new ornewly overhauled engine which hasbeen in storage, perform all of theoperations listed below. Also refer tothe “ENGINE STORAGE” sectionof this guide. Failure to follow theseinstructions may result in seriousengine damage.

Be sure you are familiar with all ofthe instruments, gauges and controlswhich are needed to operate theengine.

Note especially the location andfunction of the following:

□ Oil pressure gauge

□ Low oil pressure warning light

□ Coolant temperature gauge

□ High coolant temperature warninglight

□ Water in fuel warning light

□ Tachometer

□ Air restriction indicator

Watch for any signs of engineproblems when starting or driving. If

the engine overheats, uses excessivefuel or lubricating oil, vibrates,misfires, makes unusual noises, orshows an unusual loss of power, turnthe engine off as soon as possible anddetermine the cause of the problem.Engine damage may be avoided by aquick response to early indications ofproblems.

When starting the engine incold weather, refer to “How toSelect Coolant” in the “HOW-TOSECTION” of this guide.

System ChecksPerform the following system checksbefore starting for the first time.

Cooling System Checks

Check the cooling system as follows:

1. Make sure all drain cocks inthe cooling system are installed(drain cocks are often removedfor shipping) and are closedtightly.

2. Remove the radiator pressurecontrol cap and fill with genuineDetroit Diesel POWER COOL®antifreeze or an equivalentquality ethylene glycol (EG)or propylene glycol (PG) baseantifreeze solution in the required



concentration. In extremelyhot environments, properlyinhibited water may be used inthe summer. Keep the coolantlevel at the bottom of the fillerneck to allow for expansion ofthe coolant. For more detailedrecommendations, Refer to“How to Select Coolant” in the“HOW-TO SECTION” of thisguide.

3. Entrapped air must be purgedafter filling the cooling system.To do this, allow the engine towarm up with the pressure capremoved. With the transmissionin neutral, increase engine speedabove 1,000 rpm and add coolantto the radiator as required.

4. Check to make sure the frontof the radiator and air-to-aircharge cooler (if equipped) areunblocked and free of debris.

Lubrication System Checks

The lubricating oil film on the rotatingparts and bearings of a new or newlyoverhauled engine, or one which hasbeen in storage for six months ormore, may be insufficient when theengine is started for the first time.

NOTICE:Insufficient lubrication at startup cancause serious damage to enginecomponents.

To insure an immediate flow ofoil to all bearing surfaces at initialengine startup, the engine lubricationsystem should be charged with acommercially available pressurepre-lubricator. If this is impractical,rocker covers should be removed andclean lubricating oil should be pouredover the rocker arms. The oil shouldbe the same weight and viscosityas that used in the crankcase. Afterpre-lubricating, add additional oil tobring the level to the proper mark onthe dipstick.

For lubricant recommendation,Refer to “How to Select LubricatingOil” in the “HOW-TO SECTION” ofthis guide.

Checking the Oil Level — Checkthe oil level as follows:

1. Check the oil level using the oildipstick (See Figure 10).



PERSONAL INJURY


Figure 10 Oil Dipstick

2. If necessary, top off by fillingengine oil through the oil fill tube(See Figure 11) to the maximumfill level on the oil dipstick. Donot overfill.

Figure 11 Oil Fill Tube

Extended Storage — An enginein storage for an extended periodof time (over winter, for example)may accumulate water in the oilpan through normal condensation ofmoisture (always present in the air)on the cold, internal surfaces of theengine.

NOTICE:Failure to eliminate water-dilutedlubricating oil may lead to seriousengine damage at startup.

Lube oil diluted by water cannotprovide adequate bearing protectionat engine startup. For this reason,Detroit Diesel recommends replacingthe engine lubricating oil and filtersafter extended storage.

Fuel System Checks

Fill the tanks with the recommendedfuel. Keeping tanks full reduces watercondensation and helps keep fuelcool, which is important to engineperformance. Full tanks also reducethe chance for microbe (black slime)growth. For fuel recommendations,Refer to “How to Select Diesel Fuel”in the “HOW-TO SECTION” of thisguide. Make sure the fuel shutoffvalve (if used) is open.



NOTICE:Prolonged use of the starting motorand engine fuel pump to prime thefuel system can result in damage tothe starter, fuel pump and injectors.

This may cause erratic engineoperation due to the amount of airin the lines and filters from the fuelsupply tank to the cylinder head

NOTICE:Under no circumstances shoulda starting aid such as ether beused to run the engine until thefuel system is primed. Injectordamage will result if this methodis used.

If an external starting aid is used, theheat generated by the external fuelsource will cause the injector tips tobe damaged when the fuel cools them.The injector plunger and bushingcan be scored from running withoutlubrication.

NOTICE:Engines equipped with startingdevices dependent on compressedair or gas reservoirs should alwaysbe primed before initial startup.Otherwise, reserve pressure canbe exhausted and injectors may bedamaged from lack of lubricationand cooling.

To insure prompt starting and evenrunning, the fuel system mustbe primed if air has entered the fuelsystem. Priming is done by connectinga manual or electric priming pump tothe secondary fuel filter adaptor.



Authorized Detroit Diesel serviceoutlets are properly equipped and havethe trained technicians to perform thisservice.

Priming is not normally required ifthe filter elements are filled with cleanfuel when installed and the lines arenot drained of fuel.

If the engine is equipped with afuel/water separator, drain off anywater that has accumulated. Waterin fuel can seriously affect engineperformance and may cause enginedamage. Detroit Diesel recommendsinstallation of a fuel/water separatorwherever water contamination is aconcern.

Adding Fuel — When adding fuel,pay attention to the following:

□ Add winter or summer grade fuelaccording to the season of theyear.

□ Work in the cleanest conditionspossible.

□ Prevent water from entering thefuel tank.

For further information, Refer to the“HOW-TO SECTION” of this guide.

Priming the Fuel System —Prime the fuel system as follows:

1. If equipped with a hand pumpon the fuel filter or fuel/water

separator, work the hand pumpuntil resistance is felt.

NOTE:There should be a strong resistancein the hand pump, caused by thepressure buildup within the fuelsystem.

2. Crank the engine for 30 secondsat a time, but no longer. Wait atleast two minutes. The engineshould start within four 30-secondattempts.

Other Checks

Make sure the transmission isfilled to the proper level with thefluid recommended by the gearmanufacturer. Do not overfill.









Make sure cable connections tothe storage batteries are clean andtight. Check the hydrometer “eye” ofmaintenance-free batteries for charge.See Figure 12.

If lead-acid or low-maintenancebatteries are used, make sure batteryelectrolyte level is normal.

Use only batteries that have beencorrectly filled and serviced. Toprovide corrosion protection, applydielectric grease liberally to theterminal pads. Approved suppliers areListed in Table 1.

Manufacturer Lubricant orPart Number

Shell Oil Co. No. 71032; No.71306

Texaco, Inc. No. 955

Quaker State No. NYK-77

Table 1 Approved ElectricalLubricants

Figure 12 Maintenance-FreeBattery “Eye”

Check the turbocharger for signs ofoil or exhaust leaks. Leaks should becorrected before starting the engine.Check engine mounting bolts fortightness. Bolts should be retightened,if necessary.



Starting the Engine-For TheFirst Time

Before starting the engine the firsttime, perform the operations listed inthe System Checks section.

NOTICE:The turbocharger may be seriouslydamaged if the engine is crankedwith the air shutdown in the closedposition.

The engine may require the use of acold weather starting aid if the ambienttemperature is below 4°C (40°F).

FLAMES, EXPLOSION ANDTOXICITY

To avoid injury from flames,explosion, and toxicants whenusing ether, the followingprecautions must be taken:

□ Do not smoke when servicingether system.

□ Work in well ventilated area.

□ Do not work near open flames,pilot flames (gas or oilheaters), or sparks.

□ Do not weld or carry an openflame near the ether system ifyou smell ether or otherwisesuspect a leak.

To start an MBE 4000 engine, makesure the transmission is in neutral andturn the ignition key on.

ENGINE EXHAUST

To avoid injury from inhalingengine exhaust, always operatethe engine in a well-ventilatedarea. Engine exhaust is toxic.

PERSONAL INJURY

To avoid injury when workingnear or on an operating engine,remove loose items of clothingand jewelry. Tie back or containlong hair that could be caught inany moving part causing injury.

You will notice that both the AmberWarning Lamp (AWL)/Check Engineand the Red Stop Lamp (RSL)/StopEngine will come on. This is theresult of the Detroit Diesel ElectronicControls (DDEC®) diagnosingthe system to ensure everything isfunctional, including the light bulbsfor the warning lights. If everythingis OK, both lights will go out inapproximately five seconds.



Start the engine after the lights goout. If starting a vehicle, start theengine with foot off the foot pedal.

NOTICE:If the warning lights stay on, ordo not come on momentarily afterturning on the ignition, contactthe Detroit Diesel CustomerSupport Center at 313–592–5800.Operating the engine under thesecircumstances may result in enginedamage.

Electric Starter — Start an engineequipped with an electric startingmotor as follows:

NOTICE:To prevent serious starting motordamage, do not press the starterswitch again after the engine hasstarted.

Important: At outside temperaturesbelow –25°C (–13°F), a coolantpreheater is recommended.

1. Chock the tires, place thetransmission in neutral, and setthe parking brake.

2. With foot OFF the foot pedal,turn on the ignition switch andstart the engine

3. If the engine doesn't start after30 seconds, stop. Try again afterwaiting two minutes. The engineshould start within four 30-secondattempts.

NOTICE:Do not rev the engine if the oilpressure gauge indicates nooil pressure. To avoid enginedamage, shut down the enginewithin approximately ten seconds.Check to determine the cause of theproblem.

4. Monitor the oil pressure gaugeimmediately after starting theengine.

NOTE:Do not place the engine under full loaduntil it reaches operating temperature.



Running the EngineWhile the engine is operating, monitorthe battery charge indicator light,the oil pressure and avoid excessiveidling.

Oil Pressure

Observe the oil pressure gageimmediately after starting the engine.A good indicator that all moving partsare getting lubrication is when theoil pressure gage registers pressure(7 psi or 50 kPa at idle speed). Ifno pressure is indicated within 10to 15 seconds, stop the engine andcheck the lubrication system. Thepressure should not drop below 36 psior 250 kPa at 1800 rpm, and normaloperating pressure should be higher. Ifoil pressure does not fall within theseguidelines, it should be checked witha manual gage.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

Warm-up

Run the engine at part throttle forabout five minutes to allow it to warmup before applying a load.

Inspection

While the engine is idling, inspect thetransmission, check for fluid leaks,check the crankcase and turbocharger.

Transmission — While theengine is idling, check the automatictransmission (if equipped) for properoil level and add oil as required.

Fluid Leaks — Look for coolant,fuel or lubricating oil leaks. If anyare found, shut down the engineimmediately and have the leaksrepaired after the engine has cooled.

Crankcase — If the engine oilwas replaced, stop the engine afternormal operating temperature hasbeen reached. Allow the oil to drainback into the crankcase for abouttwenty minutes, then check the oillevel. If necessary, add oil to bringthe level to the proper mark on thedipstick. Use only the heavy-dutyoils recommended. Refer to ”How toSelect Lubricating Oil” in this guide.

Turbocharger — Make a visualinspection of the turbocharger foroil leaks, exhaust leaks, excessivenoise or vibration. Stop the engineimmediately if a leak or unusual noiseor vibration is noted. Do not restartthe engine until the cause of theconcern has been investigated and



corrected. Authorized Detroit Dieselservice outlets are properly equippedto perform this service.

Avoid Unnecessary Idling

Whenever possible, avoid unnecessaryidling.

Never allow the engine to idle formore than 30 minutes. Excessiveidling can cause oil to leak from theturbocharger.

During long engine idling periodswith the transmission in neutral, theengine coolant temperature may fallbelow the normal operating range.The incomplete combustion of fuelin a cold engine will cause crankcaseoil dilution, formation of lacquer orgummy deposits on the valves, pistons,and rings, and rapid accumulation ofsludge in the engine. When prolongedidling is necessary, maintain at least850 rpm spring/summer and 1200 rpmfall/winter.

Stopping the EngineStop an engine under normal operatingconditions as follows:

1. Reduce engine speed to idle andput all shift levers in the neutralposition.

NOTICE:Stopping a turbocharged engineimmediately after high-speedoperation without allowing asufficient cool-down period maycause damage to the turbocharger,as it will continue to turn without anoil supply to the bearings.

2. Allow the engine to run betweenidle and 1000 rpm with no loadfor four or five minutes. Thisallows the engine to cool andpermits the turbocharger to slowdown. After four or five minutes,shut down the engine.

Emergency Jump StartingThe DDEC VI system operates on 12volts DC. If a DDEC VI engine withan electric starting motor requiresemergency jump starting, do notexceed 16 volts DC.



BATTERY EXPLOSION

To avoid injury from batteryexplosion when jump starting theengine, do not attach the cableend to the negative terminal ofthe disabled battery.

NOTICE:Jump starting with voltages greaterthan those indicated or reversingbattery polarity may damage theMCM.

NOTICE:Failure to connect jumper cablesin the proper sequence can resultin alternator and/or equipmentdamage.

Before attempting to jump start theengine, make sure the jumper cablesare connected properly (positive topositive, negative to negative ground)and in the proper sequence (negativeto negative ground last).







Routine Engine StartFollowing are procedures for a routineeveryday engine start.



ENGINE EXHAUST


PERSONAL INJURY

To avoid injury when workingnear or on an operating engine,remove loose items of clothingand jewelry. Tie back or containlong hair that could be caught inany moving part causing injury.

Starting the Engine-Routine

Before a routine start, Refer tothe“Maintenance” section and see thedaily checks for your engine.

Important: Before starting theengine, carefully read all operatinginstructions in this manual and do allthe recommended pretrip inspectionsand daily maintenance. Check theengine oil and fuel levels, and draincontaminants from the fuel/waterseparator (optional).

NOTE:If you drain the fuel/water separatorcompletely, you may have to prime thefuel system.

NOTE:As a safety function, the electronicengine control system may be wired tostart the engine only If the transmissionis in neutral. This is vehicle applicationspecific.

NOTICE:Never attempt to start the MBE4000 electronic engine using etheror any other starting fluid. Seriousengine damage could result.

1. Turn on the ignition switch.

2. With the accelerator pedal in theidle position, start the engine. Ifthe engine doesn't start after 30seconds, stop. Try again afterwaiting two minutes. The engineshould start within four 30-secondattempts.

3. Check the engine for leaks.

[a] Check all hoses, hose clamps,and pipe unions on the enginefor tightness. Shut down theengine and tighten them ifnecessary.



[b] Check the oil feed and returnlines at the turbocharger fortightness. Shut down theengine and tighten them ifnecessary.

4. Shut down the engine.

5. Approximately five minutes aftershutdown, check the engine oillevel. If necessary, add oil up tothe maximum fill level on the oildipstick.(See Figure 13). Do notoverfill.


6. Check all the mounting fastenerson the engine for tightness.

Checking the Coolant Level(Cold Check)

Check coolant level as follows:

1. Ensure that all coolant plugs inthe bottom of the radiator and on

the radiator outlet pipe are secureand tight.

2. Check the coolant level. Thecooling system is correctly filledwhen the coolant is between themaximum and minimum markson the surge tank.

NOTE:For more information, Refer to the“Maintenance” section.

Checking the Coolant Level (HotCheck)

Check the coolant levels as follows:

1. Allow the engine to run forapproximately five minutes at amoderate speed.



HOT COOLANT


2. Then, with the coolanttemperature above 50°C (122°F),recheck the coolant level.

3. Add more coolant if necessary.Open the heater valves (ifequipped) before adding coolant.

4. Do not close the heater valvesuntil the engine has been runbriefly and the coolant levelagain checked and corrected asnecessary.

Monitoring EngineOperationWhile the engine is operating, monitorthe battery charge indicator light,the oil pressure and avoid excessiveidling.

Battery Charge

The battery charge indicator light(See Figure 14) must go out once theengine starts.

Figure 14 Battery Charge IndicatorLight

If the indicator light comes onwhile the engine is running, do thefollowing:

FIRE


1. Shut down the engine.

2. Check the poly-V belt fortightness.



3. Do a load test on the batteries.Charge or replace the batteries asneeded.

4. If necessary, visit the nearestauthorized dealer to have thealternator voltage and outputchecked.

Oil Pressure

When the engine has reached itsnormal operating temperature, theengine oil pressure must not dropbelow the following values:

□ 250 kPa (36 psi) at rated speed

□ 50 kPa (7 psi) at idling speed

If oil pressure drops below thesevalues, stop the engine and determinethe cause.

Excessive Idling

Never allow the engine to idle formore than 30 minutes. Excessiveidling can cause oil to leak from theturbocharger.

Changing the Idle SpeedThe rpm range of the MBE 4000engine is 600 to 850 rpm if theparameters in the Common PowertrainController (CPC) are set to the defaultrange.

Change the idle speed as follows:

1. Turn the cruise control switch tothe OFF position.

2. To increase the idle speed, pushthe "Resume" switch until the idleis fast enough.

3. To decrease the idle speed, pushthe "Decel" switch until the idleis slow enough.

Shutting Down the EngineIf the engine has been running at fulloutput or the coolant temperature hasbeen high, allow the engine to idlefor one or two minutes without load.Then turn off the ignition key switch.

If any of the following occur, shutdown the engine immediately.

□ The oil pressure swings back andforth or falls sharply.

□ Engine power and rpm fall, eventhough the accelerator pedalremains steady.

□ The exhaust pipe gives off heavysmoke.

□ The coolant and/or oil temperatureclimb abnormally.

□ Abnormal sounds suddenly occurin the engine or turbocharger.



Shutting Down After High LoadOperation

After high load operation, do thefollowing:

NOTICE:After high load operation, if theengine has been running at fulloutput or the coolant temperaturehas been high, allow the engine toidle for one or two minutes withoutload. Shutting down the enginewithout idling may cause damage tothe turbocharger.

Turn off the ignition switch and shutdown the engine.



Emergency Running ModeThe engine is equipped with theelectronic engine control system,which monitors the engine as it isrunning.

As soon as a fault is detected, it isevaluated and one of the followingmeasures is initiated.

NOTICE:To prevent possible serious enginedamage, have any faults correctedwithout delay by an authorizeddealer.

□ In conjunction with any dashboardor instrument panel display, thecode for the electronic controlunit reporting the fault can be readimmediately on the display.

□ Complete fault codes aretransmitted and can be readusing DDDL 7.0 or latest version.

□ If the fault is serious enough toimpair normal operation, theelectronic engine system switchesover to emergency running mode.When in emergency runningmode, the engine operates at aconstant 1300 rpm. This allowsyou to move the vehicle to aservice location.

For fault codes and their meanings,see the DDEC VI MBE 4000Troubleshooting Guide (6SE568).

Stop Engine OverrideOptionThe Stop Engine Override Optionis used for a momentary override.The Motor Control Module (MCM)will record the number of times theoverride is activated after a faultoccurs.

Momentary Override – A StopEngine Override (SEO) switch is usedto override the shutdown sequence(see Figure 15). This override resetsthe 60 second (30 seconds for oilpressure) shutdown timer, restoringpower to the level when the RSL (StopEngine) was illuminated. The switchmust be recycled after five seconds toobtain a subsequent override.



Figure 15 Typical SEO Switch andWarning Lamps

NOTE:The operator has the responsibility totake action to avoid engine damage.

Cold Weather OperationSpecial precautions must be takenduring cold weather. To protect yourengine, special cold weather handlingis required for fuel, engine oil, coolant,and batteries.

The engine will not require startingaids down to –15°C (5°F). Between–15°C (5°F) and –25°C (-13°F), agrid heater is required. Temperaturesbelow –25°C (-13°F), will require agrid heater, block heater, and oil panheater.

Winter Fronts

A winter front may be used to improvecab heating while idling. At least 25%of the grill opening should remainopen in sectioned stripes that runperpendicular to the charge air coolertube flow direction. This assures even

cooling across each tube and reducesheader to tube stress and possiblefailure. Winter fronts should only beused when the ambient temperatureremains below -12.2°C (10°F).


DDEC VI SYSTEM

DDEC VI SYSTEM

The engine is equipped with a fullyelectronic control system, whichregulates the fuel injection quantityand timing using solenoid valves,allowing extremely low-emissionoperation. Besides the engine andits related sensors, the system iscomposed of the following:

□ The Motor Control Module(MCM)

□ The Common PowertrainController (CPC) located underthe right-hand dash panel

The two control units are connected bya proprietary datalink through whichall necessary data and information canbe exchanged.

The CPC then broadcasts allinformation on the J1587 and J1939datalinks, where it can be read by thediagnostic tool.

The engine control system monitorsboth the engine and the datalink.When a malfunction or other problemis detected, the system selects anappropriate response; for example,the emergency running mode may beactivated.

The Accelerator Pedal Assembly(AP) eliminates the need for anythrottle linkage.

Motor Control ModuleThe MCM (See Figure 16) is locatedon the left-hand side of the engine.

The MCM processes the data receivedfrom the CPC, for example theposition of the accelerator pedal,engine brake, etc.

Figure 16 MCM

These data are evaluated togetherwith the data from the sensors onthe engine, such as coolant andfuel temperature and oil and chargepressure.



The data is then compared to thecharacteristic maps or lines stored inthe MCM. From these data, quantityand timing of injection are calculatedand the unit pumps are actuatedaccordingly through the solenoidvalves.

NOTE:To obtain a replacement MCM, allthe data given on the MCM label arerequired.

The MCM data label has the 10 digitengine serial number.

Common PowertrainControllerThe CPC communicates with theother MCM units installed on thevehicle over the J1587 and J1939 datalink.See Figure 17.

Data for specific applications is storedin the CPC. These include idle speed,maximum running speed, and speedlimitation.

Figure 17 CPC

The CPC receives data from thefollowing sources:

□ The operator (accelerator pedalposition, engine brake switch)

□ Other electronic control units(for example, the anti-lock brakesystem)

□ The MCM (oil pressure andcoolant temperature)

From these data, instructions arecomputed for controlling the engineand transmitted to the CPC via theproprietary datalink.

The CPC controls various systems,for example, communications withthe datalink, the engine brake, and theconstant-throttle valves.


DDEC VI SYSTEM

DDEC FeaturesDDEC offers a variety of features andoptions designed to warn the operatorof an engine malfunction.

Options can range from warning panellights to automatic reduction in enginepower followed by automatic engineshutdown.

DDEC has the ability to performdiagnostics for self-checks andcontinuous monitoring of othersystem components.

Depending on the application,DDEC can monitor oil temperature,coolant temperature, oil pressure, fuelpressure, coolant level and remotesensors (if used).

DDEC connects to the AWL (CheckEngine) and the RSL (Stop Engine) toprovide a visual warning of a systemmalfunction.

Cruise Control

Cruise Control is available with anyDDEC engine. Cruise Control willoperate in either Engine or VehicleSpeed Mode and maintain a targetedspeed (MPH or RPM) by increasing ordecreasing fueling. The targeted speedcan be selected and adjusted withdash-mounted switches. See Figure18.

Figure 18 Typical Cruise ControlSwitches

Cruise Control may also beprogrammed to permit fast idleusing the Cruise Control switches.With the engine at normal idle,transmission in neutral and servicebrakes on, depress the SPD CNTLSwitch, and use the RSM/ACCSwitch. The engine rpm shouldincrease to a pre-defined speed. Theengine rpm can be raised or loweredfrom this point using the SET/CSTand RSM/ACC switches.

Cruise Control will maintain the setspeed under normal road and loadconditions.



LOSS OF VEHICLE CONTROL

To avoid injury from the loss ofvehicle control, do not use cruisecontrol under these conditions:

□ When it is not possible tokeep the vehicle at a constantspeed (on winding roads, inheavy traffic, in traffic thatvaries in speed, etc.).

□ On slippery roads(wet pavement, ice-orsnow-covered roads, loosegravel, etc.).

NOTICE:When descending a hill withCruise Control OFF, do not allowthe engine to exceed 2500 rpmunder any conditions. Failure toobserve this precaution can resultin overspeeding and serious enginedamage.

It cannot limit vehicle speeds ondown grades if available enginebraking effort is exceeded, nor can itmaintain speed on upgrades if powerrequirements exceed engine powercapability.

Engine speed and power are variedunder Cruise Control to maintain the

set vehicle speed. The vehicle speedmust be above Min. Cruise Set Speedand below Max. Cruise Set Speed. Itis recommended that Max Cruise SetSpeed be set to the default to allowproper operation of other featuressuch as Fuel Economy Incentive andPasSmart. The Vehicle Speed Limitshould be used to limit vehicle throttlespeed.

When the SPD CNTL is in the ONposition, Cruise Control is engaged bymomentarily contacting the SET/CSTSwitch. As a check after each enginestart, DDEC looks for a one timeactivation of the clutch (if equipped)and service brake before DDECallows Cruise Control to be enabled.The MCM must also recognize thatthe Cruise Enable Switch has changed.If the Cruise Enable Switch is off, itneeds to be turned on. If the CruiseEnable Switch is on, it must be turnedoff then on for cruise to operate.

Holding the switch in the SET/CSTposition allows the vehicle to slow to alower speed. Toggling the switch willresult in a one mile-per-hour (1.6 kph)decrease in vehicle speed. If CruiseControl has been disabled, togglingthe RSM/ACC Switch restores thevehicle to the previously set cruisespeed.


DDEC VI SYSTEM

Cruise Control can be overridden atany time with the throttle pedal ifthe vehicle is operating at less thanthe programmed Max Road Speed.Additionally, using either the brake orthe clutch will disable Cruise Control.

Data Recording Capability

The DDEC VI contains the ability toextract detailed data on the engine’suse and performance using DDECReports software. This data, knownas DDEC Data, is stored in the CPCand contains information on engineperformance (such as fuel economy,idle time, time in top gear) and criticalincidents (such as detailed diagnosticdata records and hard braking events).DDEC Data can be downloaded usingDDEC Reports software to producereports.

DDEC Reports software is part ofthe Detroit Diesel Diagnostic Link®7.0 (DDDL 7.0) software package.DDDL 7.0 requires at least a PentiumII computer with at least 256 MB ofRAM.

Engine Brakes

Engine brakes are enabled by adash-mounted On/Off switch with aseparate intensity switch to select low,medium or high braking power.


To avoid injury from loss ofvehicle control, do not activatethe Engine Brake system underthe following conditions:

□ On wet or slippery pavement,unless the vehicle is equippedwith ABS (anti-lock brakingsystem) and you have hadprior experience drivingunder these conditions.

□ When driving without a trailer(bobtailing) or pulling anempty trailer.

□ If the tractor drive wheelsbegin to lock or there isfishtail motion after theEngine Brake is activated,deactivate the brake systemimmediately if this occurs.

The engine brakes will only operatewhen the Accelerator Pedal is fullyreleased. Disengaging the clutchwill prevent the engine brakes fromoperating.



Engine brakes will supply brakingpower even when in Cruise Control.MCM will control the amount ofengine braking with respect to theCruise Control set speed. Themaximum amount of braking (low,medium, high) is selected with thedash switches.

Engine Protection

The DDEC engine protectionsystem monitors all engine sensorsand electronic components, andrecognizes system malfunctions. Ifa critical fault is detected, the AWL(Check Engine) and RSL (StopEngine) illuminate. The malfunctioncodes are logged into the MCM'smemory.

The standard parameters which aremonitored for engine protectionare: low coolant level, high coolanttemperature, low oil pressure, andhigh oil temperature.

This system features a 30-second,stepped-power shutdown sequenceor an immediate speed reductionwithout shutdown in the event a majorengine malfunction occurs, such aslow oil pressure, high oil or coolanttemperature, or low coolant level.

PERSONAL INJURY

To avoid injury from engineshutdown in an unsafe situation,ensure the operator knows howto override the stop enginecondition on a DDEC-equippedunit.

NOTICE:Engines equipped with thepower-down/shutdown option havea system override button or switchto allow engine operation for ashort period of time. Using theoverride button so the engine doesnot shutdown in 30 seconds butoperates for an extended periodmay result in engine damage.

California Engine Idle Limiting

In order to meet the California EngineIdle Limiting Standard, an engineidle shutdown feature has been builtinto the DDEC VI Engine ControlStrategy. When the California EngineIdle Limiting feature is enabled, theengine will generally shut down afterfive minutes of continuous idlingwhen the transmission is in neutralor park and the parking brake is setor after fifteen minutes when thetransmission is in neutral or park and


DDEC VI SYSTEM

the parking brake is not set. Activatingor momentarily changing the positionof the service brake pedal, the clutchpedal, Stop Engine Override, theaccelerator pedal, or park brake statusduring the final 30 seconds beforea shutdown would otherwise occurwill prevent the engine from shuttingdown and will reset the shutdowntimer. After an automatic shutdown,the engine may be restarted andoperated normally. The automaticshutdown feature is generally disabledon engines certified by the US EPA foruse outside California but is requiredto be enabled for all Californiacertified engines with the exceptionof engines used in specific vehicletypes which the state of Californiahas determined to be exempt fromthe idle shutdown requirement.These include buses, school buses,recreational vehicles, medium dutyvehicles, military tactical vehicles,and authorized emergency vehiclesas they are defined by the state ofCalifornia. Owners of these vehicletypes that wish to have the shutdownfeature disabled should consult withCalifornia authorities to determineif their vehicles qualify for theexemption.

Idle Shutdown Timer

This feature is an optional 1 –100 minute idle shutdown system.Its purpose is to conserve fuel by

eliminating excessive idling andallowing a turbocharger cool-downperiod. To activate the shutdown, thetransmission must be in neutral withthe vehicle parking brakes set and theengine in idle or fast-idle mode.

DDEC VI Operation

NOTE:This engine is equipped with DDECsoftware. This software generallyassures optimal engine performance.The installation of software upgradesmay cause minor changes in featuresand engine performance.

Since the DDEC system is electronic,a battery is required to operate thecomputer. The system operates at12 volts. However, in the event ofa power supply malfunction, thesystem will continue to operate atreduced voltage. When this occurs,the AWL (Check Engine) will comeon. See Figure 19

Figure 19 Warning Lamps andSEO Switch



The engine will only operate atreduced rpm until the battery voltagereaches a point where the MCM willno longer function and the engineshuts down.

Should the AWL (Check Engine)come on for any reason, the vehiclecan still be operated and the driver canproceed to the required destination.This condition should be reportedto an authorized Detroit Dieseldistributor or dealer.

NOTICE:When the RSL (Stop Engine) comeson, the computer has detected amajor malfunction in the engine thatrequires immediate attention. It isthe operator's responsibility toshut down the engine to avoidserious damage.

The engine can be configured togive a warning only, to ramp down(reduce power) or to shut down.Ramp down will reduce engine rpmto a pre-determined speed, but willnot shut down the engine. Withthe 30-second shutdown option, theengine will begin a 30-second, steppedpower-down sequence until it shutsdown completely.

A “Stop Engine Override” can beprocured in case the vehicle is tooperate in a critical location.

Stop Engine Override Switch

This feature allows the operator tooverride the automatic stop enginesequence.

This is done by pressing the StopEngine Override Switch every 15 to 20seconds to prevent engine shutdownfrom occurring.

NOTE:The Stop Engine Override Switch andthe Diagnostic Request Switch are thesame.

NOTE:Holding down the Stop EngineOverride Switch will not prevent theengine shutdown sequence. Youmust continue to reset the automaticshutdown system by pressing the StopEngine Override Switch at intervals ofapproximately 15 to 20 seconds.

It takes 30 seconds from the time theautomatic shutdown sequence beginsuntil engine shutdown. Therefore,the operator must press the overrideswitch just prior to engine shutdownand continue to do so until the vehiclecan be brought to a stop in a safelocation.


DDEC VI SYSTEM

Immediate Speed Reduction

The immediate speed reduction optionwill bring engine rpm back to apredetermined speed, but will not shutdown the engine.

The engine should not be restartedafter it has been shut down by theengine protection system, unlessthe problem has been located andcorrected.

Red Stop Lamp

The conditions that will cause the RSL(Stop Engine) to come on are:

□ High coolant temperature

□ Loss of coolant

□ High oil temperature

□ Low oil pressure

□ Auxiliary shutdown

Whenever the AWL (Check Engine)or the RSL (Stop Engine) come on,the DDEC computer will determinewhere the problem is and will thenstore this information in its memory.

If the malfunction is intermittent, thelights will come on and go off as thecomputer senses the changing enginecondition.

Diagnostic Tool

The diagnostic tool for DDEC VI isDDDL 7.0. which requires at least a

Pentium II computer with at least 256MB of RAM.

Once the malfunction has beencorrected, the DDEC system willreturn the engine to normal operation.

The temperature of air in the intakesystem is increased with the additionof an EGR. DDEC is programmedto reduce fueling (power) for ashort time to reduce air and coolanttemperatures when necessary. DDECwill store an information code thatthis event occurred, but no correctiveaction is required as this actionis designed to maintain operationwithout a noticeable affect on vehicleperformance.

Flashing Malfunction Codes —All malfunction codes are four digits.The malfunction code recorded in thecomputer memory will remain until itis erased by a technician.

The flashing malfunction code canalso be obtained by the operator.To support flashing codes, a StopEngine Override/Diagnostic RequestSwitch must be configured and theAWL (Check Engine) and RSL (StopEngine) must be hard-wired. The CPCcannot flash these lamps if they arenot hard-wired.

The flashing code feature may beactivated by satisfying one of thefollowing conditions:



□ Engine speed is <100 rpm andthe SEO switch is put in the ONposition.

□ Idle Governor is activated andthe SEO switch is put in the ONposition.

□ Vehicle speed is <3 mph and ParkBrake is activated and the SEOswitch is put in the ON position.

The flashing code feature isdeactivated to the OFF position orthe listed conditions are no longersatisfied. See Figure 20.

Figure 20 RSL (Stop Engine) Flashing Code Example

Only one light will be flashing codesat any time. All codes will be flashedtwice. The inter-digit pause is 1.5seconds. The pause between codesis 3.5 seconds. The same 3.5 secondpause occurs as the switch is madefrom RSL (Stop Engine) to AWL(Check Engine).

When code flashing is initiated,the active codes will be flashed onthe RSL (Stop Engine). Then theinactive codes will be flashed on theAWL (Check Engine). When all theinactive codes have been flashed, theprocess of flashing all the active codes

followed by all the inactive codes willrepeat until the conditions for codeflashing are no longer satisfied.

If there are no active or inactive faultsthe number 3 is flashed once followedby an inter-code gap of 3 seconds.

To Read Codes: Press and hold theSEO/Diagnostic Request Switch.Active codes will be flashed on theRSL (Stop Engine) first, followed byinactive codes being flashed on theAWL (Check Engine).


DDEC VI SYSTEM

The codes will continue to flashand repeat as long as the DiagnosticRequest Switch is held in the ONposition. Both CPC and MCM faultsare included.

Active Codes – The active codes willbe flashed on the RSL (Stop Engine)in the order of most recent to leastrecent occurrence based on enginehours.

Inactive Codes – The inactive codeswill be flashed on the AWL (CheckEngine) in the order of most recentto least recent occurrence based onengine hours.



DDEC VI ENGINE DRIVING TIPS

Driving with an electronicallycontrolled engine feels different fromdriving with a mechanically governedengine.

Accelerating the VehicleEngine response versus pedalmovement may feel different fromthe mechanical-governed engine youwere driving. The Accelerator Pedal(AP) was designed to communicate“percentage” foot pedal travel tothe engine's Motor Control Module(MCM). The engine will respondaccordingly to the driver's demand.

Another throttle or governorcharacteristic you may need time toget used to is the DDEC LimitingSpeed Governor. This allows thedriver to command total engineresponse between idle and rated speed,such as accelerating at half throttle– an advantage when driving underslippery conditions.

If you require wide-open throttleengine response, either accelerating orjust plain pulling hard, the throttle APwill have to be held to the floor. Toobtain 100% fueling at any speed, theAP will have to be maintained at thefully pressed position.

Cruise ControlFor added driver convenience andcomfort, DDEC VI also features aCruise Control option that works justlike the system in your car. It canbe operated in any gear above 1000rpm or road speed faster than 32kph (20 mph), up to the rated enginespeed. And it can be programmed tohold your road speed at or below themaximum vehicle speed. The switchto energize Cruise Control is usuallymounted on the instrument panel.See Figure 21.

Figure 21 Typical Cruise ControlSwitches



Turn the switch ON to energize thesystem. Remember as a check aftereach engine start, DDEC VI looks fora one time activation of the clutch (ifequipped) and service brake beforeDDEC VI allows Cruise Control to beenabled.

DDEC VI must also see or recognizethat the Cruise Enable Switch haschanged. If the Cruise Enable Switchis OFF it needs to be turned ON. If theCruise Enable Switch is left in the ONposition at key OFF, the switch mustbe cycled OFF then ON for DDECVI to see a status change to allowCruise Control activation. The statusof DDEC VI inputs to activate CruiseControl at key ON is Listed in Table2 below.

Once Cruise Control is enabledand you reach your road speed,press the Set Switch to activateCruise Control. The cruise lightwill come on. To increase road

speed in one mile-per-hour (1.6kilometer-per-hour) increments, pressthe RSM/ACL Switch. To reduce roadspeed, press and hold the SET/CSTSwitch until the lower speed isreached.

Cruise Control is deactivated byslightly pressing the service brakes,clutch pedal, or trailer brake. TheOn/Off Switch will also deactivateCruise Control.

Cruise Control will maintain vehiclespeed even on up grades, unless powerrequirements demand a downshift.And, of course, Cruise Control doesnot limit your speed on down grades.Most likely, Cruise Control will feelstronger than driving with the footpedal because of the instantaneousand wide-open throttle response.That's why Cruise Control use is notsuggested during slippery drivingconditions.

Input Status of Input atKey ON

Status of InputBefore Cruise

Control ActivatesService Brake Switch ON OFF

Clutch Release Switch(Manual Trans only) ON OFF

Cruise Control EnableSwitch OFF ON

Table 2 Input Status to Activate Cruise Control



Use Cruise Control after down shiftingon a hill to pull the hill. Hitting theRSM/ACL Switch (not the Set Switch)will keep the truck accelerating in thelower gears up to the rated enginespeed.

Cruise Control will disengage below1000 rpm or 20 mph (32 kph) roadspeed. When using Cruise Control,if you want to pull the engine below1000 rpm, remember to hold thethrottle pedal to the floor to keep theengine pulling at wide-open throttle.Realistically, the engine will pull toabout 1050 rpm.

Remember: The electronic dataprogrammed into the DDEC VIsystem will not allow you to hurt oroverfuel the engine at low or “lug”engine speeds. There is enough oilpressure to withstand hard pulls at lowengine speeds.

Engine Brakes and CruiseControlIf your engine is equipped with bothCruise Control and engine brakeretarders, the engine retarders canoperate automatically while youare in Cruise Control. If the CruiseControl/Engine Brake function isturned ON in the MCM programming,the engine retarders will come on“low” when your set road speedincreases a few miles-per-hour(kilometers per hour) above your

cruise set speed. If your speedcontinues to increase, the MCM willincrease the engine retarders' brakingpower progressively. When thevehicle returns to the set cruise speed,the engine retarders will turn off untilyou need them.

For safety reasons, don't use CruiseControl when it is not possible to keepthe vehicle at constant speed due to:

□ Winding roads

□ Heavy traffic

□ Slippery pavement

□ Descending grades that call forengine brake assistance.

For an explanation of the engine brakeretarder system and recommendationsfor proper operation, refer to“ENGINE BRAKE SYSTEM”.

ShiftingDepending on your transmissionmodel, the gear split may vary from500 to 300 rpm. The electronicgovernor provides almost no overruncapability; and, if the transmissionis downshifted too early, you willexperience a temporary loss of pullingpower until the engine speed fallsbelow rated speed.



In general, when using a 7 or 9-speedtransmission, you should alwaysdownshift between 1250 and 1300rpm. This is true even on steep gradeswith heavy loads. When using an18-, 15- or 13-speed transmission,you will need to downshift at an rpmthat allows “less than rated” rpmbefore throttle application in the nextgear down. You may want to limitengine speed to 1900 rpm in all gears.The Series 60 provides horsepowerthrough 2100 rpm, but fuel economyis not as efficient above 1800 rpm.

Low rpm operation should feel greatlyenhanced due to the characteristicsof the variable nozzle turbocharger.Engine response should be almostinstantaneous below peak torqueengine speeds. This should encourageprogressive shifting especially duringslow vehicle speed operation.

If you decide to drive at lower rpm'sfor improved fuel economy, don't letdifferent engine noises throw youoff guard. The Series 60 soundsquiet at 1400 rpm, almost as if ithad quit pulling. Don't believe it!If you had a boost gage to look atwhile driving, you would noticethe turbocharger maintaining steadyintake manifold pressure, even asrpm's fall. Depending on the airintake arrangement, you may alsoexperience a “chuffing” sound as theengine starts to pull hard at lowerrpm's. This is caused by the velocity

changes of the air flow within the airintake plumbing. Electronic enginescan actually deliver more fuel at lowerengine speeds than at rated speed.

One difference you may notice withthe EGR equipped engine is underhood noise. The gear train has beenredesigned for quieter operation,and the EGR gas flow may benoticeable to the tuned attentive ear.The turbocharger operates at higherboost pressure forcing EGR gas flowthrough the EGR plumbing. In somesituations the driver may believehe/she has experienced a charge aircooler system leak. Even connectingtrailer light and air hoses, the drivermay hear a different tone (exhaust andunder hood with the engine idling.) Ifequipped with a turbo boost gage, thedriver may occasionally note intakemanifold pressure exceeds 35 psi.

IdlingThe common belief that idling a dieselengine causes no engine damage iswrong. Idling produces sulfuric acid,which breaks down the oil and eatsinto bearings, rings, valve stems andengine surfaces. If you must idlethe engine for cab heat or cooling,the high idle function of the CruiseControl switches should be used. Anidle speed of 1100 rpm should beenough to provide cab heat in above0° C (32° F) ambients.



ENGINE BRAKE SYSTEM

Certain MBE 4000 vehicle enginesare equipped with engine brakes,commonly referred to as retarders.Before operating the vehicle, youmust familiarize yourself with theretarder system to obtain optimumbenefit from it. Engine brake controlsystems may vary slightly, dependingon the engine brake configuration andcab design. However, basic operatorcontrols are similar for all models.

ExhaustBrake/Constant-ThrottleValvesWhen the driver activates the enginebrake, the MCM energizes the brakegate solenoid. The solenoid valvesupplies air pressure to the brakegate actuator, closing the brake gate,which closes off the large entry tothe turbocharger and the combinedexhaust stream flows through thesmall entry to the exhaust turbine.

Figure 22 Brake Gate Open


ENGINE BRAKE SYSTEM

The smaller cross-sectional area, ofthe small entry, increases the flow andspeed of the exhaust stream to theexhaust turbine, which increases theexhaust turbine speed and increasesthe boost pressure. The smallcross-sectional flow of the smallentry will increase the total exhaustmanifold pressure. This increasedboost pressure will increase the airflowforced into the cylinders, which resultsin increased resistance to the pistonsduring a compression stroke andincreases the engine braking power.

At the same time, the ConstantThrottle Valve (CTV) solenoid isenergizes allowing the CTV to beopen. The CTV partially releasesthe increased compression pressureallowing less compression on thepiston during the end of the stroke.

Increased exhaust effort is requiredfor the next exhaust stroke, all theexhaust flows across the small entry,which causes a deceleration of theengine speed.

Figure 23 Brake Gate Closed

Controlling the exhaust to the turbinethrough the small entry, the EGRvalve now controls the brake effect

by removing the necessary exhaustthrough the EGR system.



The engine brake is activated bythe Common Powertrain Controller(CPC). In engine braking mode, anengine rpm range of up to 2500 rpmcan be used by the operator. 2500 rpm,however, may never be exceeded.The engine is turned off automaticallywhen the engine rpm is:

□ Below 900 rpm for AllisonAutomatic Transmissions

□ Below 1100 rpm for all othertransmissions

Also, the engine brake is automaticallyturned off when the accelerator pedalis pressed.

NOTE:When in emergency running mode(constant rpm), the engine brake canbe activated only when the engine isin overrun. When constant rpm hasbeen attained, the engine brake isautomatically turned off.

Anti-Lock BrakingSystemsVehicles equipped with ABS(anti-lock braking systems) havethe ability to turn the engine brakeretarder OFF if a wheel-slip conditionis detected. The engine brake willautomatically turn itself ON oncethe wheel slip is no longer detected.The DDEC system will deactivatethe engine brake system when theengine speed falls below 1000 rpm

or when the vehicle slows down to apre-set speed, depending on DDECprogramming. This prevents stallingthe engine. Engine brakes can alsobe used with vehicle Cruise ControlTURNED ON.

Driving on Flat, DryPavementUse the following guidelines whendriving on flat, dry pavement:

1. If driving on flat, dry, openstretches with a light load andgreater slowing power is notrequired, place the progressivebraking switch in the LOWposition.

2. If you find you are still using theservice brakes, move the switchto a higher position until you donot need to use the service brakesto slow the vehicle down.

3. If you are carrying a heavier loadand road traction is good, movethe progressive braking switch tothe “High” position.

4. Check your progressive brakingswitch often for proper position,since road conditions can changequickly. Never skip a step whenoperating the progressive brakingswitch. Always go from OFFto LOW, and then to a higherposition.


ENGINE BRAKE SYSTEM

Descending a Long, SteepGradeAn explanation of “control speed”may be helpful in understanding howto use the engine brake system whiledescending a grade. Control Speedis the constant speed at which theforces pushing the vehicle forward ona grade are equal to the forces holdingit back, without using the vehicleservice brakes. In other words, thisis the speed the vehicle will maintainwithout using the service brakes orfueling.

BRAKE FADE

To avoid injury, do not overapply the vehicle service brakeswhen descending a long, steepgrade. Excessive use of thevehicle brakes will cause themto heat up, reducing theirstopping ability. This condition,referred to as “brake fade”, mayresult in loss of braking, whichcould lead to personal injury orvehicle/property damage or both.

Use the following guidelines whendescending a long, steep grade:

1. Before beginning the descent,determine if your engine brakesystem is operating properly by

lifting your foot briefly off thethrottle. You should feel thesystem activate.

2. Ensure the progressive brakingswitch is in the appropriate powerposition.

PERSONAL INJURY

Failure to keep the vehicle withinsafe control speed limits whiledescending a grade may resultin loss of vehicle control, whichcould cause personal injury.

NOTICE:Failure to keep the vehicle withinsafe control speed limits whiledescending a grade may result invehicle or property damage or both.

3. Do not exceed the safe controlspeedof your vehicle. Example:You could descend a 6% grade,under control only at 16 kph (10mph) without an engine brake, butat 40 kph (25 mph) with an enginebrake. You could not descendthat same hill at 80 kph (50 mph)and still expect to remain undercontrol. Get to know how muchslowing power your engine brakecan provide. So get to know



your engine brake system beforeclimbing hills and do not exceeda safe control speed.

4. Check your progressive brakingswitch often for proper position,since road conditions can changequickly. Never skip a step whenoperating the progressive brakingswitch. Always go from OFFto LOW and then to a higherposition when on slippery roads.

Driving on Wet or SlipperyPavementDo not attempt to use the engine brakesystem on wet or slippery roads untilyou have some experience with it ondry pavement.


To avoid injury from loss ofvehicle control, do not activatethe Engine Brake system underthe following conditions:

□ On wet or slippery pavement,unless the vehicle is equippedwith ABS (anti-lock brakingsystem) and you have hadprior experience drivingunder these conditions.

□ When driving without a trailer(bobtailing) or pulling anempty trailer.

□ If the tractor drive wheelsbegin to lock or there isfishtail motion after theEngine Brake is activated,deactivate the brake systemimmediately if this occurs.

NOTE:On single trailers or combinations,a light air application of the trailerbrakes may be desirable to helpkeep the trailer stretched out. Followthe manufacturer's recommendedoperating procedure when using yourtrailer brakes.


ENGINE BRAKE SYSTEM

On wet or slippery pavement, startwith the master switch in the OFFposition and use the gear you wouldnormally use under these conditions.

If the vehicle is maintaining traction,place the selective braking switch inthe LOW position and turn ON theengine brake system. If the drivewheels are maintaining traction andyou desire greater slowing power,move the braking switch to the nexthighest position.

However, if the tractor drive wheelsbegin to lock or there is a fishtailmotion, turn the engine brake systemOFF immediately and do not activateit until road conditions improve.

Check your progressive brakingswitch often for proper position, sinceroad conditions can change quickly.Never skip a step when operating theprogressive braking system. Alwaysgo from OFF to LOW and then to ahigher position.



ENGINE SYSTEMS

The engine systems are the following:

Fuel SystemThe fuel system consists of DDEC,fuel injectors, fuel manifolds (integralwith the cylinder head), ElectronicUnit Pumps (EUP), fuel pump, acooling plate for the Motor ControlModule (MCM) on non-automotiveengines, primary and secondary fuelfilters, and the necessary connectingfuel lines.

The gear-type fuel pump is locatednear the front of the crankcase on theleft hand side. The pump is drivenfrom the forward end of the camshaft.

Lubrication SystemThe lubricating oil system consists ofan oil pump, oil cooler, full-flow oilfilter, bypass at the oil filter housingstand pipe, oil level dipstick and an oilpressure regulator at the oil pump.

There is a force-feed lubricating oilcircuit supplied by a gear-type oilpump. This pump is positioned at therear of the oil pan and driven by gearsfrom the crankshaft. The oil cooler isintegrated with the oil filter housingon the right-hand side.

Air SystemThe outside air drawn into theengine passes through the air filterand is pulled into the turbochargerand compressed. It then moves tothe air-to-air charge cooler (heatexchanger) and is cooled. Next itflows to the intake manifold and intothe cylinders, where it mixes withatomized fuel from the injectors.

For optimum protection of theengine from dust and other airbornecontaminants, service the dry typeair cleaners used when the maximumallowable air restriction has beenreached, or annually, whicheveroccurs first.

Cooling SystemA radiator/thermo-modulated fancooling system is used on MBE 4000engines. This system has a centrifugaltype fresh water pump to circulatecoolant within the engine. Twofull-blocking type thermostats locatedin a housing attached to the right sideof the cylinder head control the flowof coolant.


ENGINE SYSTEMS

Electrical SystemThe electrical system consists ofa starting motor, starting switch,battery-charging alternator, storagebatteries, and the necessary wiring.

Exhaust SystemExhaust gases exit the cylindersthrough exhaust ports and the exhaustmanifold. These exhaust gases expandthrough the exhaust turbine and drivethe turbocharger compressor impeller.The gases are then released throughthe exhaust pipes and the muffler tothe atmosphere.

Exhaust Gas RecirculationSystemThe purpose of the Exhaust GasRecirculation System (EGR) is toreduce engine exhaust gas emissionsin accordance with EPA regulations.

The MBE 4000 engines foron-highway EPA 2007 regulationapplications use a cooled EGR systemconsisting of an EGR cooler, EGRcontrol valve, and an EGR mixer.

In the cooled EGR system, part of theexhaust gasses from the front threecylinders are routed from the exhaustmanifold through the EGR cooler, pastcontrol, and are mixed with the intakemanifold charge air.

The addition of cooled exhaustgasses back into the combustionairflow reduces the peak in cylindercombustion temperature. Less oxidesof nitrogen (NOx) are produced atlower combustion temperatures.

The recycled exhaust gases are cooledbefore engine consumption in a tubeand shell engine water cooler.



AFTERTREATMENT SYSTEM

In order to meet current emissionsregulations, the traditional muffler hasbeen replaced by a new AftertreatmentDevice (ATD). This device consistsof a Diesel Oxidation Catalyst (DOC)and a Diesel Particulate Filter (DPF).Together these two components burnoff collected particulate matter in aprocess called “regeneration.” The

key to successful regeneration is highexhaust temperature for an extendedperiod of time. Without adequatetemperatures for regeneration, thefilter will continue to trap particulatesand eventually plug. In order to avoidplugging, Detroit Diesel has designedan actively regenerated AftertreatmentSystem (ATS). See Figure 24.

Figure 24 Aftertreatment System Schematic



Operating RequirementsOxidation of the particulate matteris the key to filter performance.This requires that the catalyzingagent (platinum coated passages)are providing optimum enhancementto the oxidation process. Thefollowing requirements must be met,otherwise the ATD warranty may becompromised:

NOTICE:Do not use kerosene or fuel blendedwith used lube oil.

□ Use Ultra-Low Sulfur Diesel(ULSD) fuel with (15 ppm sulfurcontent maximum), based onASTM D2622 test procedure

□ Lube oil must have a sulfated ashlevel less than 1.0 wt %; currentlyreferred to as CJ-4 oil

NOTICE:Not following the operatingrequirements may result in damageto the ATD or accelerated ashplugging of the diesel particulatefilter.

Parked RegenerationProcedureRegeneration of the ATS isfundamental for the oxidation of

soot. This process happens duringthe normal operation cycle of thevehicle; it can occur both passivelyand actively. Regardless of this,the operator will see no differencein vehicle performance or vehiclecontrol. If the ATS is not capableof completing an over-the-roadregeneration due to duty cycleconstraints or other restrictions, aparked regeneration may need tooccur.

The driver will be notified of theneed for a DPF regeneration byillumination of the DPF RegenerationLamp. Refer to section DRIVERACTIONS .

NOTE:If the DDEC VI electronics have notrequested the initiation of a parkedregeneration (the DPF RegenerationLamp is not illuminated), the Regenrequest switch is disabled.

NOTE:The driver MUST stay with the vehiclethroughout the regeneration process.

NOTE:Not all vehicles may be equippedwith a Regen request switch due toapplication or user specification.



NOTE:The procedure will take up to40 minutes (depends on engine typeand the amount of soot accumulatedin the filter).

To initiate a parked regeneration,perform the following:

1. Keep engine at slow idle (cannotbe in PTO mode).

2. Transmission is in neutral withparking brake ON.

3. Cycle the parking brake fromOFF to ON.

NOTE:Air tank pressure must be high enoughfor the parking brake switch to hold inthe OFF position.

4. Press and release clutch pedal (ifequipped with clutch pedal).

5. Cycle transmission to DRIVEand back to NEUTRAL (if notequipped with clutch pedal).

6. Hold DPF Switch in the ONposition for five seconds andthen release (engine speed willincrease and DPF Lamp will goout).

The regeneration will take up to 40minutes.

The regeneration is completed whenthe engine returns to low idle and theDPF Lamp remains off. The HighExhaust System Temperature (HEST)Lamp will remain on but the vehiclecan be driven.

If the Parked Regeneration exits andthe DPF Lamp remains on, repeat theprocedure. If the second try also fails,contact the Detroit Diesel CustomerSupport Center at (313) 592-5800.

NOTE:A Parked Regeneration will stop if thekey is turned to the OFF position, thevehicle is put into gear, or the parkingbrake is released.

Hazardous Applications

The MCM should be configured tonot allow automatically triggeredover-the-road regenerations (DPFManual Regen Only Enable =Enabled).

NOTE:This is for hazardous applications only.



There are two CPC options:

□ DPF Stationary Regen Only =0-Disabled

□ DPF Stationary Regen Only =1-Enabled

DPF Stationary Regen Only =0-Disabled — This option allowsthe DPF Regen Switch to requesta parked regeneration if the parkedregeneration entry conditions are met.This option also allowsMCM-initiatedover-the-road regenerations to occur.

DPF Stationary Regen Only =1-Enabled — This option onlyallows a parked regeneration tooccur by using the DPF RegenerationSwitch. The MCM will be unableto initiate an active over-the-roadregeneration when this option isenabled.

Service RecordIt is mandatory that customers ordistributors maintain a proper recordof the particulate filter servicing andcleaning. This record is an agent towarranty considerations. The recordmust include information such as:

□ Date of cleaning or replacement

□ Vehicle mileage at the time ofcleaning or replacement

□ Particulate filter part number andserial number

MaintenanceA high amount of black smokeemitting from the vehicle orillumination of an AWL (CheckEngine) or RSL (Stop Engine) areindications of a system problem.Should this occur, refer to theAftertreatment System Technician'sGuide (7SE63), or contact the DetroitDiesel Customer Support Center at313–592–5800.

Illumination of the Diesel ParticulateFilter (DPF) lamp indicates that aparked regeneration is required.

There is a need to periodicallyremove accumulated ash, derivedfrom engine lube oil, from the filter.This ash does not oxidize in thefilter during the regeneration processand must be removed through acleaning procedure. All Detroit DieselATD device equipped engines willilluminate a dashboard warning lampindicating the need for ash cleaning.For information on this cleaningprocedure, refer to the AftertreatmentSystem Technician's Guide (7SE63),or contact the Detroit Diesel CustomerSupport Center at 313–592–5800.



DRIVER ACTIONS

Name IndicatorLamp Description Driver Action

SOLID: Exhaust is athigh temperature andvehicle is at low speedor parked.

High ExhaustSystem

Temperature(HEST) Lamp

FLASHING: A ParkedRegeneration is inprocess and the systemis not up to temperature.

No change in drivingstyle is required.

MalfunctionIndicator

Lamp (MIL)

Indicates a failure ofan Emission ControlDevice. The MIL mayilluminate at the sametime as the CheckEngine Lamp.

Vehicle can bedriven to end ofthe shift. If the MILremains on afterthree drive cycles,call for service.

DPFRegeneration

Lamp

SOLID: Indicates thata Regeneration may beneeded.

FLASHING: Indicatesthat a Regeneration isrequired as soon aspossible.

Perform a ParkedRegeneration ORbring vehicle tohighway speedsto allow foran AutomaticRegeneration.

DPFRegeneration

Lamp+

CheckEngine Lamp

FLASHING+

Indicates that a ParkedRegeneration MUST beperformed.

A ParkedRegeneration mustbe performed.

ENGINE DERATE


DRIVER ACTIONS

Name IndicatorLamp Description Driver Action

DPFRegeneration

Lamp+

CheckEngine Lamp

+Red Stop

Lamp (RSL)

FLASHING+

+

Indicates that a ParkedRegeneration MUST beperformed.

A ParkedRegeneration mustbe performed.

ENGINE DERATE

Table 3 Driver Actions



INSTRUMENT PANEL LAMPS

Lamp Indicator Description Results

AmberWarning

Lamp (AWL)

Indicates a fault with theengine controls.

Vehicle can bedriven to end ofshift. Call forservice.

Red StopLamp (RSL)

Indicates a major enginefault that may result inengine damageEngine derate and/orshutdown sequence willbe initiated.

Move the vehicleto the nearestsafe location andshutdown theengine. Call forservice

DPFRegeneration

Lamp

Solid yellow indicates aparked regeneration isrequired.Blinking yellow, derate,and/or shutdown arepossible as soot loadcontinues to increase.Lamp will shut off duringregeneration.

Lamp Solid - parkedregenerationrequired.Lamp Flashing- parkedregenerationrequiredimmediately.

High ExhaustSystem

Temperature(HEST) Lamp

This is an informationindicator. Indicatesexhaust temperature isabove a preset limit andthe unit is operating atlow vehicle speed. Lampflashes once every tenseconds during a parkedregen. Lamp is yellow.

Vehicle can bedriven.

MalfunctionIndicator

Lamp (MIL)

Yellow lamp Indicates afailure of an EmissionControl device. Mayilluminate at the sametime as the AmberWarning Lamp

Vehicle can bedriven to end ofshift. Call forservice.

Table 4 Instrument Panel Lamps


INSTRUMENT PANEL LAMPS

The activation conditions arelisted in Table 5.

Lamp Lamp Solid Lamp Flashing

□ At the start of every ignitioncycle (a bulb check).

□ When an electronic systemfault occurs (problemshould be diagnosed assoon as possible).

□ Diagnostic Request Switchis used to activate the AWLto flash inactive codes.

□ Last 90 seconds before idleshutdown if programmedfor override.

□ Idle shutdown or theOptimized Idle shutdownoccurs.


□ A potential enginedamaging fault isdetected.

□ When Engine ProtectionShutdown occurs.

□ Diagnostic Request Switchis used to activate the RSLto flash active codes.

□ Parked regeneration isrequired.


When a parked regenerationis required immediately (Ifthe lamp flashing is ignored,derate and/or shutdown couldoccur.


□ Vehicle speed is less than5 mph and the DPF outlettemperature is greaterthan 525°C (977°F).

Flashes every 10 secondsduring a parked regen


□ For any emission relatedfault (light out when thefault is inactive)

Never flashes

Table 5 Lamp Activation Conditions



MAINTENANCE

When performed on a regular basis,changing the engine oil and filters isthe least costly way of obtaining safeand reliable vehicle operation. Addedbenefits and savings occur when youcheck that the valves, fuel injectors,and oil and cooling circuits are in goodworking order during oil changes.

The maintenance section of thismanual explains when you shouldchange your oil and what to look forwhen checking for wear or damage.

For additional information, pleasecontact the Detroit Diesel CustomerSupport Center at 313–592–5800.

Scheduled IntervalsAll service intervals and maintenanceoperations are based on the parts andaccessories expressly approved foryour engine.

The scope and frequency ofmaintenance work are determinedby the engine's operating conditions:severe duty, short haul, or long haul.

Evidence of regular maintenance isessential if a warranty claim has to besubmitted.

If optional equipment is installed, besure to comply with the maintenancerequirements for these extra items.

Important: If the engine is stored formore than 18 months, the oil must bechanged and the lubrication systemmust be primed before the engine canbe brought into service. See MBE4000 Service Manual (6SE420).

Maintenance Schedule Types

There are three types of maintenanceschedule:

□ Severe Service

□ Short Haul

□ Long Haul

To determine which schedule to use,find the distance traveled by thevehicle in a year, regardless of vehicletype.

Severe Service — Applies tovehicles that annually travel up to10,000 miles (16,000 kilometers) orthat operate under severe conditions.Examples of Severe Service usageinclude: operation on extremely poorroads or where there is heavy dustaccumulation; constant exposureto extreme hot, cold, salt-air, orother extreme climates; frequentshort-distance travel; construction-siteoperation; city operation (fire truck,garbage truck), or farm operation.


MAINTENANCE

Short-Haul — Applies to vehiclesthat annually travel up to 15,000miles (24,000 kilometers) and operateunder normal conditions. Examplesof Short-Haul usage are: operationprimarily in cities and denselypopulated areas; local transport withinfrequent freeway travel; or highpercentage of stop-and-go travel.

Long-Haul — Long Haul(over-the-road transport) is forvehicles that annually travel more than30,000 miles (48,000 kilometers),with minimal city or stop-and-gooperation. Examples of Long-Haulusage are: regional delivery thatis mostly freeway miles; interstatetransport; or any road operation withhigh annual mileage.

Maintenance Intervals — Thethree tables show which maintenanceoperation must be performed atthe actual distances (in miles orkilometers) for each maintenanceoperation. The schedule of actualdistances is based on the intervalsgiven in the Maintenance Tables

The three maintenance tablesare: referred to in section“Maintenance Tables.”

□ Maintenance Interval Table,Severe Service (listed in Table 7)

□ Maintenance Interval Table, ShortHaul (listed in Table 8)

□ Maintenance Interval Table, LongHaul (listed in Table 9)

Schedule Use

Before placing your new vehiclein service, determine the correctmaintenance intervals that apply toyour intended use of the vehicle.Refer to section “Maintenance Tables”to determine the distance interval atwhich each maintenance operationmust be performed to comply withyour vehicle's schedule.

When the vehicle reaches the actualdistance given for an interval,refer to section “Maintenance Tables”.

When maintenance is requiredfor hours of engine operationfor severe applicationsrefer to section “MaintenanceTables”. Listed in Table 6 providesan engine hours conversion forapplications that may require serviceintervals based on hours and notmileage. The intervals are based ona collaboration of field and fleet data.For a more accurate analyst of whenfluids should be changed, such asengine oil, refer to publication EngineRequirements – Lubricating Oil, Fueland Filters, (7SE270), available fromauthorized Detroit Diesel distributors.

Complete each maintenance operationat the required interval.



Maintenance Tables

Procedure Severe (hrs) Short-Haul(hrs)

Long-Haul(hrs)

Engine Oil and Filter 300 - or 3Months

500 - or 6months —

Fuel Filter 600 — —

Valve Lash Adjustment 600 then every1200 — —

Table 6 Maintenance Intervals by Engine Hours


MAINTENANCE

Miles (X 1000) 10 12 20 24 30 36 40 48 50 60 70 72

Km (X 1000) 17 19 32 38 50 57 68 77 84 100 113 116

Item Procedure

1. Lubricating Oil/Filter R R R R R R R

2. Cooling System Intervals are based on type of coolant usedas listed in Table 17 in the How to Select

Coolant section of this guide.

3. Valve Lash Checkingand Adjustment

First adjustment at 20,000 mi. (32,000 Km) andthen every 40,000 mi. (68,000 Km)

4. Drive Belts I I I I I I I

5. Fuel/WaterSeparator

Inspect at every fuel fill. Replace when fuellevel is at top of filter.

6. Fuel Filters R R R R R R

7. Air System I I I I I I

8. Exhaust System I I I I I I I

9 Air Compressor I I I I I I I

10. AftertreatmentDevice

Inspect same as exhaust system interval, ashremoval at 300,000 Miles (480,000 Km)

11. Vibration Damper Replace at major overhaul or earlier if dented orleaking.

12. REPTO torsionaldamper checking

10,000 mi. (16,000 Km) or 300 hours or 1 year,whichever comes first.

All items are described in refer to section “Preventive MaintenanceIntervals”

I – Inspect, service, test, correct or replace as necessary.R – Replace.

Table 7 Maintenance Intervals (Severe Service)



Miles (X 1000) 15 30 45 60 75 90 105 120 135 150 165 180

Km (X 1000) 25 50 75 100 125 150 169 193 217 241 266 290

Item Procedure1. Lubricating

Oil/Filter R R R R R R R R R R R R



3. Valve LashChecking andAdjustment

First adjustment at 30,000 mi. (50,000 Km) and thenevery 60,000 mi. (100,000 Km)

4. Drive Belts I I I I I I I I I I I I




7. Air System I I I I I I I I I I I I

8. Exhaust System I I I I I I I I I I I I

9. Air Compressor I I I I I I I I I I I I

10. AftertreatmentDevice

Inspect same as exhaust system interval, ashremoval at 300,000 miles (480,000 Km)

11. VibrationDamper

Replace at major overhaul or earlier if dented or leaking.

12. REPTO torsionaldamper checking

First inspection at 60,000 mi. (100,000 Km) or 3000hours and then every 30,000 mi (50,000 Km) or 1500hours.

All items are described in refer to section “Preventive MaintenanceIntervals.”

I – Inspect, service, test, correct or replace as necessary.R – Replace.

Table 8 Maintenance Intervals (Short Haul)


MAINTENANCE

Miles (X 1000) 30 60 90 120 150 180 210 240 270 300 330 360

Km (X 1000) 50 100 150 198 241 290 338 386 435 483 531 579

Item Procedure

1. LubricatingOil/Filter R R R R R R R R R R R R



3. Valve Lash Checkand Adjustment

First adjustment at 60,000 mi. (100,000 Km) and thenevery 120,000 mi. (198,000 Km)

4. Drive Belts I I I I I I I I I I I I




7. Air System I I I I I I I I I I I I

8. Exhaust System I I I I I I I I I I I I

9. Air Compressor I I I I I I I I I I I I

10 AftertreatmentDevice

Inspect same as exhaust system interval, ashremoval at 300,000 Miles (480,000 Km)

11. Vibration Damper Inspect at oil changes. Replace at major overhaul orearlier if dented or leaking.

12. REPTO TorsionalDamper Checking

First inspection at 60,000 mi. (100,000 Km) or 3000hours and then every 30,000 mi (50,000 Km) or 1500hours.

All items are described in refer to section “Preventive MaintenanceIntervals.”

I – Inspect, service test, correct or replace as necessary.R – Replace.

Table 9 Maintenance Intervals (Long Haul)



Preventive MaintenanceIntervalsThis section describes the items listedin the tables.

As the operator of a vehicle, routine“Daily” inspections of the engine andchassis should be performed. Thiswill provide the best opportunity toidentify major concerns or concernsthat could stretch a longer time spanlike slow coolant loss.

For new or stored engines,refer to section “OPERATINGINSTRUCTIONS FOR STARTINGTHE ENGINE” in this guide.

Item 1 – Lubricating Oil Filter

Lubricating Oil: – Check the oillevel daily with the engine stopped.If the engine has just been stoppedand is warm, wait approximately 20minutes to allow the oil to drain backinto the oil pan before checking. Addthe proper grade of oil to maintainthe correct level on the dipstick.See Figure 25.


NOTICE:When adding lubricating oil, donot overfill. Oil may be blown outthrough the crankcase breatherand/or aeration of the oil can occur.

All diesel engines are designed to usesome oil, so the periodic addition ofoil is normal.

NOTICE:If the oil level is constantly abovenormal and excess oil has not beenadded to the crankcase, consultwith an authorized Detroit Dieselservice outlet for the cause. Fuel orcoolant dilution of lubricating oil canresult in serious engine damage.

Before adding lubricating oil,refer to section “How to SelectLubricating Oil” in this guide.


MAINTENANCE

Lubricating Oil Filter: – The oilfilter is a cartridge style element andis located on the front right side of theengine. See Figure 26. If followedcorrectly, an oil filter change can beperformed quickly with minimal oilcleanup. Refer to section “How toReplace the Lube Oil and Filter” inthis guide.

Figure 26 Lubricating Oil Filter

PERSONAL INJURY


Make a visual check of all lubricatingoil lines for wear and/or chafing. Ifany indication of wear is evident,replace the oil lines and correct thecause.

Check for oil leaks after starting theengine.

Item 2 – Cooling System

Coolant Flush and Fill – Propermaintenance of the cooling system isvital to its performance and longevity.The cooling system must, on aconstant basis, deal with cavitation,temperature/pressure variations, andcontinuous threats on the additivepackage. Once the additives have beendepleted from the coolant, it will onlybe a matter of time until the enginecomponents suffer. Refer to section“How to Select Coolant“ in this guide.

Cooling System Inspection – Inspectthe cooling system as follows:

HOT COOLANT


1. Inspect the radiator, condenser,coolant pump, engine oil cooler,freeze plugs, and heat exchangerfor damage and leaks.

2. Check all cooling system pipesand hoses for damage and leaks;



ensure they are positioned toavoid chafing, and are securelyfastened.

3. Check the outside of the radiatorand condenser for blockage.Check fins for damage; straightenthem if necessary.

Proper maintenance of the coolingsystem is vital to its performanceand longevity. The cooling systemmust, on a constant basis, deal withcavitation, temperature/pressureswings, and continuous threatson additive package. Once theadditives have been depleted fromthe coolant, it is only be a matter oftime until the engine componentssuffer. Refer to section “How to SelectCoolant” in this guide.

Coolant Inhibitor Test Intervals– Coolant inhibitor level shouldbe checked at the intervals aslisted in Table 17 in the How to SelectCoolant section of this guide.

If topping off is needed, add coolantwhich is identical to the initial fillcoolant.

Item 3 – Valve Lash Checkingand Adjustment

Valve lash checking and adjustmentshould be performed per the prescribedunder the proper service category forthe engine, refer to section “ScheduledIntervals” in this guide. All three

service categories (Severe, Short Haul,and Long Haul) require a “first time”valve lash adjustment at a shorterinterval. After the initial adjustment,all others are based on the samemileage intervals. Refer to section“Maintenance Tables” in this guide.Proper valve lash clearance allowsthe engine to produce the bestpossible performance with the lowestemissions. Valve lash adjustmentsshould be performed by an authorizedDetroit Diesel maintenance or repairfacility.

Item 4 – Drive Belts

Belts should be neither too tight nortoo loose. Belts that are too tightimpose extra loads on the crankshaft,fan and/or alternator bearings,shortening both belt and bearing life.Excessively overtightened belts canresult in crankshaft breakage. A loosebelt will slip and generate excessiveheat that may cause damage to the beltand accessory drive components.


MAINTENANCE

PERSONAL INJURY

To avoid injury from rotating beltsand fans, do not remove anddiscard safety guards.

Belt Replacement – Drive belts (Vand poly-V) should be replaced every2,000 hours or 100,000 miles (160,000km).

After an extended time in service,minor rib cracks may appear, usuallyone or two cracks per inch isconsidered normal. See Figure 27.A concern occurs when the belt ribsexhibit severe multiple cracking or“chunking”. At this point, the beltshould be replaced.

Figure 27 Minor Rib Cracking

Auto Tensioner – Auto tensionersare usually maintenance free for thelife of the engine. However, routineinspections should be performed.

Uneven belt wear can indicate a loose,wore out, or bad bearing on the autotensioner. A build up of dirt or grimearound the front bearing surface of thewheel can indicate a future bearingfailure due to inadequate lubrication.

Item 5 – Fuel/Water Separator

If the vehicle is equipped with afuel/water separator located on theframe rail, follow the manufacturesrecommendation on draining thetrapped water and priming the fuelsystem. Refer to section “Fuel/WaterSeparator Prefilter Element Cleaning”or refer to section “Replace Davco382 Fuel Pro®Fuel/Water SeparatorElement” in this guide.

Item 6 – Fuel Filters

The engine uses a cartridge style fuelfilter. If followed correctly, a fuel filterchange can be performed quickly withminimal cleanup. Refer to section“How to Replace the Fuel Filters” inthis guide.



One method of determining whenfilters are plugged to the extent thatthey need replacing is based on thefuel pressure at the fuel filter housing.See an authorized Detroit Diesel repairfacility to determine a clogged filter.The maximum pressure differencebetween the inlet and outlet of the fuelfilter housing is 0.3 bar (4.0 psi).

NOTE:Filter change intervals may beshortened to conform to establishedpreventive maintenance schedules,but should never be extended.

Item 7– Air System

Air Cleaner – The air cleaner elementshould be inspected per the scheduledmaintenance or more often if theengine is operated under severe dustconditions.

Replace the element, if necessary.Check the gaskets for deteriorationand replace, if necessary. If the drytype air cleaner is equipped with anaspirator, check for aspirator damageor clogging. Clean, repair or replace,as necessary.

NOTICE:Do not allow the air inlet restrictionto exceed 5.0 kPa (20 in. H2O) under any engine operatingconditions. A clogged air cleanerelement will cause excessive intakerestriction and reduced air supplyto the engine resulting in increasedfuel consumption, inefficient engineoperation and reduced engine life.

Inspect the entire air system for leaksdaily. Look especially for torn air inletpiping or boots and loose or damagedclamps. Have worn or damaged partsrepaired or replaced, as required.Retighten loose connections.

Air Cleaner Replacement – Drytype air cleaner elements should bereplaced after one year of service orwhen the maximum allowable airintake restriction has been reached,whichever comes first.

Air-to-Air Charge Cooler –Periodically inspect the air-to-aircharge cooler for buildup of dirt, mud,etc. and wash off using a mild soapsolution. Check the charge cooler,ductwork, and flexible connections forleaks and have repaired or replaced,as required.


MAINTENANCE

Item 8– Exhaust System

The exhaust manifold retaining boltsand other connections should beinspected for leaks. The exhaust piperain cap should be checked for properoperation, if so equipped. With theintroduction of an Aftertreatmentsystem, the sealing of the exhaustsystem is critical and should beinspected regularly.

Item 9 – Air Compressor

The air compressor incorporatesthree of the major systems of a dieselengine (air, lubrication, and coolant).Proper inspection of air compressorwould include inspecting for air, oil,and coolant leaks. Due to inadequateinternal sealing air compressors,when failed, can produce excessivecrankcase pressure or allow an engineto ingest oil.

Item 10 – Aftertreatment System(ATS)

There is a need to periodically removeaccumulated ash, derived from enginelube oil, from the filter. The ashdoes not oxidize in the filter duringthe regeneration process and mustbe removed through a cleaningprocedure. All Detroit Diesel ATDequipped engines will illuminate adashboard warning lamp indicatingthe need for ash cleaning.

Item 11 – Vibration Damper

The viscous vibration damper shouldbe inspected periodically and replacedif dented or leaking.See Figure 28 for“Viscous Vibration Damper"

1. Viscous Vibration Damper

Figure 28 Viscous VibrationDamper

Heat from normal engine operationmay, over a period of time, cause thefluid within the damper to break downand lose its dampening properties.For this reason, the viscous vibrationdamper must be replaced at timeof normal major engine overhaul,regardless of apparent condition.



Item 12 – REPTO TorsionalDamper Checking

The REPTO accessory drive is anoption on the MBE4000 engine. Thedrive provides continuous live poweranytime the engine is operating. TheREPTO is driven by the camshaft gearand is an integral part of a uniqueSAE#1 flywheel housing. All REPTOinstallations require a torsionalcoupling installed at the flange ofthe drive unit (i.e. hydraulic pump).The torsional coupling incorporates arubber element designed to reduce theunwanted stresses from reaching theengine. See Figure 29.

Figure 29 MBE4000 REPTOConnection Illustration

REPTO Torsional DamperInspection — Inspect the REPTOtorsional damper as follows:

1. Inspect the outer casing of thetorsional damper for dents orbulges. If damage is found

replace the damper. Regardlessof the condition, the torsionalcoupling must be replaced atnormal engine overhaul.

2. Inspect the torsional damperrubber element as follows:

[a] Check the rubber element forbulges or cracks. If damage isfound replace the damper.

[b] Inspect the rubber elementteeth for wear. If the teethare worn to less than one-halfof the new part length (11.0mm [0.433 in.]), replace thetorsional damper. See Figure30.

Figure 30 REPTO TorsionalDamper

REPTO Torsional DamperCleaning — Clean the REPTOtorsional damper as follows:


MAINTENANCE

The torsional damper couplingwill withstand normal exposure tohydraulic oil, diesel fuel, anti-freezesolutions, and muriatic acid. Thecoupling should be washed with amild soap solution and rinsed withwater after contact with the aboveitems. The coupling can be powerwashed without damage as long as it isinstalled in the vehicle. If the couplingis power washed when not connectedto a cardan shaft, debris may be forcedinternally at the bolt flanges damagingthe coupling.

Required MaintenanceOperationsThe following sections describe therequired maintenance operations .

Engine Inspecting

Inspect engine as follows:

1. Visually check the engine forsigns of leakage. A slightdampness at the sealing points isno cause for concern.

NOTE:More severe leaks, combined with acontinual loss of oil, must be correctedwithout delay.

2. Visually inspect all lines andhoses. Listen for any sound ofleaking. Make sure all pipes andhoses are undamaged, correctly

positioned to avoid chafing, andproperly secured.



HOW-TO SECTION

This section covers Detroit Diesel'srecommendations on how to selectlubricating oil, diesel fuel, and coolantand includes basic engine maintenanceprocedures which can be performedby the operator.

NOTICE:The manufacturer's warrantyapplicable to MBE 4000 enginesprovides in part that the provisionsof such warranty shall not applyto any engine unit that has beensubject to misuse, negligence oraccident. Accordingly, malfunctionsattributable to neglect or failure tofollow the manufacturer's fuel orlubricating recommendations maynot be within the coverage of thewarranty.

How to Select LubricatingOilThe selection of the proper lubricatingoil is important to achieve the longand trouble-free service which DetroitDiesel engines are designed toprovide. The proper lubricating oil formodel year 2007 MBE 4000 enginesis selected based on SAE viscositygrade and API (American PetroleumInstitute) service designation. Onlyoils licensed to display the API symbolshould be used. See Figure 31.

NOTICE:Lubricating oil must have a sulfatedash level less than 1.0% mass;currently referred to as CJ–4 oil

Figure 31 API Lubricant Symbol

Lubricant Requirements

API CJ-4 oils must be used inengines meeting January 2007,and later build, exhaust emissionregulations.

Cold Weather Starting

At ambient temperatures below–20°C (–4°F) when sufficient starterspeed cannot be achieved with SAE15W-40 oils, the use of 5W-XX oilsand 10W-XX oils (XX =30 or 40) isallowed to improve starting.


HOW-TO SECTION

NOTICE:

Monograde oils should not beused in MBE 4000 engines,regardless of API serviceclassification. Monograde oilsgel at lower ambient temperatures,reducing lubricant flow, andthey do not provide adequatelubricity at higher engine operatingtemperatures. These factors canresult in severe engine damage.

The oils must be API CJ-4that have demonstrated fieldperformance in Detroit Diesel engines.These oils must possess a HighTemperature/High Shear (HT/HS)viscosity of 3.7 minimum. For furtherinformation, refer to publicationEngine Requirements – LubricatingOil, Fuel and Filters, (7SE270),available from authorized DetroitDiesel distributors.

Select the SAE class (viscosity) on thebasis of the average air temperaturefor the season. See Figure 32.

NOTE:Continued use of a single SAE classwill result in frequent oil changes. Forthis reason, view the temperatureranges for the various SAE classes.

Figure 32 Engine Oil TemperatureRanges

Synthetic Oils

Synthetic oils may be used in DetroitDiesel engines, provided they are APIlicensed and meet the performanceand chemical requirements ofnon-synthetic oils outlined in thispublication. Synthetic oils offerimproved low-temperature flowproperties and high-temperatureoxidation resistance. However,they are generally more costly thannon-synthetic oils.

Product information about syntheticoils should be reviewed carefully.Performance additive systems oftenrespond differently in synthetic oils.

Their use does not permit extension ofrecommended oil drain intervals.



The Use of SupplementalAdditives

Lubricants meeting the DetroitDiesel specifications outlined in thispublication already contain a balancedadditive treatment. Supplementaladditives are generally not necessaryand can even be harmful. Theseadditives may be marketed as eitheroil treatments or engine treatments andare discouraged from use in DetroitDiesel engines.

Engine damage resulting from theuse of such materials is not coveredby your Detroit Diesel Corporationwarranty. Detroit Diesel will notprovide statements beyond thispublication relative to their use.

When to Change Oil

The length of time an engine mayoperate before an oil change dependsupon the lubricant and fuel used,engine oil consumption, and theoperating cycle.

USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

The maximum interval at whichthe engine may operate before theoil and filters must be changed islisted in Table 10.

Engine Application Drain IntervalLong Haul — Highway Truck & MotorCoach — operates more than 60,000miles (100,000 kilometers) per year

30,000 Miles (50,000 km)

Sort Haul — City Transit — operatesup to 60,000 miles (100,000kilometers) per year

15,000 Miles (25,000 km)

Severe Service — Fire Truck orCrash/Rescue Vehicle — operates upto 6000 miles (9,600 kilometers) orunder severe conditions

10,000 Miles (16,000 km), 300 hoursor 1 year, whichever comes first

Table 10 Oil Drain and Filter Change Interval


HOW-TO SECTION

Oil analysis may be used to determinewhether this interval should beshortened, but it should not be usedto lengthen the interval. For detailedinformation refer to publicationEngine Requirements – LubricatingOil, Fuel and Filters (7SE270),available from authorized DetroitDiesel distributors.

Disposing of Waste Oil — Disposeof used lubricating oil and filters in anenvironmentally responsible manner,according to federal (EPA) and/or staterecommendations. The disposal ofwaste oil may be best addressed by theengine oil supplier, who may acceptresponsibility for proper disposal ofthis material as part of the business ofproviding lubricant.

How to Replace the LubeOil and FilterFilters are an integral part of thelubricating oil system. Properfilter selection and maintenanceare important to satisfactory engineperformance and service life.

Filters should be used to maintaina clean system, not to clean up acontaminated system.

Replace Lubricating Oil andFilter

Drain oil as follows:

1. Chock the tires, place thetransmission in neutral, and setthe parking brake.

NOTE:Change the engine oil only whenthe engine is at a temperature ofapproximately 60°C (140°F).

2. Clean the outside of the oil filterhousing, then unscrew the oilfilter cap from the housing.

NOTE:Use care to prevent foreign objectsfrom entering the filter housing.

3. Using a 36-mm socket, unscrewthe cap and filter and allow the oilto drain into the housing. Afterdraining, remove the assemblyfrom the housing. (see Figure 33).



1. Oil FilterCap

3. Oil FilterHousing

2. O-ring

Figure 33 Oil Filter Element

FIRE

To avoid injury from fire, keepopen flames, sparks, electricalresistance heating elements, orother potential ignition sourcesaway when draining lubricationoil. Do not smoke when draininglubricating oil.

4. Remove the element by pressingand twisting the side anddetaching it from the cap.

5. Remove the oil filter O-ring anddiscard it. Lightly grease a newO-ring with engine oil and installit on the filter cap.

6. Check the filter housing for anydebris.

7. Insert a new filter element intothe cap.

8. Insert the element and capassembly into the housing.Torque the cap to 25 N·m (18lb·ft).

9. Drain the oil from the oil pan.

[a] Place a suitable receptaclebeneath the oil drain plug onthe underside of the oil pan.

[b] Carefully unscrew the oildrain plug on the oil pan andallow the oil to drain out(See Figure 34).

Figure 34 Engine Oil Drain Plug,Oil Pan

[c] Discard the O-ring on the oildrain plug.

10. Install the oil drain plug, using anew O-ring. Tighten the plug to65 N·m (48 lb·ft).


HOW-TO SECTION

PERSONAL INJURY


11. Add new engine oil throughthe oil fill tube (See Figure35) until the maximum fill levelon the oil dipstick has beenreached.Listed in Table 11 are theengine fill capacities.

Figure 35 Oil Fill Tube

Oil Pan Capacity Engine Oil System Fill Capacity(Includes oil filter)

36 L (38 qts) 39.5 L (41.7 qts)

Table 11 Engine Lubricating Oil Capacity

To avoid injury when workingnear or on an operating engine,remove loose items of clothing,jewelry, tie back or contain longhair that could be caught in anymoving part causing injury.

12. Start the engine with theaccelerator pedal in the idleposition. Monitor the oil pressuregauge.

NOTICE:Keep the engine running at idlingspeed until an oil pressure reading isobtained. If no oil pressure is shownafter approximately 10 seconds,stop the engine and determine thecause. Failure to do so could resultin engine damage.

13. Check the filter and oil drain plugfor signs of leakage.

14. Stop the engine. Check the oillevel again after approximatelyfive minutes. If necessary, add oil



up to the maximum fill level onthe oil dipstick.

How to Select Diesel FuelDetroit Diesel engines in 2007are designed to operate ONLY onUltra-Low Sulfur Diesel (ULSD) fuel,see Figure 36.

Figure 36

Quality

Fuel quality is an important factorin obtaining satisfactory engineperformance, long engine life, andacceptable exhaust emission levels.

In general, fuels meeting theproperties of ASTM designationD 975 (grades 1-D and 2-D) haveprovided satisfactory performance.

The fuels used must be clean,completely distilled, stable, andnon-corrosive. For more informationregarding the significance of theseproperties and selection of the properfuel, refer to publication, Engine

Requirements – Lubricating Oil, Fueland Filters (7SE270), available fromauthorized Detroit Diesel distributors.

NOTICE:Use only Ultra-Low Sulfur Diesel(ULSD) fuel (15 ppm sulfur contentmaximum), based on ASTMD2622 test procedure. Using fuelother than ULSD will damage theAftertreatment Device.

Fuel Contamination

Generally, fuel contaminationoccurs as the result of improper fuelhandling. The most common typesof contamination are water, dirt, andmicrobial growth (“black slime”).The formation of varnishes andgums resulting from poor stability orextended storage (“stale fuel”) alsoaffects fuel quality. The best treatmentfor contamination is prevention bymaintaining a clean storage systemand choosing a reputable fuel supplier.

Supplemental additives are notrecommended due to potentialinjector system or engine damage.Our experience has been that suchadditives increase operating costswithout providing benefit.


HOW-TO SECTION

The use of supplemental fuel additivesdoes not necessarily void the enginewarranty. However, repair expenseswhich result from fuel system orengine component malfunctions ordamage attributed to their use willnot be covered.

These products should beaccompanied by performancedata supporting their merit. It isnot the policy of Detroit DieselCorporation to test, evaluate, approveor endorse such products.

Biodiesel — Biodiesel fuels meetingASTM D 6751 specification, priorto blending can be mixed up to 5%maximum by volume in petroleumdiesel fuel. Detroit Diesel highlyrecommends biodiesel fuels madefrom soybean or rapeseed oil throughthe proper transesterification reactionprocess. Other feedstock sourceof biodiesel fuels such as animalfat and used cooking oils are notrecommended by Detroit Diesel. Theresulting mixture must meet ASTM D975 specification. More informationis available in the Detroit Dieselpublication Lubricating Oil, Fuel, andFilters (7SE270).

Failures attributed to the use ofbiodiesel fuel will not be coveredby Detroit Diesel product warranty.Also, any engine performanceproblem related to the use of biodieselfuel would not be recognized

nor considered Detroit Diesel'sresponsibility.

Prohibited Additives

The following fuel additives are notallowed and MUST NOT be mixedwith diesel fuel:

Used Lubricating Oil — Do not usefuel blended with used lubricating oil.Detroit Diesel specifically prohibitsthe use of used lubricating oil in dieselfuel.

NOTICE:Burning used lubricating oil in

fuel cannot be tolerated as it willcause the diesel particulate filter to

prematurely plug with ash.

Used lubricating oil containscombustion acids and particulatematerials which can severely erodefuel injector components, resulting inloss of power and increased exhaustemissions. In addition, the use ofdrained lubricating oil will increasemaintenance requirements due to filterplugging and combustion deposits.

Fuel Additives with Sulfuror Sulfated Ash — Do notuse non-approved fuel additivescontaining sulfur or sulfated ash.



Gasoline — The addition ofgasoline to diesel fuel will create aserious fire hazard. The presenceof gasoline in diesel fuel will reducefuel cetane number and increasecombustion temperatures.

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.

Tanks which contain a mixture ofgasoline and diesel fuel should bedrained and cleaned as soon aspossible.

Detroit Diesel Corporation will not beresponsible for any detrimental effectsit determines resulted from addingdrained lubricating oil or gasoline tothe diesel fuel.

How to Replace the FuelFiltersFilters are an integral part of thefuel system. Proper filter selectionand maintenance are important tosatisfactory engine operation andservice life. Filters should be used tomaintain a clean system, not to cleanup a contaminated system.

An optional fuel/water separator maybe installed in place of the standardprimary filter.

Replace Main Fuel Filter Element

Change the main fuel filter element asfollows:

1. Open the fuel tank fill cap torelease pressure in the fuelsystem. Replace and tighten thecap.

2. Clean the outside of the fuel filterhousing (See Figure 37).

1. Filter Housing Cap

2. O-ring

3. Filter Element

Figure 37 Main Fuel Filter


HOW-TO SECTION

3. Using a 36-mm socket, unscrewthe cap on the main fuel filterhousing. Remove the cap and liftthe filter element a short distancewithin the filter housing allowingthe fuel to drain off the filter.

4. Remove the filter element fromthe cap and clean the filter cap.Discard the filter element and theO-ring from the cap.

NOTICE:To prevent damage to the filterhousing, do not allow dirt to get intothe filter housing.

5. Clean the filter housing cap.

6. Replace the O-ring.

7. Lubricate the rubber seal, on thebottom of the filter element witha light coat of fuel oil and insertit into the filter housing. Pushdown and rotate the filter elementwhile installing to ensure it isseated properly at the base of thehousing.

NOTE:A properly seated filter element willhold the fuel in the filter housing andprevent it from draining back to thetank. If the fuel does not stay in thehousing the element is not seatedproperly, repeat steps 1 and 2.

8. Fill fuel filter housing with cleanfuel oil.

9. Install a new O-ring on the filtercap and screw the cap onto thefilter housing. Tighten the cap to25 N·m (18 lb·ft).

10. Prime the fuel system by workingthe hand pump until resistance isfelt.

NOTE:There should be a strong resistancein the hand pump, caused by thepressure build-up within the fuelsystem.

11. Crank the engine for 30 secondsat a time, but no longer. Beforecranking again, wait at least twominutes, then crank again. Theengine should start within four30-second attempts.

12. Once the engine starts allow it toidle for at least one minute or untilidle is smooth before applyingthe throttle. Check the fuel filterhousing for leaks.



Fuel/Water Separator PrefilterElement Cleaning

Clean the prefilter element as follows:

1. Loosen the bleed screw.See Figure 38.

2. Unscrew the drain plug and drainthe fuel in the prefilter.

3. Twist off the sight bowl andremove the filter element from theseparator head.

4. Separate the sight bowl fromthe filter element. Clean thesight bowl. Discard the old filterelement and both O-rings.

5. Replace the filter element andO-rings.

6. Assemble the sight bowl and theprefilter element.

[a] Lubricate one O-ring with alight coating of engine oil andinsert it into the sight bowl.

[b] Screw the prefilter elementand sight bowl together.

7. Assemble the prefilter elementand the separator head.

[a] Lubricate the other O-ringwith a light coating of engineoil and insert it into the openend of the prefilter element.

[b] Screw the prefilter elementonto the separator head and

tighten firmly, using handsonly.

Figure 38 Fuel/Water Separator


HOW-TO SECTION

NOTE:Do not use tools to tighten the prefilterelement.

8. Tighten the drain plug.

9. Prime the fuel system.

[a] If equipped with a hand pumpon the fuel/water separator,work the hand pump untilresistance is felt.

NOTE:There should be a strong resistancein the hand pump, caused by thepressure build-up within the fuelsystem.

[b] Crank the engine for 30seconds at a time, but nolonger. Before cranking theengine again, wait at least twominutes. The engine shouldstart within four 30 secondattempts.

Replace Davco 382 FuelPro®Fuel/Water SeparatorElement

Replace the fuel/water separatorelement as follows:

Figure 39 Davco 382 FuelPro®Fuel/WaterSeparator



1. Remove the vent cap, open thedrain valve and drain fuel intoapproved container, until level isbelow the collar. See Figure 39.

2. Using a collar wrench removecollar and cover.

3. Remove the filter element fromthe separator head and discardfilter cover seal and vent seal.Dispose of filter properly.

4. Clean the cover and the mountingsurface on the body.

5. Install the filter element withbottom grommet and new coverseal. Install the cover and collar.Hand tighten only.

6. Fill cover completely with cleanfuel through the vent cap opening.

7. Replace seal on the vent cap andinstall in cover. Hand tightenonly.

NOTE:Do not use tools to tighten the collaror vent cap.

8. Tighten the drain plug.

9. Crank the engine for 30 secondsat a time, but no longer. Beforecranking the engine again, waitat least two minutes. The engineshould start within four, 30second attempts.

10. Start the engine and raise the rpmfor one minute to purge the air.After the air is purged stop theengine, loosen the vent cap untilthe fuel level lowers to just abovethe collar. Tighten the vent capby hand. Check for leaks.

Replace Davco 382/382E FuelPro® Fuel Filter Element

The Davco 382/323E Fuel Prodiesel fuel filter system consists of apermanently mounted fuel processor,a replaceable filter element and sealinggrommet assembly, a filter spring, asee-thru cover and seal, a cover collar,and a vent cap and seal. See Figure 40.


HOW-TO SECTION

Figure 40 Davco 382E FuelPro Fuel ProcessorAssembly

The system also includes a fuel heaterelement, thermostatic switch andwiring harness.

Replace the element as follows:

1. Shut down the engine and allowit to cool.

2. With the engine at ambienttemperature and cool to the touch,place a suitable container underthe filter.

3. A fuel shutoff valve may beinstalled on the discharge side ofthe fuel filter. If installed, turn thehandle on the shutoff valve to theclosed position (perpendicular tothe valve).

4. Open the drain valve at the baseof the fuel processor and drain thefuel until it is below the bottomof the filter in the see-thru cover.Close the drain valve. The fuelmay be returned to the tank.

5. Using filter collar/vent capwrenchDavco part number 382002 orequivalent, remove the collarby turning counterclockwise.Remove the cover, filter springand cover seal ring by liftingstraight up and over the filterelement.

6. Remove the element from thecenter stud (fuel outlet pipe)by pulling upward and twistingslightly.

NOTE:Current filter elements include anintegral sealing grommet. If a formerelement is replaced, make sure theseparate sealing grommet is removedfrom the center stud before installingthe new element.

7. Dispose of the used element andgrommet in an environmentallyresponsible manner, according



to federal (EPA) and/or staterecommendations.

8. Check to make sure the sealinggrommet is included in the baseof the replacement filter element,then install the element onto thecenter stud by pushing down andtwisting slightly.

9. Check to make sure the spring isinstalled at the top of the cover.If missing, this spring must bereplaced to insure proper filteroperation. Wipe the cover lip andcover seal clean.

NOTICE:Do not use a wrench of any kindto tighten the collar, since this maylead to overtightening, which candamage the collar and/or the cover.

10. After making sure the seal isproperly positioned at the base ofthe cover, install the cover andcollar onto the fuel processor.Tighten the collar by hand untilsecure.

11. Using filter collar/vent capwrench 382002 or equivalent,remove the vent cap from the topof the cover by turning the capcounterclockwise. Fill the coverfull of clean fuel. After makingsure the O-ring seal is installed onthe vent cap, reinstall the cap andtighten by hand.

NOTICE:To avoid cover or vent cap damage,do not use tools to tighten the ventcap.

12. Open the fuel shutoff valve (ifinstalled) and start the engine.When the lubrication systemreaches its normal operatingpressure, increase engine speed tohigh idle for 2 to 3 minutes.

NOTICE:Do not allow the fuel level in thesee-thru cover to fall below the topof the collar, since this may leadto interruption of the fuel flow andengine stalling.

13. After the air is purged and withthe engine still running, loosenthe vent cap. The fuel level inthe cover will start falling. Whenthe fuel level falls to the top ofthe collar, tighten the vent capquickly by hand.

14. Shut down the engine and tightenthe collar again by hand . Restartthe engine and check for leaks.

NOTE:The filter cover will not fill completelyduring engine operation. It willgradually fill over time, and the fuellevel will rise as the filter mediumbecomes clogged. The filter element


HOW-TO SECTION

does nor require changing untilthe fuel level has risen to the topof the element, or after one year ofservice, whichever comes first.

Engine Out of Fuel — Howto RestartWhen an engine has run out of fuel,there is a definite procedure to followwhen restarting it.

NOTICE:The starting motor and fuel pumpshould never be used to prime thefuel filters. Prolonged used of thestarting motor and fuel pump toprime the fuel system can result indamage to the starter, fuel pumpand injectors and cause erraticrunning of the engine due to theamount of air in the fuel lines andfilters.

Engines with Fuel Pro Filters

Use the following procedure for anengine with Fuel Pro filters.

1. Remove the vent cap fromthe top of the filter by turningcounterclockwise. Fill the coverfull of clean fuel. After makingsure the O-ring seal is installed onthe vent plug, reinstall the plugand tighten by hand only.

NOTICE:To avoid cover or vent dap damage,do not use tools to tighten the ventcap.

NOTICE:Do not allow the fuel level in thesee-thru cover to fall below the topof the collar, since this may leadto interruption of the fuel flow andengine stalling.

2. Start the engine and allow thelubrication system to reach itsnormal operating pressure, thenincrease engine speed to high idlefor 2 to 3 minutes.

3. After the air is purged and withthe engine still running, loosenthe vent cap on the filter cover.The fuel level in the cover willstart falling. When the fuel levelfalls to the top of the collar on theFuel Pro cover, tighten the ventcap quickly by hand.

Engine Mounted Fuel Filter

Use the following procedure for anengine mounted fuel filter.

1. If the engine is equipped with ahand priming pump located onthe fuel filter module, operate the



priming pump for two to threeminutes or until resistance is felt.

2. If the engine is equipped withonly a priming port located onthe fuel filter module, have anauthorized repair facility primethe fuel system.

3. Crank the engine for 30 secondsat a time, but no longer. Beforecranking the engine again, waitat least two minutes. The engineshould start within four 30 secondattempts.

4. If the engine fails to start, ensurethe vehicle has adequate fuel andthe fuel system is not leakingexternally.

5. If problem persists, call anauthorized repair facility.

How to Clean the EngineImportant: Observe all environmentalprotection regulations.

High-Pressure CleaningEquipment

Information on suitable cleaningand protective products is availablefrom any authorized dealer. Note theequipment manufacturer's operatinginstructions.

NOTICE:To prevent damage to enginecomponents, keep the watermoving at all times while cleaning.Never direct water onto electricalcomponents, plug connectors, sealsor flexible hoses.

To avoid injury, wear a face shieldor goggles.

Comply with the minimum workingdistance between the high-pressurenozzle and the surface being cleaned:

□ Approximately 700 mm (28inches) for circular pattern jets

□ Approximately 300 mm (12inches) for 25-degree flat jets anddirt cutters

How to Clean the CoolingSystemImportant: Collect the used coolant,cleaning solutions, and washingliquids and dispose of them in anenvironmentally responsible manner.

Clean as follows:


HOW-TO SECTION

NOTICE:Clean at moderate pressures only;otherwise the fins of the radiatorgrille could be damaged.

1. First remove debris (dust, insects,etc.) from the fins of the radiatorgrille.

EYE INJURY


2. Remove the debris by blowingthem through with compressed airor spraying them out with water.Work from the rear of the radiator(in the opposite direction of thenormal cooling air flow).

3. Drain the coolant whenthe engine is cold. Fordetailed procedures, see thevehicle/chassis maintenancemanual. For types of coolant,Refer to the”How to SelectCoolant" section.

4. If the HVAC unit is connectedto the cooling system, open theregulating valves all the way.

Degreasing

Degrease as follows:

1. Fill the cooling system with a 5%solution (1.6 ounces per quart ofwater — 50 grams per liter) of amildly alkaline cleaning agent,such as sodium carbonate.

2. Run the engine at moderate speeduntil the thermostat starts to open,at an operating temperature ofapproximately 80°C (176°F).Then run it for about five minuteslonger. Shut down the engine andallow it to cool to approximately50°C (112°F).



HOT COOLANT


3. Drain all the cleaning solution.

4. Flush the cleaning solution fromthe cooling system.

[a] Immediately after drainingthe cleaning solution, flushthe system with clean water.

[b] Once the clean water hasdrained, fill the system againwith clean water.

[c] Run the engine. Allowthe engine to warm up toapproximately 80°C (176°F),and then run it about fiveminutes longer.

[d] Drain the hot water.

5. Fill the cooling system with newcoolant. For detailed procedures,see the vehicle/chassismaintenance manual. Fortypes of coolant, refer to the

“How to Select Coolant” sectionin this guide.

How to Select CoolantThis section covers selection ofthe required coolant for MBE 4000engines.

Definitions

To help ensure completeunderstanding of the information, thedefinitions of the following terms areprovided:

Antifreeze — Ethylene Glycol (EG)or Propylene Glycol (PG) containinga corrosion inhibitor package andmeeting an appropriate heavy-dutyspecification, i.e., TMC RP-329 “TypeA” EG, TMC RP 330 “Type A” PG orTMC RP organic acid ethylene glycol.

NOTE:TMC RP-329 and TMC RP-330 “TypeA” formulations are phosphate free.

Coolant — The fluid mixturecirculating in the engine coolingsystem, typically a mixture of 50%water and 50% antifreeze.

Drop–Out — Precipitated sludge ordeposit formation in or on coolingsystem components.


HOW-TO SECTION

Fully Formulated Antifreeze —Contains all the necessary inhibitorsto protect a diesel engine and doesnot, therefore, require a pre-charge ofSCA before its first use.

Initial–Fill Coolant — The coolantthat is used in a new or rebuilt engine,or any time the cooling system isemptied and then refilled with newcoolant.

OAT — Organic Acid Technology:An inhibitor system based on organicacid inhibitors.

SCA — Supplemental CoolantAdditive – SCAs are used in apreventive maintenance program toprevent corrosion, cavitation and theformation of deposits.

Approved Coolants

The approved and preferred coolantsfor MBE 4000 are .Listed in Table 12.

Once installed, these coolantsshould be maintained accordingto the procedures discussed underMaintenance in this section.

NOTICE:Required specifications for water,ethylene glycol, propylene glycol,inhibitor packages and inhibitorconcentration are included in thispublication. To avoid possibleengine damage from inadequateor over-concentrated coolant,this publication should be readthoroughly before replacing coolant.



Coolant Fill Option ProductEthylene Glycol and Water +Conventional Corrosion Inhibitors 1 DDC Power Cool

Commercial Equivalent of DDC PowerCool

Fully Formulated TMC RP-329 Type AAntifreeze and Water

Propylene Glycol and Water +Conventional Corrosion Inhibitors 1

Fully formulated TMC RP-330 "TypeA" Antifreeze and Water

Ethylene Glycol & Water + OATInhibitors DDC Power Cool Plus

Water Only + Conventional CorrosionInhibitors 2 Water + DDC Power Cool 3000

Water Only + OAT Inhibitors 2 Water + DDC Power Cool Plus 60001 Preferred Coolant2 Water-only coolant systems offer no freeze protection and should not

be used where ambient temperatures can fall to 32° F (0° C).

Table 12 Initial Fill Coolant Options

Ethylene Glycol / Water+ CONVENTIONALCORROSION Inhibitor,propylene Glycol / Water +CONVENTIONAL CORROSIONInhibitor — These products areavailable as Fully Formulated,Phosphate-Free, Extended ServiceInterval (ESI) coolants. They arecommercially available from DetroitDiesel (recommended) and othermanufacturers as either a concentratedantifreeze or as a pre-mixed antifreeze.The pre-mixed antifreeze is ready touse, while the concentrated coolantmust be mixed with water prior to use.

Detroit Diesel Power Cool® EngineCoolant (P/N 23512138) is thepreferred ethylene glycol coolantas Listed in Table 12. If other

commercial brands of ethylene glycolare used, they must be equivalent toPower Cool. Detroit Diesel does notmarket a propylene glycol coolant.If a propylene glycol coolant isused, it must also meet the followingrequirements:

□ Fully formulated ethyleneglycol-based, low silicateantifreeze or coolant mustmeet TMC RP-329 “Type A”requirements.

□ Fully formulated propyleneglycol-based, low silicateantifreeze or coolant mustmeet TMC RP-330 “Type A”requirements.


HOW-TO SECTION

NOTE:Fully formulated antifreeze does notrequire a dosage of SCA prior to initialuse.

Mixing EG or PG Antifreeze andWater — If a concentrated EthyleneGlycol (EG) or Propylene Glycol(PG) antifreeze is purchased, mixthe antifreeze with water meetingthe required quality standards andfill the cooling system. For waterrequirements, If a concentrated EGor PG antifreeze is purchased, mixthe antifreeze with water meetingthe required quality standards andfill the cooling system. For waterrequirements, refer to section WaterRequirements. If a pre-diluted, fullyformulated coolant is purchased,simply fill the cooling system.

For best overall performance, a coolantconsisting of 50% concentration ofantifreeze (50% antifreeze, 50%water) is recommended. An antifreezeconcentration of over 67% (67%antifreeze, 33% water) is notrecommended due to poor heattransfer, reduced freeze protection(IEG only), and possible silicatedropout. An antifreeze concentrationbelow 33% (33% antifreeze, 67%water) offers too little freeze and/orcorrosion protection and is notrecommended.



Always verify that the freeze pointand nitrite concentration of theantifreeze/water mix are correct byusing a POWER Trac® 3-Way Test

Strip. If chemical analysis is used,elements in the coolant must fallwithin the limits as listed in Table 13

Fully Formulated Glycol Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 200 – 3200 PPM

Silicon 50 – 250 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Table 13 Fully Formulated Glycol Coolant Limits with TMC RP-329,TMC RP-330 Chemistry Type A (50/50 Coolant/WaterMixture)

Recycled Antifreeze — Antifreezeor coolant recycled by reverseosmosis, distillation, and ionexchange, properly re-inhibited tomeet TMC RP-329 “Type A” orRP-330 “Type A” requirementshas been demonstrated to provideservice equivalent to virgin antifreeze.Recycled antifreeze or coolants ofthese types are preferred. Otherrecycled coolants, especially coolantsrecycled through filtration processes,are not recommended.

ETHYLENE GLYCOL /WATER + OAT INHIBITOR,PROPYLENE GLYCOL / WATER+ OAT INHIBITOR — Ethyleneglycol and propylene glycol arealso available with an Organic Acid

Technology (OAT) corrosion inhibitorpackage. These coolants require lessmaintenance over the useful life of theengine. The cooling system shouldeither be equipped with a “blank”coolant filter or the coolant filterand piping may be omitted from thesystem.


HOW-TO SECTION

OAT fully formulated antifreezesare available as concentrated andpre-mixed. Concentrated antifreezesshould be mixed at 50% (50%antifreeze 50% water). OAT coolantsshould not be mixed with conventionalcoolants. If OAT and conventionalcoolants are mixed, no damage willresult, but the long-life advantagesof the OAT coolant will be lost. Inthis event, the coolant should bemaintained as a fully formulated ESI(Extended Service Interval) coolant,not as an OAT coolant.

Detroit Diesel markets OAT-inhibitedethylene glycol coolants – DDCPOWER COOL Plus and POWERCOOL Plus Marine (30% glycol, 70%water). POWER COOL Plus coolantscontain all of the required inhibitors.If a non-DDC OAT antifreeze is used,it must conform to TMC RP-338specification. Do not add extender tonew OAT antifreeze or coolant.

WATER ONLY + SCA,WATER ONLY + OATINHIBITOR — In warm climateswhere freeze protection is notrequired, water only with corrosioninhibitors is approved for use.Water-only systems need to be treatedwith the proper dosage of corrosioninhibitors. Detroit Diesel-approvedconventional SCA or OAT corrosioninhibitors must be added to the waterto provide required corrosion and

cavitation erosion protection. Initialfill options are listed in Table 1. OATinhibitors such as POWER COOLPlus 6000 are available for water-onlysystems. OAT inhibitor should bemixed at 7.5% – 10% by volumewith water. Refer to section POWERCOOL ENGINE PRODUCTS for alisting of POWER COOL products.

Conventional SCA (POWER COOL3000) can also be used to protectthe engine. Listed in Table 14are POWER COOL 3000 coolantconcentration limits.

NOTE:Do not use Power Trac 3–Way TestStrips to test OAT coolant.



Power Cool 3000 Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 0 – 1000 PPM

Silicon 50 – 250 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Table 14 Power Cool 3000 Concentration Limits (5% Power Cool3000/ 95% Water)

POWER COOL 3000 SCA inhibitorsshould be mixed at 5% by volumewith water (1 quart per 5 gallons ofwater). These additions can be madeby adding liquid SCAs available in avariety of sizes. Coolant filters arealso available for different coolingsystem capacities. These filters releasethe proper amount of SCA at initialfill.

Water Requirements —Distilled or de-ionized water, whicheliminates the adverse effects ofminerals in tap water, is preferred.High levels of dissolved chlorides,sulfates, magnesium, and calcium insome tap water causes scale deposits,sludge deposits and/or corrosion.These deposits have been shownto result in water pump failuresand poor heat transfer, resulting inoverheating. If tap water is used, themineral content in the water must be

below the maximum allowable limitslisted in Table 15.

NOTICE:Do not add additional SCA tonew, fully formulated antifreeze orcoolant. This can result in dropoutand/or the formation of deposits.

Coolants Not Recommended

The following coolants are notrecommended for use in Detroit Dieselengines.

All Antifreezes And CoolantsContaining Phosphate — Thesecoolants are not recommended. Dropout, overheating and water pump sealfailures can result from the use ofcoolant or inhibitor packages based onphosphate.


HOW-TO SECTION

Automotive Type Coolants —These coolants generally contain highlevels of phosphate and silicate, offerno liner pitting protection, and arenot suitable for use in Detroit Dieselengines.

Methyl Alcohol-BasedAntifreeze — This must not beused because of its effect on thenon-metallic components of thecooling system and its low boilingpoint.

Maximum AllowableParts per Million Grains per Gallon

Chlorides 40 2.5

Sulfates 100 5.8

Total Dissolved Solids 340 20Total Hardness –Magnesium and Calcium 170 10

Table 15 Satisfactory Water Limits – Make-Up Water Only

Glycol-based CoolantsFormulated For HVAC —These coolants formulated forHeating/Ventilation/Air Conditioning(HVAC) should not be used. Thesecoolants generally contain high levelsof phosphates, which can depositon hot internal engine surfaces andreduce heat transfer.

Additives Not Recommended

The following additives are notrecommended for use in MBE 4000engines.

Soluble Oils — Soluble oil additivesare not approved for use in DetroitDiesel engine cooling systems. Asmall amount of oil adversely affects

heat transfer. For example, a 1.25%concentration of soluble oil increasesfire deck temperature 6%. A 2.50%concentration increases fire decktemperature 15%. The use of solubleoil additives may result in engineoverheating and/or failure.

Chromates — Chromate additivesare not approved for use in DetroitDiesel engine cooling systems.Chromate additives can formchromium hydroxide, commonlycalled “green slime.” This, in turn,can result in engine damage due topoor heat transfer. Cooling systemsoperated with chromate-inhibitedcoolant must be chemically cleanedwith POWER COOL Twin Packcooling system cleaner/conditioner



(or equivalent sulfamic acid/sodiumcarbonate cleaner) and flushed.POWER COOL cleaners arelisted in Table POWER COOLCooling System Cleaners

Coolant Inhibitor Test Intervals

The coolant inhibitor level should bechecked at the intervals listed in Table16.

Service Application Inhibitor Test IntervalLong Haul — Highway Truck & MotorCoach — operates more than 60,000miles (100,000 kilometers) per year

20,000 Miles (32,000 km)

Sort Haul — City Transit — operatesup to 60,000 miles (100,000kilometers) per year

6,000 Miles (9,600 km) or threemonths, whichever comes first

Severe Service — Fire Truck orCrash/Rescue Vehicle — operates upto 6000 miles (9,600 kilometers) orunder severe conditions

6,000 Miles (9,600 km) or threemonths, whichever comes first

Table 16 Required Coolant Inhibitor Test Intervals

HOT COOLANT


If topping off is needed, add coolantwhich is identical to the initial fillcoolant.

Supplemental Coolant Additivesfor Fully Formulated Coolant —The concentrations of some inhibitorswill gradually deplete during normalengine operation. SCAs replenishthe protection for cooling systemcomponents. The coolant mustbe maintained with the properconcentration of SCA. Detroit DieselPower Cool maintenance SCAs arerecommended.

The proper application of SCA willprovide:

□ pH control.

□ Restored inhibitor levels to preventcorrosion.


HOW-TO SECTION

□ Water softening to deter formationof mineral deposits.

□ Cavitation protection to protectwet sleeve cylinder liners.

Maintenance Intervals — Checkthe nitrite concentration at the regularintervalslisted in Table 17 with aPower Trac 3–Way Test Strip.



Coolant Interval 1 Action

20,000 Miles (32,000 km)or 3 Months*

Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.

Antifreeze / Water +SCA Inhibitor (DDCPower Cool) 300,000 Miles

(480,000 km)Drain and clean system.Refill with new coolant.


Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.

Ethylene Glycol/ Water + SCAInhibitororPropylene Glycol/ Water + SCAInhibitor

300,000 Miles(480,000 km)

Drain and clean system.Refill with new coolant.

Test at 1 Year. —300,000 Miles(480,000 km) or 2 Years*

Add Power Cool PlusExtender

Ethylene Glycol/ Water + OATInhibitororPropylene Glycol/ Water + OATInhibitor

600,000 Miles(960,000 km)

Drain and clean system.Replace with new coolant.


Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.Water Only + SCA

Inhibitor 300,000 Miles(480,000 km)

Drain and clean system.Replace with new coolant.

300,000 Miles(480,000 km) or 2 Years*

Add Power Cool PlusExtenderWater Only + OAT

Coolant 600,000 Miles(960,000 km)

Clean and drain. Replacewith new coolant.

1 based on application. Drain interval dependent on proper maintenance.

Table 17 Coolant Maintenance Intervals

Nitrite levels must be within theranges listed in Table 13.


HOW-TO SECTION

NOTICE:Failure to properly maintain coolantwith SCA can result in damageto the cooling system and itsrelated components. Conversely,over-concentration of SCA inhibitorcan result in poor heat transfer,leading to engine damage.Always maintain concentrations atrecommended levels. Do not usetraditional SCAs with OAT coolant.

Additional SCA must be added to thecoolant when it becomes depleted, asindicated by a nitrite concentrationof 900 PPM or less. If the nitriteconcentration is greater than 900PPM, do not add additional SCA. Ifthe nitrite concentration is above 3200PPM, the system is over-inhibited andshould be partially drained and filledwith a 50/50 mix of water and EG orPG.

In this case the EG or PG shouldcontain no inhibitors and shouldconform to ASTM D4985. Thiswill dilute the over-concentratedinhibitors.

NOTE:In non-OAT systems, nitriteconcentration of 5000 PPM orhigher on a MBE 4000 enginesuggests problematic additiveover-concentration. This conditionmust be corrected by immediatedraining and flushing of the coolingsystem. Refill the system with new fullyformulated or pre-charged coolant.Check the nitrite concentration levelat the next with a Power Trac 3–WayTest Strip.

SCA Test Procedures

Detroit Diesel Power Trac 3–WayCoolant Test Strips should beused to measure nitrite and glycolconcentrations. Part numbersare in refer to section POWERCOOL ENGINE PRODUCTS andrefer to section POWER TRACCoolant Testing And AnalysisProducts. Cavitation/corrosion isindicated on the strip by the level ofnitrite concentration. Freeze/boil overprotection is determined by glycolconcentration.



HOT COOLANT


For best results make the test whilethe coolant is between 50° – 140° F(10° – 60° C). Wait at least 60, butnot longer than 75, seconds beforereading the nitrite level. Use the teststrips as follows:

1. Dip the strip into coolant forone second. Remove and shakebriskly to eliminate excess fluid.

2. Immediately compare the pad end(% glycol) to the color chart onthe container.

3. Sixty seconds (one minute) afterdipping, compare the nitrite padto the color chart.

4. Color change of the additiveindicator (middle pad) indicatesthe presence of inhibitor that isnot approved by Detroit Diesel.

Promptly replace and tighten the teststrip container cap after each use.

Discard unused strips if they haveturned light pink or tan.

A factory coolant analysis program isavailable through authorized DetroitDiesel service outlets. Part numbersare in refer to section POWERTRAC Coolant Testing And AnalysisProducts in the Specifications section.To verify coolant acceptability, submita sample for coolant analysis everytwo (2) years, 300,000 miles (480,000km), or 10,000 operating hours,whichever comes first.

Need Release Coolant Filters(Non-OAT Systems)

Spin-on coolant filters are available forDetroit Diesel engines. Membranesin the filters release SCAs beforethe coolant approaches a corrosivecondition, protecting the engine fromcorrosion. The elements release theSCA charge as needed, as opposed tothe maintenance SCA elements, whichinstantaneously release the SCAcharge. Coolant filter elements shouldbe replaced after one (1) year, 120,000miles (192,000 km) or 2,000 operatinghours, whichever comes first.


HOW-TO SECTION

Dropout

Excessive amounts of some inhibitorsin the coolant can cause a gel orcrystalline deposit that reduces heattransfer and coolant flow. The deposit,called “dropout,” takes the color ofthe coolant when wet, but appears as awhite or gray powder when dry. It canpick up solid particles in the coolantand become gritty, causing excessivewear of water pump seals and othercooling system components.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

The wet gel can be removed by usinga non-acid (alkali) type heavy-dutycleaner, such as Detroit Diesel PowerCool On-Line Cleaner (sodiumnitrite/sodium tetraborate). Partnumbers are inrefer to section POWERCOOL ENGINE PRODUCTS.

NOTE:If the gel is allowed to dry, it isnecessary to disassemble theengine and clean it with a causticsolution or physically clean individualcomponents.

Coolant Extender InhibitorAdditive for “OAT” Coolant

The inhibitors in OAT coolant mustalso be maintained, but less oftenthan traditional SCA-type coolants.A portable test is available to test thelevels of OAT inhibitors in coolant.Where this is not used, fleet testinghas determined that a OAT coolantextender package should be added tothe coolant at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. The propermaintenance dosages for all OATcoolants are listed in Table 17 ,reflecting 0.6% by volume extender.This dosage should be added to thewater-only and the glycol systems atthe same interval.

The proper application of extender toOAT coolant will provide:

□ pH Control

□ Restored inhibitor levels to preventcorrosion

□ Cavitation protection to protectwet sleeve cylinder liners

NOTE:Do not use traditional SCAs inOAT coolant, and do not useOAT extender in traditional coolant.



OAT Coolant Drain Interval —A properly maintained OAT-inhibitedcoolant will last 600,000 miles(960,000 km), four (4) years, or10,000 operating hours, whichevercomes first. At this time the coolantshould be drained, and the coolingsystem should be thoroughly cleaned,flushed, and filled with new, properlyinhibited OAT coolant.

Chronic Coolant SystemProblems

The most commonly seen coolantsystem problems result frommaintenance and formulation factorssuch as:

□ Hard water

□ Dilution of the coolant by theaddition of untreated water

□ Over dosage or under dosage ofcorrosion inhibitors

□ Improper corrosion inhibitor (mostoften phosphated)

□ Mixing SCAs

□ Improper testing

Detroit Diesel Cooling SystemMaintenance Products

The following products are availableto do maintenance on the coolingsystem.

Power Cool SCAs — Power CoolSCAs are water-soluble chemicalcompounds. These products areavailable in coolant filter elements,liquid packages, and in fullyformulated Power Cool antifreeze.

NOTE:Power Cool 3000 liquid SCA is morecompatible with hard water thanPower Cool 2000 SCA.

Power Cool Coolant FilterElements — Power Cool coolantfilter elements (spin-on canisters) areavailable in various sizes suitable forcooling systems of varying capacities.Selection of the proper element sizeis vital when pre-charging non-fullyformulated coolant at initial fill andat s. A fully formulated antifreezemust not have SCA added at initialfill. Do not use SCA-containingfilters with OAT antifreeze orcoolant. The need for maintenanceelements is determined by the resultsof the nitrite concentration testperformed at each cooling systeminterval. Do not automaticallyinstall maintenance elements atmaintenance intervals, unless thenitrite concentration falls below 900parts per million.

Power Cool Cleaners — PowerCool Liquid On-Line Cleaner is usedfor light deposits. Power Cool Dry


HOW-TO SECTION

Chemical Cleaner/Conditioner is usedfor heavy deposits or scale.

Summary of CoolantRecommendations

HOT COOLANT


1. Always maintain the enginecoolant to meet Detroit Dieselspecifications.

2. Only use water that meets thespecifications listed in Table 15.Distilled, de-mineralized (reverseosmosis) or de-ionized water ispreferred.

3. The proper dosage of inhibitorsmust be included in the coolantat initial fill for all Detroit Dieselengines. This dosage is usuallyincluded in the fully formulatedantifreeze used, or it may need tobe added if water alone or if lessthan 50% antifreeze is used. The

user is urged to refer to the fulltext of this section to determinethe proper dosage. Mixingof different manufacturers'technologies (brands) could causecooling system problems.

4. Maintain the inhibitor at theprescribed concentration. Testthe nitrite concentration by usinga titration kit or Detroit DieselPower Trac 3-Way Coolant TestStrips. Add SCA only if the nitriteconcentration is below 900 PPM.Do not use SCA in OAT coolant,and do not use Power Trac 3-WayCoolant Test Strips to test OATcoolant.

NOTE:If the nitrite concentration exceeds3200 PPM, the coolant must bedrained and replaced with newcoolant. A thorough cleaning of thecooling system may be required.

5. Do not use another manufacturer'stest kit to measure the SCAconcentration of Detroit Dieselmaintenance products.

6. Pre-mix coolant makeup solutionsto the proper concentration beforeadding to the cooling system.

7. Do not mix OAT and othercoolants in the same engine.

8. Do not use automotive coolants.



9. Where antifreeze/boil overprotection is required, use onlyantifreeze that meets TMCRP-329 “Type A” EG orTMC RP-330 “Type A” PGspecifications. Always maintaincoolant at the proper level.

10. Do not use the following inDetroit Diesel engine coolingsystems:

□ Soluble oil

□ High silicate, automotive-typeantifreeze

□ Chromate SCAs

□ Methoxy propanol-basecoolant

□ Methyl alcohol-base coolant

□ Sealer additives or coolantcontaining sealer additives.

□ HVAC coolant

□ Phosphated coolants

Coolant life of Glycol Coolant —A properly maintained coolingsystem, filled with phosphate-freecoolant consisting of a 50/50 mix ofantifreeze and water per TMC RP-329“Type A” EG or TMC RP-330 “TypeA” PG specifications can be operatedto the limits recommended. Theproper maintenance involves periodicevaluation using Power Trac 3-WayCoolant Test Strips and the addition of

SCA as needed, indicated by the striptest. To verify coolant acceptability,submit a sample for coolant analysisevery 300,000 miles (480,000 km),three (3) years, or 5,000 operatinghours, whichever comes first. Submitthe sample in a DDC Power TracCoolant Test Bottle. Required partnumbers are inrefer to section POWERCOOL ENGINE PRODUCTS.

Coolant Life of OAT Coolant — Aproperly maintained OAT coolant maybe operated 600,000 miles (960,000km), four (4) years, or until overhaul,whichever comes first. At this time thesystem must be completely drained,thoroughly cleaned, and refilled. OATCoolants require the addition of anextender at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. Use 1 pintof extender for every 20 gallons ofcoolant.

Coolant Life of Other Coolants—Other properly maintained coolantsmay be operated up to 250,000 miles(480,000 km), two (2) years, or 4,000operating hours, whichever comesfirst. At this time the system mustbe completely drained, thoroughlycleaned, and refilled.


HOW-TO SECTION

Coolant Flushing and Changing

Flush and change the coolant asfollows:

HOT COOLANT


1. Open the cap on the surge tankslowly, to allow excess pressureto escape. Set the cap aside.

2. Open the water regulating valvefor the heating system.

3. Place a large receptacleunderneath the coolant drainplug and open the coolant drainplug on the bottom of the radiator.

NOTE:Make sure the coolant can flowunobstructed into the receptacle.

NOTICE:Do not apply more than 140 kPa (20psi) air pressure for a radiator flush;more pressure could damage theradiator or heater core.

4. Start radiator flushing byattaching a flushing gun nozzle tothe radiator outlet and run waterin until the radiator is full.

EYE INJURY


5. Apply no more than 140 kPa (20psi) air pressure intermittently tohelp dislodge sediment buildup inthe core.

6. Drain the radiator, and flush theradiator until clean water flowsfrom the radiator. Remove theflushing gun.

7. When the coolant has drained,install the coolant drain plug onthe radiator.



8. Add coolant in the specifiedconcentration until the maximummark on the surge tank is reached.

9. Start the engine and run it forabout one minute at varyingspeeds to release air pockets inthe cooling system. Ensure theheater valve is still open. Checkthe coolant level and add morecoolant if necessary.

10. Shut down the engine, close andtighten the cap on the surge tank.

Cooling System Inspecting

NOTE:Before doing this inspection, do either"Coolant Concentration Checking," or"Coolant Flushing and Changing."

Inspect the cooling system as follows:

HOT COOLANT


1. Inspect the radiator, condenser,water pump, engine oil cooler,freeze plugs, and heat exchangerfor damage and leaks.

2. Check all cooling system pipesand hoses for damage and leaks;ensure they are positioned toavoid chafing, and are securelyfastened.

3. Check the outside of the radiatorand condenser for blockage.Check fins for damage; straightenthem if necessary.


TROUBLESHOOTING

TROUBLESHOOTING

In addition to operating the enginecarefully and maintaining it properly,make sure to correct any malfunctionpromptly.

When the electronic engine controlsystem detects a fault, it broadcastsa message on the datalink. Thedash display will show the code"Motor Control Module (MCM) 128,"indicating there is an engine fault.

Important: To read the completefault code, bring the vehicle to anauthorized dealer. Complete fault

codes can be read using the NexiqDDR or DDDL 7.0 version or later.

For fault codes and their meanings,see the next section in this guide.

The tables that follow are designedto identify the causes of commonproblems, suggest further checks andappropriate remedies. When dealerservice is necessary, this is mentionedin the table.

NOTE:Remember to follow all cautions whentroubleshooting the engine.

Problem - The Engine Will Not Crank

Cause Remedy

The batteries are damaged or weak. Test the batteries. Replace them, ifneeded.

The ignition switch is damaged. Replace the ignition switch.

The battery cables are damagedand/or corroded. Replace the battery cables.

The starter is damaged and/or worn. Have an authorized repair facilityreplace the starter.

The clutch or transmission isdamaged.

Bring the vehicle to an authorizedrepair facility for service.

There is internal damage to theengine.




Problem—The Engine Turns Over Slowly

Cause Remedy


The ignition switch is damaged. Replace the ignition switch.

The battery cables are damagedand/or corroded Replace the battery cables.

The starter is damaged and/or worn. Have an authorized repair facilityreplace the starter.

The engine oil does not meet thecorrect specifications.

Change the engine oil, using thecorrect type of oil.

The transmission fluid does not meetthe correct specifications.

Change the transmission fluid, usingthe correct type of fluid.


TROUBLESHOOTING

Problem—The Engine Cranks, But Won't Start

Cause Remedy


The cranking speed is not set correctly. Bring the vehicle to an authorizedrepair facility for service.

No intake air preheater is installed,and it is too cold to start without one. Install an intake air preheater.

The intake air preheater ismalfunctioning.

Check the intake air preheater, andreplace it, if necessary.

The camshaft position (CMP) sensorand/or the crankshaft position (CKP )sensor are out of adjustment.

Push both sensors into their holes asfar as they will go. If this does notsolve the problem, bring the vehicle toan authorized repair facility for service.

The camshaft position (CMP) sensorand/or the crankshaft position (CKP )sensor are damaged.


There is air in the fuel system.Check the fuel lines for air pockets.Prime the fuel system and start theengine.

The air filter is clogged. Clean or replace the air filter.

The fuel filter is clogged. Replace the filter element.

The exhaust brake valve ismalfunctioning.

Have an authorized repair facilitycheck the operation of the valve.

The valves are not adjusted properly. Check the valve lash.

There are other problems in the fuelsystem.




Problem—The Engine Starts Only After Cranking for a Long Time

Cause Remedy

The fuel tank is low or empty. Add fuel and prime the fuel system, ifnecessary.

There are leaks in the fuel lines. Check the fuel lines for leaks andrepair them, if necessary.


The fuel line, the fuel prefilter, or thescreen in the fuel tank is blocked.

Clean and prime the system. Havethe fuel lines and filters checked by anauthorized repair facility.








TROUBLESHOOTING

Problem—The Engine Starts, But Dies

Cause Remedy

The fuel tank is low or empty. Add fuel and prime the fuel system, ifnecessary.


The fuel line, the fuel prefilter, or thescreen in the fuel tank is blocked.

Clean and prime the system. Havethe fuel lines and filters checked by anauthorized repair facility.





The constant-throttle valves aremalfunctioning.




Problem—The Engine Fan Doesn't Work

Cause RemedyThe fan hub is damaged. Replace the fan hub.

The fan wiring is damaged. Repair the fan wiring.

The parameter settings in the MCM orCommon Powertrain Controller (CPC)are incorrect.

Have an authorized repair facilityreprogram the control unit.



Problem—The Engine Fan Is Constantly On

Cause Remedy

The fan override switch is on. Check the operation of the fan overrideswitch.

The fan hub is damaged. Replace the fan hub

The parameter settings in the MCM orCPC are incorrect.

Have an authorized repair facilityreprogram the control unit.

AC switch is damaged Check AC switch.

Problem—Fuel Consumption Is Too High

Cause RemedyThe tires are not properly inflated. Check all tires for correct pressure.

The air filter and/or intake air systemis clogged.

Check the air restriction indicator.Clean the intake air system andreplace the air filter if necessary.




TROUBLESHOOTING

Problem—The Engine Performs Poorly, Does NotDevelop Full Power

Cause Remedy






There are other problems with the fuelsystem.


The valves are not adjusted properly Check the valve lash.

The coolant temperature sensor isdamaged or reading incorrectly.


The fuel temperature sensor isdamaged or reading incorrectly.


The engine oil temperature sensor isdamaged or reading incorrectly.


The charge-air temperature sensor isdamaged or reading incorrectly.


There are problems with the MCM orCPC.






Problem—The Engine Is in Emergency Running Mode(constant speed 1,300 rpm)

Cause Remedy

The MCM or CPC is damaged. Bring the vehicle to an authorizedrepair facility for service.

An incorrect parameter is in the MCMor CPC.

Bring the vehicle to an authorizedrepair facility and have the parametersettings reprogrammed in the MCMor CPC.

Problem—The Coolant Temperature Is Above Normal

Cause Remedy

The coolant level is too low. Check for coolant leaks, and repair asneeded.

The poly-V belt is loose. Tighten or replace the poly-V belt.

The coolant temperature gauge and/orsensor is not reading correctly.


The radiator is damaged or dirty. Clean the radiator. Repair or replacethe radiator if necessary.

The water pump is damaged. Have an authorized repair facilityreplace the water pump.

The thermostat is damaged. Have an authorized repair facilityreplace the water pump.

The fan is not operating properly.

Bring the vehicle to an authorizedrepair facility and have the fan hubchecked or have the parametersettings reprogrammed in the MCMor CPC.


TROUBLESHOOTING

Problem—The Coolant Temperature Is Below Normal

Cause RemedyThe coolant temperature gauge and/orsensor is not reading correctly.


The thermostat is not operatingproperly.

Have an authorized repair facilityreplace the thermostat.

The fan is not operating properly.

Bring the vehicle to an authorizedrepair facility and have the fan hubchecked.Bring the vehicle to an authorizedrepair facility and have the parametersettings reprogrammed in the MCMor CPC.

Problem—The Cooling System Is Losing Coolant

Cause RemedyThere is an external coolant leak. Repair the leaking component.

The radiator cap is leaking. Replace the radiator cap.

The air compressor head is damaged. Have an authorized repair facilityreplace the air compressor.

The cylinder head gasket is leaking. Have an authorized repair facilityreplace the head gasket.

Problem—There Is Coolant in the Engine Oil

Cause Remedy

The cylinder head gasket is damaged. Have an authorized repair facilityreplace the head gasket.

The oil/water heat exchanger isleaking.

Have an authorized repair facilityreplace the heat exchanger.

There is an internal coolant leak. Bring the vehicle to an authorizedrepair facility for service.



Problem—There Is Foam in the Engine Oil

Cause RemedyThe oil level is too low or too high. Correct the oil level.

The oil has not been changed withinthe recommended interval. Change the oil.

The oil is not of the recommendedquality. Change the oil.

Problem—The Engine Oil Pressure Is Low

Cause RemedyThe oil pressure gauge and/or sensoris not reading correctly.


There is fuel in the oil. Bring the vehicle to an authorizedrepair facility 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 isdamaged.

Have an authorized repair facilityreplace the oil pump.

Problem—The Engine Exhaust Is White

Cause RemedyThe fuel is of poor quality. Add fuel of the right quality.


Check the intake air preheater, andreplace it, if necessary.



TROUBLESHOOTING

Problem—The Engine Exhaust Is Black

Cause Remedy






Check that the heater is not staying onall of the time.


There is damage to the fuel system:the fuel pump, one or more fuelinjectors, or one or more unit pumpsare damaged.


The charge-air temperature sensor isdamaged.




Problem—The Engine Exhaust Is Blue

Cause RemedyThe engine oil level is too high(engine oil is reaching the combustionchamber).

Adjust the oil level, and then have theoil level checked by an authorizedrepair facility.

The turbocharger is leaking oil. Have an authorized repair facilityreplace the turbocharger

The valve stem seals are loose ordamaged.

Have an authorized repair facilityreplace the seals.

The piston rings are worn. Have an authorized repair facilityreplace the piston rings.



Problem—Engine Brake Performance Is Poor

Cause RemedyThe engine brake control switch isdamaged. Replace the switch

The exhaust brake is not operatingproperly.


The constant-throttle valves aremalfunctioning.


Components of the MCM and/or CPCare damaged.


Problem—Cruise Control Is Not Working

Cause RemedyOne or more of the cruise controlswitches are damaged. Replace the damaged switch.

Components of the MCM and/or CPCare damaged or not working properly.


Problem—The Battery Charge Indicator Light Does NotCome On When the Engine Is Not Running

Cause RemedyThe bulb is bad. Replace the bulb.

The circuit is broken. Repair the break in the circuit.


TROUBLESHOOTING

Problem—The Battery Charge Indicator Light ComesOn When the Engine is Running

Cause Remedy

The poly-V belt is too loose.Check the belt tension; if necessary,Have an authorized repair facilityreplace the belt tensioner.

The belt tensioner is damaged. Have an authorized repair facilityreplace the belt tensioner.

The poly-V belt is worn or damaged. Replace the belt.

The alternator is damaged (has adamaged rectifier or voltage regulator).

Have an authorized repair facilityreplace the alternator.



ENGINE STORAGE

When an engine is to be stored orremoved from operation for a periodof time, special precautions shouldbe taken to protect the interior andexterior of the engine, transmissionand other parts from rust accumulationand corrosion. The parts requiringattention and the recommendedpreparations are given below.

Preparing Engine forStorageIt will be necessary to remove allrust or corrosion completely fromany exposed part before applying rustpreventive compound. Therefore,it is recommended that the enginebe processed for storage as soon aspossible after removal from operation.

The engine should be stored ina building that is dry and can beheated during the winter months.Moisture-absorbing chemicals areavailable commercially for use whenexcessive dampness prevails in thestorage area.

Temporary Storage (30 Days orLess)

To protect the engine for a temporaryperiod of time (30 days or less), followthis procedure:

1. With the engine at ambienttemperature and cool to the touch,drain engine crankcase oil into asuitable container. Dispose of theoil in an environmentally friendlymanner, according to state and/orfederal (EPA) recommendations.

2. Fill the crankcase to the properlevel with the recommendedviscosity and grade of oil.

3. Fill the fuel tank with therecommended grade of fuel oil.Operate the engine for two (2)minutes at 1200 rpm and no load.Do not drain the fuel system orthe crankcase after this run.

4. Check the air cleaner and serviceit, if necessary.

5. If freezing weather is expectedduring the storage period, checkthe antifreeze/coolant for requiredfreeze and inhibitor protection.Add antifreeze solution to thecooling system in accordance withDetroit Diesels recommendations.Refer to “How to Select Coolant”in this guide.

NOTE:If an antifreeze solution is not requiredduring storage, flush the coolingsystem with a good soluble oil (3% –5% by volume) rust inhibitor to prevent


ENGINE STORAGE

rusting of the outside diameter of thecylinder liners.

EYE INJURY


6. Clean the exterior of the engine(except electrical parts) with fueloil and dry with compressed air.

7. Seal all engine openings. Thematerial used must be waterproof,vapor proof and possess sufficientphysical strength to resistpuncture and damage from theexpansion of entrapped air.

An engine prepared in this manner canbe returned to service in a short timeby removing the seals at the engineopenings and by checking the enginecoolant, fuel oil, lubricating oil andtransmission oil levels.

Extended Storage (More than 30Days)

To prepare an engine for extendedstorage (more than 30 days), followthis procedure:

1. Drain the cooling system andflush with clean, soft water. Refillwith clean, soft water and adda rust inhibitor to the coolingsystem.

2. Circulate the coolant by operatingthe engine until normal operatingtemperature is reached.

3. Stop the engine.

4. With the engine at ambienttemperature and cool to the touch,drain the engine crankcase oilinto a suitable container. Removethe oil filters. Dispose of the oiland filters in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations. Replace thedrain plug and tighten to 80 N·m(59 lb·ft) torque.

5. Install new lubricating oilfilters. Fill the crankcase tothe proper level with Tectyl®930A preservative lubricatingoil or an equivalent 30–weightpreservative lubricating oilmeeting Mil-L-21260C, Grade 2Specification.

6. Drain the fuel tank. Refill withenough clean No. 1 diesel fuelor pure kerosene to permit theengine to operate for about ten(10) minutes. If draining thefuel tank is not convenient, use



a separate, portable supply ofrecommended fuel.

NOTE:If engines are stored wherecondensation of water in the fueltank may be a problem, additivescontaining methyl carbitol or butylcellusolve may be added to the fuel.Follow manufacturer's instructionsfor treatment. Where biologicalcontamination of fuel may be aproblem, add a biocide such asBiobor® JF (or equivalent) to thefuel. When using a biocide, followthe manufacturer's concentrationrecommendations and observe allcautions and warnings.

7. Drain the fuel system and removethe fuel filters. Dispose of usedfilters in an environmentallyresponsible manner, accordingto state and/or federal (EPA)recommendations. Fill the newfilters with No. 1 diesel fuel orpure kerosene and install on theengine.

8. Operate the engine for five (5)minutes to circulate the clean fuelthroughout the engine. Be surethe engine fuel system is full.

9. Stop the engine and allow tocool. Then disconnect the fuelreturn line and the inlet line atthe primary filter and securely

plug both to retain the fuel in theengine.

10. Transmission: Follow themanufacturer's recommendationsfor prolonged storage.

11. Power Take-Off: If equipped,follow manufacturer'srecommendations for prolongedstorage.

NOTICE:Failure to properly seal off theturbocharger air inlet and exhaustoutlet openings before enginestorage may permit air drafts tocirculate through the turbochargerand rotate the turbine/compressorshaft without an adequate flow oflubricating oil to the center housingbearings. This can result in severebearing damage.

12. Turbocharger: Sinceturbocharger bearings arepressure lubricated through theexternal oil line leading fromthe oil filter adaptor while theengine is operating, no furtherattention is required. However,the turbocharger air inlet andturbine exhaust outlet connectionshould be sealed off withmoisture-resistant tape.

13. Apply a non-friction rustpreventive compound to allexposed engine parts. If


ENGINE STORAGE

convenient, apply the rustpreventive compound to theengine flywheel. If not, disengagethe clutch mechanism to preventthe clutch disc from sticking tothe flywheel.

NOTE:Do not apply oil, grease or anywax-base compound to the flywheel.The cast iron will absorb thesesubstances, which can “sweat” outduring operation and cause the clutchto slip.

14. Drain the engine cooling system.

15. Drain the preservative oil fromthe engine crankcase. Reinstalland torque the oil drain plug to80 N·m (59 lb·ft).

16. Remove and clean the batteryand battery cables with a bakingsoda-water solution and rinsewith fresh water. Do not allowthe soda solution to enter thebattery. Add distilled water tothe electrolyte (if necessary) andfully charge the battery. Store thebattery in a cool (never below 0°C or 32° F) dry place. Keep thebattery fully charged and checkthe level and specific gravity ofthe electrolyte regularly.

17. Insert heavy paper strips betweenthe pulleys and drive belts toprevent sticking.

18. Seal all engine openings,including the exhaust outlet,with moisture-resistant tape. Usecardboard, plywood or metalcovers where practical.

19. Clean and dry the exterior paintedsurfaces of the engine and spraywith a suitable liquid automobilebody wax, a synthetic resinvarnish, or a rust preventivecompound.

20. Protect the engine with a goodweather-resistant tarpaulin andstore it under cover, preferablyin a dry building which can beheated during the winter months.

Outdoor storage of the engine is notrecommended. If units must be keptout of doors, follow the preparationand storage instructions alreadygiven. Protect units with quality,weather-resistant tarpaulins (or othersuitable covers) arranged to providefor air circulation.



NOTICE:Do not use plastic sheeting foroutdoor storage. Plastic is finefor indoor storage. When usedoutdoors, however, enough moisturecan condense on the inside of theplastic to rust ferrous metal surfacesand pit aluminum surfaces. If a unitis stored outside for any extendedperiod of time, severe corrosiondamage can result.

The stored engine should be inspectedperiodically. If there are anyindications of rust or corrosion,corrective steps must be taken toprevent damage to the engine parts.Perform a complete inspection at theend of one year and apply additionaltreatment as required.

Procedure for Restoring toService an Engine that Has Beenin Extended Storage

If an engine has been in extendedstorage, prepare it for service asfollows:

1. Remove the covers and tape fromall the openings of the engine, fueltank and electrical equipment. Donot overlook the exhaust outlet.

2. Remove the plugs from the inletand outlet fuel lines and reconnectthe lines to their proper positions.

3. Wash the exterior of the enginewith fuel oil to remove therust preventive. Do not washelectrical components.

4. Remove the rust preventive fromthe flywheel. Flush any solubleoil rust inhibitor (if used) in thecooling system.

5. Remove the paper strips frombetween the pulleys and drivebelts.

6. Fill the crankcase to the properlevel with the required grade oflubricating oil. Use a pressurelubricator to insure all bearingsand rocker shafts are lubricated.

7. Fill the fuel tank with the requiredfuel.

8. Close all drain cocks and fill theengine cooling system with clean,soft water and required inhibitors.If the engine is to be exposedto freezing temperatures, installgenuine Detroit Diesel PowerCool antifreeze or an equivalentethylene glycol-base or propyleneglycol-base antifreeze solutionwhich provides required freeze,boil over, and inhibitor protection.Refer to section “How to SelectCoolant.”

9. Install and connect the battery.Make sure the average specificgravity of the battery is 1.260


ENGINE STORAGE

or higher. Charge the battery, ifnecessary.

10. Service the air cleaner, if required.

11. Transmission: Follow themanufacturer's recommendationscovering the return of thetransmission to service.

12. Power Take-Off: If equipped,follow the manufacturer'srecommendations covering thereturn of the power take-off toservice.

13. Turbocharger: Remove thecovers from the turbochargerair inlet and turbine outletconnections. Reconnectpiping as required. Prelubethe turbocharger center bearinghousing. Refer to “LubricationSystem Checks” in the“OPERATING INSTRUCTIONSFOR STARTING THE ENGINE”section of this guide.

ENGINE EXHAUST


14. After all preparations arecompleted, start the engine.

NOTE:The small amount of rust preventivewhich remains in the fuel systemwill cause smoky exhaust for a fewminutes.

NOTE:Before subjecting the engine to a loador high speed, allow it to reach normaloperating temperature. Then check fortrouble codes.



CUSTOMER ASSISTANCE

The satisfaction and good will ofthe owners of Detroit Diesel enginesare of primary concern to DetroitDiesel and its distributor/dealerorganizations.See Figure 41 forDetroit Diesel NAFTA On-Highwayservice regions.

Figure 41 Detroit Diesel NAFTAOn-Highway ServiceRegions


CUSTOMER ASSISTANCE

NAFTA ON-HIGHWAY SERVICE REGIONSDETROIT DIESEL REGIONALSALES OFFICES

DETROIT DIESEL REGIONALSERVICE OFFICES

NORTHEAST REGIONDetroit DieselPowder Miss Plaza, Suite 3A51 Gibralter DriveMorris Plains, NJ 07950-1274Phone: 973-492-6555Fax: 973-267-5922

NORTH EASTERN REGIONDetroit Diesel13400 Outer Drive WestDetroit, MI 48239-4001Telephone: 313-592-5420Fax: 311-592-5887

CENTRAL REGIONDetroit Diesel9255 Indian Creek Parkway, Suite 850Overland Park, KS 66210Phone: 678-570-2389

NORTH CENTRAL & WESTERNREGIONSDetroit Diesel7700 Irvine Center, Suite 275Irvine CA 92618Phone: 949-753-7710Fax: 949-753-7711

SOUTHERN REGIONDetroit Diesel3325 Paddocks Parkway, Suite 230Suwanne, GA 30024Phone: 678-341-6100Fax: 678-341-6150

SOUTHERN REGIONDetroit Diesel3325 Paddocks Parkway, Suite 230Suwanne, GA 30024Phone: 678-341-6100Fax: 678-341-6150

WESTERN REGIONDetroit Diesel7700 Irvine Center, Suite 275Irvine CA 92618Phone: 949-753-7710Fax: 949-753-7711

CANADA REGIONDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171

CANADA REGIONDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171

MEXICO REGIONDetroit Diesel Allison de Mexico, S.A.Av. Santa Rosa 58Col. Ampliacion NorteSan Juan Ixtacala, TlanepantlaC.P. 54160, Edo de MexicoPhone: 525-333-1802Fax: 525-333-1870



Road Service in the U.S. orCanadaIf you require road service for anyreason in the U.S. or Canada, you maycall the 1–800–445–1980 customerassistance phone number. An operatorwill assist you in determining whattype of service is required. Not allproblems are engine related and notall problems are covered by engineor vehicle warranties. YOU MAYBE RESPONSIBLE FOR REPAIREXPENSES.

Before calling Customer Assistance,please do the following:

□ Check coolant level

□ Check fuel level

□ Check DDEC fuses

□ Check for fuel leaks

□ Make sure manual shutoff valve (ifinstalled) on the fuel filter adaptor,fuel processor body or fuel supplyline is open.

□ Check the oil level on the dipstick.

□ Check diagnostic codes.

If you call, have the followinginformation available:

□ Engine serial number

□ Vehicle make and model

□ Odometer mileage (kilometers) orhourmeter hours

□ Vehicle owner/company name

Working with Detroit DieselService OutletsAs the owner of a Detroit Dieselproduct you have a complete networkof Detroit Diesel service outlets in theU.S. and Canada, plus many outletsworldwide that are prepared to meetyour parts and service needs:

□ Service by trained personnel

□ Sales teams to help determine yourspecific power requirements

□ In many areas, emergency service24 hours a day

□ Complete parts support includingreliabilt® remanufactured parts

□ Product information and literature

We recognize however, that despitethe best intentions of everyoneconcerned, misunderstandings mayoccur. Normally, any situationthat arises in connection with thesale, operation, or service of yourproduct will be handled by theauthorized service outlet in your area(in the U.S. and Canada check theYellow Pages or service locator atwww.detroitdiesel.com for the DetroitDiesel service outlet nearest you).


CUSTOMER ASSISTANCE

Detroit Diesel has established athree-step procedure that customersshould follow when experiencinga problem with any Detroit DieselProduct or Part. Detroit Diesel fullyrealizes that ultimately the customer'sconcerns will be resolved at theDistributor/Dealer level and thereforeencourages customers to follow theprocedure outlined below:

Step One

Customers should discuss the problemwith a member of managementfrom the authorized service outlet.Frequently, complaints are the resultof a breakdown in communicationand can quickly be resolved by amember of management. If they havealready discussed the problem withthe Distributor or Dealer Sales orService Manager, they should contactthe General Manager.

Step Two

When it appears that the problemcannot readily be resolved at theDistributor/Dealer level withoutadditional assistance, the DetroitDiesel Customer Support Center(CSC) should be contacted at313–592–5800.

The information provided to the CSCwill be forwarded to the appropriateRegional Product Support Manager.The customer will then be assisted

be a member of the Regional ProductSupport Managers staff, depending onthe nature of his/her problem.

Prior to this contacting the CSC, thecustomer should have the followinginformation available:

□ Name and location of authorizedservice outlet

□ Type, make and vehicleidentification number ofequipment

□ Engine model and serial number

□ Engine delivery date andaccumulated miles/kilometers orhours of operation

□ Nature of problem

□ Chronological summary ofengine's repair history

Step Three

If the customer is still not satisfied,he/she should present the entire matterin writing or by phone to:

Director of Technical Service orManager, Service Operations BX5Detroit Diesel13400 Outer Drive, WestDetroit, Michigan 48239–4001Phone: 313–592–5000Fax: 313–592–5888



SPECIFICATIONS

This section lists the various POWERCOOL engine products.

Fuel and Lubricating OilFiltersConsult with a Detroit DieselDistributor to obtain the proper fuelfilters and lubricating oil filters.

OIL PAN CAPACITY

Engine oil capacity can vary,depending on the oil pan used andthe engine application. Contact theDetroit Diesel Customer Support

Center (313 592–5800) if you needthis specific information.

POWER COOL ENGINEPRODUCTSMaintenance of the cooling systemrequires the chemical make-up of thesystem to be balanced.

POWER COOL Fully FormulatedIEG Coolant

The part numbers and sizes ofconcentrated POWER COOL andpre-blended 50:50 POWER COOL areListed in Table 18

Coolant Type Part Number Description

23512138 1 Gallon Jug – 6Per Case

23512139 55 Gallon Drum

23529295 330 Gallon ToteConcentrated

23512140 Bulk Delivery – 1,000Gallon Min.



23528544 330 Gallon TotePre-Blended 50:50


Table 18 POWER COOL Fully Formulated IEG Coolant


SPECIFICATIONS

POWER COOL 2000 and 3000Supplemental Coolant Additive

Coolant Type Part Number Description23507858 Pint Bottle – 12 Per case

23507859 Half Gallon Jug – 6Per Case

23507860 5 Gallon Pail

For Power Cool IEGCoolant


Table 19 POWER COOL 2000 Supplemental Coolant Additive

Coolant Type Part Number Description23507854 Pint Bottle – 12 Per Case

23507855 Half Gallon Jug – 6Per Case

23507856 5 Gallon Pail

For POWER COOL IEGCoolant


Table 20 POWER COOL 3000 Supplemental Coolant Additive



POWER COOL 3000Supplemental Additive CoolantFilters


23507545 4 Ounce (1 PintEquivalent)





For POWER COOL IEGCoolant


Table 21 POWER COOL 3000 Supplemental Additive Coolant Filters

POWER COOL SupplementalAdditive Need Release CoolantFilters

Coolant Type Part Number DescriptionNF2091 For 0 – 8 Gallon Systems

For POWER COOL IEGCoolant 23516489 For 8 – 20 Gallon

Systems

Table 22 POWER COOL Supplemental Additive Need ReleaseCoolant Filters


SPECIFICATIONS

POWER COOL Plus ExtendedLife OAT Coolant



23519394 55 Gallon DrumConcentrated


23519396 One Gallon Jug – 6Per Case

23519398 55 Gallon DrumPre-Blended 50:50


Table 23 POWER COOL Plus Extended Life OAT Coolant

POWER COOL Plus ExtenderFor Use With POWER COOLPlus OAT Coolant


For Power Cool Plus 23519400 Quart Bottle – 6 PerCase

Table 24 POWER COOL Plus Extender for Use with POWER COOLPlus OAT Coolant

POWER COOL Cooling SystemCleaners


200164 On-Half Gallon Jug –6 Per Case

200105 5 Gallon PailOn-Line Cleaner

200155 55 Gallon DrumTwin Pack 201549 Twin Pack – 2 Per Case

Table 25 POWER COOL Cooling System Cleaners



POWER TRAC Coolant TestingAnd Analysis Products

Application Part Number DescriptionIndicates Nitrite,

Molybdate & GlycolLevels

235194013-Way Coolant Test

Strips(Single Foil Packs)

Indicates Nitrite,Molybdate & Glycol

Levels23519402

3-Way Coolant TestStrips

(Bottle of 50)Indicates Nitrite,

Molybdate & GlycolLevels

235227743-Way Coolant Test

Strips(Bottle of 10)

Complete IEG/IPGCoolant Analysis 23516921 Coolant Analysis Bottle

(Carton of 6)

Organic CoolantAnalysis 23523398

Laboratory CoolantAnalysis Bottle(Carton of 6)

Table 26 Power Trac Coolant Testing and Analysis Products


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