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MBE 4000 SERVICE MANUAL

Factors

Considerations

Winter-front Installation

Improper installation or usage of a winter-front will result in extremely high
intake air temperatures and reduced mass flow of air into the combustion
chamber.

Vehicle Application

Unusual applications such as triple drive axles, PTO's, pumps, high air
compressor duty cycle, etc., will have higher parasitic loses resulting in less
horsepower at the wheels.

Foot Pedal

Make sure the foot pedal has complete travel. The foot pedal position can
be monitored on DDDL (accelerator pedal pos.)

Table 17-1

Factors Affecting Wheel Horsepower

All information subject to change without notice.

(Rev. 2007)

6SE412 0702

Copyright © 2007 DETROIT DIESEL CORPORATION

From Bulletin 1–MBE 4000–07

17-5

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Summary of Contents for MBE4000

Page 1: ...oting concern has its own chapter Service Manual Chapter Decsription 15 Troubleshooting The Electronic Engine Control System 16 General Mechanical Troubleshooting 17 Low Power Concern Table 1 Troubleshooting Chapters Chapter 17 includes factors that affect wheel horsepower and other associated low power information ADDITIONAL SERVICE INFORMATION Additional service information is available in the D...

Page 2: ...15 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM Section Page 15 1 ELECTRONIC ENGINE CONTROL SYSTEM 15 3 ...

Page 3: ... Rev 2007 All information subject to change without notice 15 2 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION ...

Page 4: ...code ECU 128 indicating there is an engine fault NOTE To read the complete fault code refer to the MBE Electronic Controls Troubleshooting Guide 6SE422 or bring the vehicle to an authorized repair facility Complete fault codes can be read using minidiag2 All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 MBE 4000 07 15 3 ...

Page 5: ...15 1 ELECTRONIC ENGINE CONTROL SYSTEM Rev 2007 All information subject to change without notice 15 4 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION ...

Page 6: ...16 GENERAL MECHANICAL TROUBLESHOOTING Section Page 16 1 MECHANICAL TROUBLESHOOTING 16 3 ...

Page 7: ... Rev 2007 All information subject to change without notice 16 2 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION ...

Page 8: ...to an authorized dealer for service There is internal damage to the engine Bring the vehicle to an authorized dealer for service Problem The Engine Turns Over Slowly Cause Remedy The batteries are damaged or weak Test the batteries Replace them if needed The ignition switch is damaged Replace the ignition switch The battery cables are damaged and or corroded Replace the battery cables The starter ...

Page 9: ...ning Have an authorized dealer check the operation of the valve The valves are not adjusted properly Check the valve lash There are other problems in the fuel system Bring the vehicle to an authorized dealer for service Problem The Engine Starts Only After Cranking for a Long Time Cause Remedy The fuel tank is low or empty Add fuel and bleed the fuel system if necessary There are leaks in the fuel...

Page 10: ...maged Replace the fan hub The fan wiring is damaged Repair the fan wiring The parameter settings in the PLD or VCU control unit are incorrect Have an authorized dealer reprogram the control unit Problem The Engine Fan Is Constantly On Cause Remedy The fan override switch is on Check the operation of the fan override switch The fan hub is damaged Replace the fan hub The parameter settings in the PL...

Page 11: ... vehicle to an authorized dealer for service Problem The Engine Performs Poorly Does Not Develop Full Power Cause Remedy The air filter and or intake air system is clogged Check the air restriction indicator Clean the intake air system and replace the air filter if necessary The exhaust brake valve is malfunctioning Have an authorized dealer check the operation of the valve The fuel filter is clog...

Page 12: ...zed dealer and have the parameter settings reprogrammed in the engine control unit PLD or vehicle control unit VCU Problem The Coolant Temperature Is Below Normal Cause Remedy The coolant temperature gauge and or sensor is not reading correctly Bring the vehicle to an authorized dealer for service The thermostat is damaged Have an authorized dealer replace the thermostat The fan is not operating p...

Page 13: ...Is Low Cause Remedy The oil pressure gauge and or sensor is not reading correctly Bring the vehicle to an authorized dealer for service There is fuel in the oil Bring the vehicle to an authorized dealer for service The oil filter is clogged Replace the filter element The oil filter bypass valve is damaged Replace the bypass valve The oil pump and or relief valve is damaged Have an authorized deale...

Page 14: ...ber Adjust the oil level and then have the oil level checked by an authorized dealer The turbocharger is leaking oil Have an authorized dealer replace the turbocharger The valve stem seals are loose or damaged Have an authorized dealer replace the seals The piston rings are worn Have an authorized dealer replace the piston rings Problem Engine Brake Performance Is Poor Cause Remedy The engine brak...

Page 15: ... The poly V belt is too loose Check the belt tension if necessary have an authorized dealer replace the belt tensioner The belt tensioner is damaged Have an authorized dealer replace the belt tensioner he poly V belt is worn or damaged Replace the belt The alternator is damaged has a damaged rectifier or voltage regulator Have an authorized dealer replace the alternator Rev 2007 All information su...

Page 16: ...SEPOWER INTERVIEW 17 6 17 3 AERATED FUEL 17 13 17 4 RESTRICTED AIR CLEANER ELEMENT 17 15 17 5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING INTAKE MANIFOLD 17 16 17 6 FAULTY EXHAUST SYSTEM 17 18 17 7 HIGH INLET AIR TEMPERATURE 17 20 17 8 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER 17 22 ...

Page 17: ... Rev 2007 All information subject to change without notice 17 2 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION ...

Page 18: ... of testing for the filter condition Make sure the recommended fuel filter is being used Refer to Technical Service Letter 05 TS 12REV MBE 4000 Fuel Filter Update Fuel System Leak Fuel system leaks which result in aerated fuel are normally caused by a leak at the connections and or filters between the suction side of the fuel pump to the supply tank and not between the pressure side of the pump an...

Page 19: ...aust system can result in high exhaust back pressure Refer to the engine specification sheets for maximum allowable pressure Barometric Pressure Sensor The engine will transition between EGR and boost mode at an altitude of 13 120 ft Altitude is determined by the Barometric Pressure Sensor located in the PLD A faulty Barometric Pressure Sensor will compromise the availability of boost pressure EPV...

Page 20: ...ons such as triple drive axles PTO s pumps high air compressor duty cycle etc will have higher parasitic loses resulting in less horsepower at the wheels Foot Pedal Make sure the foot pedal has complete travel The foot pedal position can be monitored on DDDL accelerator pedal pos Table 17 1 Factors Affecting Wheel Horsepower All information subject to change without notice Rev 2007 6SE412 0702 Cop...

Page 21: ... the driver questionnaire the troubleshooting tree and the low power troubleshooting chart 17 2 1 Driver Questionnaire This section should serve as a guideline for the technician Rev 2007 All information subject to change without notice 17 6 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION ...

Page 22: ...n example of the driver questionnaire see Figure 17 1 Figure 17 1 Driver Questionnaire All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 MBE 4000 07 17 7 ...

Page 23: ...problem occur during other conditions e g during or after rain spray washing snow 9 Did the problem occur at a specific vehicle speed If so at what vehicle speed 10 Does the problem occur at specific engine RPM If so at what engine RPM 17 2 1 2 Questionnaire Response Guideline The following are typical responses to the driver questionnaire PERSONAL INJURY To avoid injury from loss of vehicle vesse...

Page 24: ...omer Support Center or a dealer in that area They may have helpful experience 7 If possible troubleshoot the problem in a similar temperature range 8 If the problem seems to occur during or after the engine is subjected to rain spray washing thoroughly inspect the connectors for moisture entry 9 If the problem occurs at a specific vehicle speed check the parameters affecting vehicle speed to verif...

Page 25: ...ooting Tree Following is the troubleshooting tree for low horsepower Figure 17 2 Troubleshooting Tree Rev 2007 All information subject to change without notice 17 10 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION ...

Page 26: ...im Check the VCU PLD parameters progressive shift settings and torque limiting values Are they correct Is proper rating applied If vehicle is new is it spec d correctly Check that the dyno measured power is within DDC specifications as listed in Table 17 3 for minimum acceptable wheel HP data Record data on AFA claim NOTE Service information letter instructions published following the date of this...

Page 27: ...1 X X X X EPV or Air Supply Lines refer to section 17 1 X X X X Charge Air Cooler Leak refer to section 17 5 X X X Intake or Exhaust Manifold Leak refer to section 17 5 and section 17 6 X X X Quality Grade of Fuel refer to section 17 1 X X X X X Restricted Air Intake refer to section 17 1 X X X Crankcase Overfilled refer to section 17 1 X X X Faulty Fan Operation Always On refer to section 17 1 X ...

Page 28: ...e surface of the fuel within the container a If air bubbles are not present shut down engine check for high fuel pressure refer to section 17 4 b If air bubbles are present shut down engine refer to section 17 3 1 17 3 1 Aerated Fuel Resolution Perform the following steps to resolve aerated fuel 1 Tighten all fuel line connections between the fuel tank and fuel pump refer to OEM guidelines 2 Visua...

Page 29: ... to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine and refer to section 17 4 Rev 2007 All information subject to change without notice 17 14 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION ...

Page 30: ...cement refer to section 17 4 1 1 17 4 1 1 Test the Engine with Replaced Air Filter Element Perform the following steps to determine if the new filter element resolved lack of power To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked ENGINE EXHAUST To avoid injury from inhaling engine exhaust always o...

Page 31: ...ng surface area 7 Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress cracks a If charge air cooler leaks are present around the joints replace the charge air cooler refer to section 17 5 1 b If the intake manifold leaks repair intake manifold refer to section 17 5 2 c If neither charge air cooler nor intake manifold leaked check the exhaust system refer ...

Page 32: ...engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further tro...

Page 33: ... 3 Start and run the engine at idle with a no load for approximately 5 minutes allowing the engine coolant to reach normal operating range 4 Install the vehicle on a chassis dynamometer and run the engine speed to full load a If the exhaust back pressure at full load is less than 10 kPa 4 0 in H2 O check for high inlet air temperature refer to section 17 7 b If the exhaust back pressure at full lo...

Page 34: ...e vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check for high inlet air temperature refer to section 17 7 All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPO...

Page 35: ... to replace the radiator fan drive and or shroud 1 Remove and replace the radiator fan drive and or shroud refer to OEM guidelines 2 Verify replacement refer to section 17 7 1 1 17 7 1 1 Test the Engine with Radiator Fan Fan Drive or Fan Shroud Replacement Perform the following steps to determine if replaced radiator fan fan drive or fan shroud resolved lack of power condition To avoid injury befo...

Page 36: ...equired Shut down the engine b If lack of power occurred during the test drive shut down the engine contact the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 MBE 4000 07 17 21 ...

Page 37: ...a without proper ventilation the engine will be subject to high ambient air temperatures High air inlet temperatures can result in false low power readings on the dynamometer To help ensure accurate horsepower readings the dynamometer room should have a ceiling mounted fan with a 850 to 1133 m3 min 30 000 to 40 000 ft3 min capacity This will provide proper ventilation of exhaust gases and heat rad...

Page 38: ...warmed up before placing the vehicle on the dynamometer Both oil and coolant temperature should be at least 82 C 180 F When loading the vehicle on the dynamometer make sure the vehicle is positioned onto the rollers as straight as possible For direct engine cooling Detroit Diesel recommends the use of a 368 m3 min 13 000 ft3 min or greater capacity barrel type ram air fan This should be portable s...

Page 39: ...ue 1500 rpm 1750 rpm 350 bhp 1900 RPM 1350 lb ft 1100 RPM 258 272 370 bhp 1900 RPM 1350 lb ft 1100 RPM 258 287 370 bhp 1900 1450 lb ft 1100 RPM 276 287 410 bhp 1900 1450 lb ft 1100 RPM 276 318 410 bhp 1900 1550 lb ft 1100 RPM 295 318 435 bhp 1900 1450 lb ft 1100 RPM 276 338 435 bhp 1900 1550 lb ft 1100 RPM 295 338 450 bhp 1900 1550 lb ft 1100 RPM 295 349 Table 17 3 Minimum Acceptable Wheel HP Mode...

Page 40: ...Detroit Diesel DDC and the spinning arrows design are registered trademarks of Detroit Diesel Corporation Copyright 2007 Detroit Diesel Corporation All rights reserved Printed in U S A ...

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