The service manual has been restructured to add a “Low
Contents
1. All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 16 3 16 1 MECHANICAL TROUBLESHOOTING Problem The Engine Cranks But Won t Start The batteries are damaged or weak The cranking speed is not set correctly No intake air preheater is installed and it is too cold to start without one The intake air preheater is malfunctioning The camshaft TDC sensor and or the crank angle position sensor are out of adjustment The camshaft TDC sensor and or the crank angle position sensor are damaged There is air in the fuel system The air filter is clogged Remedy Test the batteries Replace them if needed Bring the vehicle to an authorized dealer for service Install an intake air preheater Check the intake air preheater and replace it if necessary Push both sensors into their holes as far as they will go If this does not solve the problem bring the vehicle to an authorized dealer for service Bring the vehicle to an authorized dealer for service Check the fuel lines for air pockets Bleed the fuel system and start the engine Clean or replace the air filter The fuel filter is clogged Replace the filter element sah H hori ler check th ration of the The exhaust brake valve is malfunctioning ban A ISE Ma operationer The valves are not adjusted properly Check the valve lash There are other problems in th2. refer to OEM guidelines 3 Verify exhaust system resolution refer to section 17 6 1 1 Rev 2007 All information subject to change without notice 17 18 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 17 6 1 1 Test the Engine with Replaced Exhaust System Perform the following steps to determine if replaced engine exhaust system components resolved lack of power condition 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved Ifno lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b Iflack 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 CORPORATION From Bulletin 1 4000 07 17 19 17 7 HIGH INLET AIR TEMPERATURE 17 7 HIGH INLET AIR TEMPERATURE To determine if high inlet air temperature is causing lack of power perform the following 1 Test the radiator fan fan drive or fan shroud for proper operation or configuration refer to OEM guidelines NOTE The engine will be torque limited to protect the turbocharger and charge air cooler this is normal engine operation for component protection 2 Examine test results a Ifthe radiator fan fan drive or fan shrou
3. Fuel Tank Vent Restriction A plugged fuel tank vent will create a vacuum in the tank and result in a loss in fuel pressure at the injectors This will reduce fuel delivery rate Air in Fuel Aerated fuel caused by a fuel system leak will result in reduced fuel delivery and late injection timing Plugged or Cracked Fuel Tank Stand If the fuel tank stand pipe is plugged by a shop rag fuel delivery will be Pipe restricted A cracked stand pipe will allow air to enter the fuel system and reduce fuel flow and cause late injection timing Faulty Injector Unit Pump A faulty injector unit pump will limit fuel delivery and alter the combustion process such that power is compromised Using Idle Smooth Balance ISB in DDDL can help identify a faulty injector nozzle Valve Lash Incorrect valve lash will alter the combustion process such that power is compromised Air Flow Restriction Air flow must not be inhibited by a plugged filter or inadequate inlet air duct shrouding Faulty Turbocharger A turbocharger that has wheel rubbing oil leaks bent blades etc will not provide adequate air supply All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 17 3 17 1 FACTORS THAT AFFECT WHEEL HORSEPOWER Considerations Temperature Controlled Fan A faulty thermo control will cause the fan to be locked on and drain power on a continuous basis Air Syst
4. Road or Contact the Customer Support Center If settings are correct likely issue is break in time Review when over 50 000 miles Derate codes are not to be diagnosed They are normal protection operation Refer to EGR Guide 1 Extract DDEC Reports without resetting 2 Save Extracted report for submission to DDC 3 Extract copy of Parameter settings Save for submission to DDC Move to Dyno for testing Operate at 100 load Manual mode Test at Rated Speed Log Turbo boost Air inlet pressure Coolant Temperature Pulsewidth Inlet Restriction Exhaust Backpressure Crankcase Pressure Fuel Pressure Return to Road or Contact the Customer Support Center All information subject to change without notice 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 17 2 3 Low Power Troubleshooting Chart There are three basic checks that should be performed Check for active historic codes Refer to MBE DDEC Application Installation Manual 7SA825 Appendix A fault codes All causes need to be checked once the fault is identified Record faults on the Application For Adjustment AFA claim if there is to be a claim 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 Ta
5. at a specific engine operating temperature If so at what engine temperature Does the problem occur at a specific engine operating altitude If so at what altitude Does the problem occur only when above or below specific outside temperatures If so what temperature range Does the problem occur during other conditions e g during or after rain spray washing snow Did the problem occur at a specific vehicle speed If so at what vehicle speed 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 17 8 WARNING PERSONAL INJURY To avoid injury from loss of vehicle vessel control the operator of a MBE electronic controlled engine must not use or read any diagnostic tool while the vehicle vessel is moving If the problem is repeatable take the vehicle for a drive with Detroit Diesel Diagnostic Link DDDL connected and note the conditions when the problem occurs Be prepared to take snapshot data using DDDL Ensure you operate the vehicle after correcting the problem and duplicate the operating conditions before releasing the unit in order to verify the problem is corrected If the vehicle has been to other shops for the same problem call the other shops and find out what has been done Avoid replacing the same components again unless absolutely Rev 2007 All information subject to chan
6. before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked AM WARNING ENGINE EXHAUST To avoid injurv from inhaling engine exhaust alwavs operate the engine in a well ventilated area Engine exhaust is toxic Start and run the engine 4 Operate the engine at 1000 rpm Visually check to see if air bubbles are rising to the 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 Visually inspect all fuel lines between the fuel tank and fuel pump for leaks Repair damaged components as required refer to OEM guidelines 4 Verify aerated fuel resolution refer to section 17 3 1 1 17 3 1 1 Test the Engine with Aerated Fuel Resolution Perform the following steps to determine if aerated fuel resolution resolved lack of power condition All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 MBE 4000 07 17 13 17 3 AERATED FUEL 1 Start and run the engine 2 Run the engine at idle with a no load for approximately
7. connector refer to OEM guidelines 4 Attach an air pressure hose to the air chuck at the regulator and gradually pressurize the air inlet system to a pressure of 207 kPa 30 psi 5 Apply a water and soap solution to each hose connection across the face of the charge air cooler 6 Apply a water and soap solution to the air intake manifold and cylinder head mating 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 Ifthe intake manifold leaks repair intake manifold refer to section 17 5 2 Ifneither charge air cooler nor intake manifold leaked check the exhaust system refer to section 17 6 8 Inspect charge air cooler for leaks hoses clamps etc 17 5 1 Charge Air Cooler Replacement Perform the following steps to replace the charge air cooler 1 Remove and replace the charge air cooler refer to OEM guidelines 2 If the intake manifold doesn t leak verify replacement of the charge air cooler refer to section 17 5 2 1 3 Ifthe intake manifold leaks repair intake manifold refer to section 17 5 2 17 5 2 Air Intake Manifold Repair Perform the following steps to repair the air intake manifold 1 Remove the air intake manifold refer to MBE 4000 Service Manual 6SE412 Air system chapter 6 1 Rev 2007 All inform
8. 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 and Supply Lines Variable pressure output devices control the variable geometry turbo vanes and EGR valve position Improper turbo vane or EGR valve positions will alter the air flow system balance and subsequently the combustion process Air Compressor Leak An air compressor leak will cause the air compressor to work more and increase the parasitic load on the engine Air Conditioner Leak An air conditioner leak will cause the air conditioner to work more and increase the parasitic load on the engine Excessive Play in Power Steering Continuous movement of the steering wheel will call for continuous work by System the power steering unit This will increase the parasitic load on the engine Alternator Load Excessive use of vehicle electrical power will cause increased use of the alternator This will increase the parasitic load on the engine Under inflated tires will significantly increase driveline resistance to rotation Trailer Aerodynamics Alignment A trailer that has poor aerodynamics or has misaligned axles causing dog tailing will significantly increase vehicle inertia and res
9. run and during the actual testing Follow all applicable safety procedures from the chassis dynamometer manufacturer Observe the air intake duct and charge air fan shrouding to identify misalignments Correct as necessary Make sure the differential lock is if equipped Make sure the radiator charge air cooler system fan s are locked on If the vehicle is equipped with anti lock brakes ABS disable the ABS controller by unplugging it or removing its power fuse breaker Instrument the engine for fuel pressure air inlet restriction exhaust backpressure and crankcase pressure and note these readings during the dynamometer run Make sure the vehicle hood is down and locked into its normal position Make sure the engine is fully 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 so that it can be conveniently placed three to five feet approximately one to two meters in front of the truck and aimed directly at the charge air cooler This is especially important at high altitudes During high ambient temperature conditions 90 F 32 C it may also be necessary to u
10. vehicle to an authorized dealer for service reading incorrectly There are problems with the PLD or VCU control unit Bring the vehicle 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 Performs Poorly Does Not Develop Full Power Cause Remedy A A Check the air restriction indicator Clean the intake air The air filter and or intake air svstem is clogged ISE svstem and replace the air filter if necessarv hori ler check th i f th The exhaust brake valve is malfunctioning e The fuel filter is clogged Replace the filter element There are other problems with the fuel system Bring the vehicle to an authorized dealer for service The valves are not adjusted properly Check the valve lash See The coolant temperature sensor is damaged or readin A 4 p 9 9 Bring the vehicle to an authorized dealer for service incorrectiv The fuel i in A 8 9 temperature sensor is pamager radny Bring the vehicle to an authorized dealer for service incorrectly h i il i j emperaire senses damaged Bring the vehicle to an authorized dealer for service reading incorrectly he cnarge air Bring the vehicle to an authorized dealer for service reading incorrectly There are problems with the PLD or VCU control unit Bring the vehicle to an authorized dealer for service There i
11. 412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 6SE412 Problem The Engine Exhaust Is Black Remedy MEN Check the air restriction indicator Clean the intake air The air filter and or intake air system is clogged Ii system and replace the air filter if necessary The exhaust brake valve is malfunctioning an authorized dealer check the operation of the The intake air preheater is malfunctioning Check that the heater is not staying on all of the time The valves are not adjusted properly Check the valve lash There is damage to the fuel system the fuel pump one or more fuel injectors or one or more unit pumps are Bring the vehicle to an authorized dealer for service damaged The charge air temperature sensor is damaged Bring the vehicle 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 Exhaust Is Blue The engine oil level is too high engine oil is reaching Adjust the oil level and then have the oil level checked the combustion chamber 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 Remedy The engine brake c
12. 5 minutes allowing the engine coolant to reach normal operating range 3 Test drive the vehicle to ensure lack of power has been resolved Ifno 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 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 MBE 4000 SERVICE MANUAL 17 4 RESTRICTED AIR CLEANER ELEMENT To determine if a restricted air cleaner element is causing lack of power perform the following steps 1 Remove the air filter element from the air cleaner container refer to OEM guidelines 2 Visually inspect the air cleaner element for damage or clogging damage or clogging is found check the charge air cooler refer to section 17 5 b If damage or clogging is found refer to section 17 4 1 NOTE Replace the air filter if close to a maintenance interval 17 4 1 Air Filter Element Replacement Perform the following steps to replace the air filter element 1 Remove and replace the damaged or clogged air filter element refer to OEM guidelines 2 Verify air filter element replacement 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 r
13. 7 6 FAULTY EXHAUST SYSTEM To determine if a faulty exhaust system is causing lack of power perform the following steps 1 Drill an 11 32 in hole in the exhaust pipe 127 305 mm 5 12 in from the turbocharger exhaust outlet NOTE The tapped hole must be in a comparatively straight area of the turbocharger exhaust outlet 2 Tap the hole to accommodate a 1 8 in pipe plug Connect a manometer to the tapped hole 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 AM WARNING ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 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 H O check for high inlet air temperature refer to section 17 7 b If the exhaust back pressure at full load is 10 kPa 4 0 in H O or greater refer to section 17 6 1 17 6 1 Engine Exhaust System Resolution Perform the following steps to resolve the engine exhaust system 1 Visually inspect the engine exhaust system refer to OEM guidelines 2 Repair or replace defective exhaust system components
14. B 1100 RPM 435 bhp 1900 1450 Ib ft B 1100 RPM 435 bhp 1900 1550 Ib ft B 1100 RPM 450 bhp 1900 1550 Ib ft B 1100 RPM Table 17 3 Minimum Acceptable Wheel HP Model 460 Rev 2007 All information subject to change without notice 17 24 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION DETROIT DIESEL Qj CORPORATION 13400 Outer Drive West Detroit Michigan 48239 4001 Telephone 313 592 5000 www detroitdiesel com 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
15. DETROIT DIESEL MBE4000 Service Information NUMBER 1 4000 07 S M REF see tablet ENGINE MBE 4000 DATE February 2007 SUBJECT LOW POWER CONCERN PUBLICATION EPA 04 MBE 4000 SERVICE MANUAL 6SE412 The service manual has been restructured to add a Low Power Concern chapter Previously the troubleshooting concerns were found in chapter 15 now each troubleshooting concern has its own chapter Service Manual Chapter Decsription Troubleshooting The Electronic Engine Control System ne TO 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 Detroit Diesel MBE 4000 Service Manual 6SE412 The next revision to this manual will include the revised information 15 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM Section Page 15 1 ELECTRONIC ENGINE CONTROL SYSTEM 15 3 Rev 2007 All information subject to change without notice 15 2 From Bulletin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 6SE412 15 1 ELECTRONIC ENGINE CONTROL SYSTEM When the electronic engine control system detects a fault it broadcasts a message on the datalink The dash display will show the code ECU 128 indicating there is an engine fault NOTE To re
16. ad 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 4000 07 15 3 15 1 ELECTRONIC ENGINE CONTROL SYSTEM Rev 2007 All information subject to change without notice 15 4 From Bulletin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION 16 GENERAL MECHANICAL TROUBLESHOOTING Section 16 1 MECHANICAL TROUBLESHOOTING 6 Rev 2007 All information subject to change without notice 16 2 From Bulletin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 6SE412 16 1 MECHANICAL TROUBLESHOOTING The tables that follow are designed to identifv the causes of common problems suggest further checks and appropriate remedies When dealer service is necessarv this is mentioned in the table Problem The Engine Will Not Crank Remedy Test the batteries Replace them if needed Replace the ignition switch Replace the battery cables Have an authorized dealer replace the starter Change the engine oil using the correct type of oil The transmission fluid does not meet the correct Change the transmission fluid using the correct type specifications of fluid
17. ant leaks How often do you add coolant How Much What kind ofcoolant do you use What kind of inhibitor do you use Comments OIL CONSUMPTION How much oil are you adding How often miles Have you noticed any oil leaks Yes No Have you noticed any smoke out the exhaust Yes No At Idle Light or no load Heavy load How often do you change oil What Brand Have you changed brands recently Yes No How amp when do you check your oil Comments 4 eee 44272 Figure 17 1 Driver Questionnaire All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 17 7 17 2 LOW HORSEPOWER INTERVIEW 17 2 1 1 Driver Questionnaire Ask the driver to answer the following questions before attempting to repair an intermittent problem or a problem with symptoms but no diagnostic codes Use this and the response as a guideline Refer to section 17 2 1 2 Questionnaire Response Guideline 1 9 10 How often does the problem occur Can you and the driver take the vehicle and demonstrate the problem in less than 30 minutes Has the vehicle been to other shops for the same problem If so what was done there Did the radio dash gages or lights momentarily turn OFF when the problem occurred Does the problem occur only at specific operating conditions If so at what load Is it light medium or heavy Does the problem occur
18. ation subject to change without notice 17 16 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 2 Inspect the air intake manifold refer to MBE 4000 Service Manual 6SE412 Air system chapter 6 1 3 Install the air intake manifold refer to MBE 4000 Service Manual 6SE412 Air system chapter 6 1 2 4 Verify repair of the intake manifold refer to section 17 5 2 1 17 5 2 1 Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold To determine if the repairs resolved the lack of power condition perform the following steps 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 A WARNING 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 Ifno 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 the exhaust system refer to section 17 6 All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 MBE 4000 07 17 17 17 6 FAULTY EXHAUST SYSTEM 1
19. ble 17 3 for minimum acceptable wheel HP data Record data on AFA claim NOTE Service information letter instructions published following the date of this document take precedence All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 17 11 172 LOW HORSEPOWER INTERVIEW Possible causes of low power and symptoms are listed in Table 17 2 Symptoms Faulty Injector s refer to section 17 1 Faulty Turbocharger refer to section 17 1 EGR Valve refer to section 17 1 EPV or Air Supply Lines refer to section 17 1 Charge Air Cooler Leak refer to section 17 5 Intake or Exhaust Manifold Leak refer to section 17 5 and section 17 6 Quality Grade of Fuel refer to section 17 1 Faulty Fan Operation Always On refer to section 17 1 Debris in Fuel Tank Air Vent Plugged refer to section 17 1 Table 17 2 Low Power Troubleshooting Chart Rev 2007 All information subject to change without notice 17 12 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 17 3 AERATED FUEL To determine if aerated fuel is causing lack of power perform the following steps 1 Disconnect the fuel line return hose from the fitting located at the fuel tank refer to OEM guidelines 2 Place the open end of the fuel line into a suitable container To avoid injury
20. d pass OEM test check high altitude operation refer to section b Ifthe radiator fan drive or shroud did not operate correctly refer to section 17 7 1 17 7 1 Radiator Fan Drive and Shroud Replacement Perform the following steps 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 before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked AM WARNING ENGINE EXHAUST To avoid injurv from inhaling engine exhaust alwavs 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 Rev 2007 All information subject to change without notice 17 20 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL Ifno 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 contact the Detroit Diesel Custome
21. e fuel system Bring the vehicle to an authorized dealer for service Problem The Engine Starts Only After Cranking for a Long Time The fuel tank is low or empty Add fuel and bleed the fuel system if necessary There are leaks in the fuel lines The fuel filter is clogged The fuel line the fuel pre filter or the screen in the fuel tank is blocked The camshaft TDC sensor and or the crank angle position sensor are out of adjustment The camshaft TDC sensor and or the crank angle position sensor are damaged There are other problems in the fuel system 16 4 From Bulletin 1 4000 07 Check the fuel lines for leaks and repair them if necessary Replace the filter element Clean and bleed the system Have the fuel lines and filters checked by an authorized dealer Push both sensors into their holes as far as they will go If this does not solve the problem bring the vehicle to an authorized dealer for service Bring the vehicle to an authorized dealer for service Bring the vehicle to an authorized dealer for service Rev 2007 All information subject to change without notice 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 6SE412 Remedy Add fuel and bleed the fuel system if necessary Replace the filter element tank is blocked filters checked by an authorized dealer Push both sensors into their holes as far as they will go If this does not solve the probl
22. em bring the vehicle to an authorized dealer for service The camshaft TDC sensor and or the crank angle i fa Bring the vehicle to an authorized dealer for service position sensor are damaged The constant throttle valves are malfunctioning Bring the vehicle to an authorized dealer for service There are other problems in the fuel svstem Bring the vehicle to an authorized dealer for service The camshaft TDC sensor and or the crank angle position sensor are out of adjustment Problem The Engine Fan Doesn t Work The fan hub is damaged Replace the fan hub The fan wiring is damaged Repair the fan wiring Th rameter ings in the PLD or V ntrol uni Dee ameter setings in the Have an authorized dealer reprogram the control unit are incorrect Problem The Engine Fan Is Constantly On The fan override switch is on Check the operation of the fan override switch The fan hub is damaged Replace the fan hub Th rameter ings in the PLD or V ntrol uni l G pa ameter setings in thg EA en kolu Have an authorized dealer reprogram the control unit are incorrect Problem Fuel Consumption Is Too High The tires are not properly inflated Check all tires for correct pressure are Check the air restriction indicator Clean the intake air The air filter and or intake air system is clogged system and replace the air filter if necessary The fuel filter is clogged Replace the filter element The exhau
23. em Leaks gaskets and seals Air system leaks will result in insufficient air for optimum combustion Biodiesel Should not be higher than 5 Refer to Engine Requirements Lubricating Oil Fuel and Filters 7SE270 available from authorized Detroit Diesel distributors Charge Air Cooler Leak Air system leaks will result in insufficient air for optimum combustion Climate fresh air temp The maximum allowable temperature rise from ambient air to engine inlet is 15 F Undersized or dirty air cleaner element as well as damaged or obstructed air inlet piping can cause low power Make sure under hood hot air is not being taken in Pressure drop across the air to air charge cooler should be checked 3 0 in Hg maximum from turbo discharge to intake manifold Check turbocharger boost pressure and compare to specification Altitude Performance Site altitude has an effect on engine horsepower Expect approximately 2 loss in power when operating at an altitude of 1 mile relative to sea level PLD VCU Settings Make sure vehicle settings such as axle ratio tire size top gear ratio etc are set correctly to avoid a false sense of engine performance EGR Valve A misadjusted or malfunctioning EGR valve will alter the amount of oxygen available for combustion as well as introduce inert gas that does not promote combustion Exhaust Restriction A damaged undersized or otherwise restricted muffler or exhaust system can result in high exhaust back
24. esolved lack of power To avoid injurv before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked A WARNING ENGINE EXHAUST To avoid injurv from inhaling engine exhaust alwavs 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 lack of power did not occur 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 the charge air cooler refer to section 17 5 All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 17 15 17 5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING INTAKE MANIFOLD 17 5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING INTAKE MANIFOLD To determine if a restricted or cracked charge air cooler or leaking manifold is causing lack of power perform the following steps 1 Attach air to air charge air cooler test kit J 41473 refer to OEM guidelines 2 Disconnect the air inlet hose from the outlet side of the turbocharger compressor housing refer to appropriate service manual air intake system chapter 3 Attach the air to air cooler test kit adaptor plug to fit into the hose at the compressor
25. etting causing a perceived lack of power Crank Case Overfilled If the crank case level is too high there will be a loss of power due to churning losses created by the crank shaft throws contacting the oil Fuel Blend specific gravity Check the specific gravity of the fuel vehicle system A good number 2 diesel fuel has a specific gravity of 0 840 or higher 60 F It should be noted that No 1 diesel fuel can reduce horsepower to 7 less than No 2 fuel Blends of No 1 and No 2 common in winter will produce less horsepower depending on the percent of the blend This is a common concern when dealing with low power complaints in cold climate locations Fuel Filter Restriction Check for fuel flow restrictions which can be caused by fuel heaters water separators fuel flow meters undersize or improperly routed damaged fuel lines faulty check valves contaminated fuel filters or high fuel pressure resulting from a plugged restricted fitting or regulator valve Replacing the fuel filter is often the best recommendation in lieu 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 and engine
26. ge without notice From Bulletin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL sure they are the problem It is unlikely a component will fail again following a recent replacement 3 If other vehicle devices are affected this indicates there may be something wrong with the ignition wiring 4 Operate the engine under similar load and temperature conditions Check the fuel system for restrictions fuel filter and fuel tanks for foreign objects blocking the fuel supply Also check the air system Utilize the DDDL snapshot feature 5 Operate the engine at this temperature while attempting to duplicate the problem Use the DDDL snapshot feature 6 It may not be possible to duplicate the fault or problem unless you can operate the unit in similar environment You may want to talk to the Customer 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 Ifthe problem seems to occur during or after the engine is subjected to rain spray washing thoroughly inspect the connectors for moisture entry 9 Ifthe problem occurs at a specific vehicle speed check the parameters affecting vehicle speed to verify they are programmed close to the vehicle speed where the problem occurs Check vehicle speed and watch DDDL snapshot for changes to see if the pulse wheel VSS signal is loose 10 Ift
27. he problem occurs at a specific engine rpm unplug the oil coolant and air temperature sensors and note any changes to the problem Gather this data and contact the DDC Customer Support Center at 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 9 172 LOW HORSEPOWER INTERVIEW 17 2 2 Troubleshooting Tree Following is the troubleshooting tree for low horsepower Low HorsePower Complaint Handling Interview Define the Problem Decision if any are true move to the next column Poo 1 Verify Basic Troubleshooting 2 Air filter 3 Fuel Pressures Initial Acceleration 4 Codes Always been bad Review DDEC Parameters or VCU parameters LG Torque limit Rating applied Progressive shift Injector Codes Is the complaint between Diagnose oniv if fuel qualitv is September and Mav7 verified to be proper specific gravitv Diagnose codes then retur Review DDEC Parameters Mileage is less than 50 000 or VCU parameters Injector Codes Review DDEC Parameters or VCU parameters oy LG Torque limit Injector Codes Review DDEC Parameters Just won t pull or VCU parameters No Power in top gears Must downshift too often Too slow over a hill Injector Codes Figure 17 2 Troubleshooting Tree 17 10 From Bulletin 1 4000 07 Rev 2007 Direction Action Return to
28. in 30 000 to 40 000 ft3 min capacity This will provide proper ventilation of exhaust gases and heat radiated by the operating engine 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 so that it can be conveniently placed three to five feet approximately one to two meters in front of the truck and aimed directly at the radiator charge air cooler package 17 8 2 Chassis Dynamometer Test and Run in Procedure The function of the dynamometer is to absorb and measure the engine output after it has been transmitted through the vehicle transmission and driveline to the drive tires Rev 2007 All information subject to change without notice 17 22 From Bulletin 1 MBE 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL The vehicle is connected to dynamometer through the roller absorption unit The load on the vehicle may be varied from zero to maximum by decreasing or increasing the resistance in the unit The amount of power absorbed in a water brake type dynamometer as an example is governed by the volume of fluid within the working system The fluid offers resistance to a rotating motion By controlling the volume of water in the absorption unit the load may be increased or decreased as required The following are some tips to keep in mind in preparing the vehicle before the dynamometer
29. istance to forward motion Vehicle Payload As vehicle loading increases vehicle inertia and resistance to forward motion increases Rev 2007 All information subject to change without notice 17 4 From Bulletin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL Fatos O 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 5 172 LOW HORSEPOWER INTERVIEW 17 2 LOW HORSEPOWER INTERVIEW To determine if low horsepower is causing a power concern use 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 Bulle
30. maged Have an authorized dealer replace the thermostat Bring the vehicle to an authorized dealer and have the fan hub checked The fan is not operating properly Bring the vehicle to an authorized dealer and have the parameter settings reprogrammed in the engine control unit PLD or vehicle control unit VCU Bring the vehicle to an authorized dealer for service All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 16 7 16 1 MECHANICAL TROUBLESHOOTING Problem There Is Coolant in the Engine Oil Bring the vehicle to an authorized dealer for service Problem There Is Foam in the Engine Oil The oil level is too low or too high Correct the oil level The oil has not been changed within the recommended interval Change the oil The oil is not of the recommended quality Change the oil Problem The Engine Oil Pressure Is Low he oil i i 2 U gauge and or sensor is not reading Bring the vehicle to an authorized dealer for service Problem The Engine Exhaust Is White The fuel is of poor quality Add fuel of the right quality heck the intake ai h it if The intake air preheater is malfunctioning 2 intake air preheater ana replaceriti The valves are not adjusted properly Check the valve lash Rev 2007 All information subject to change without notice 16 8 From Bulletin 1 4000 07 6SE
31. ontrol switch is damaged Replace the switch A Have an authorized dealer check the operation of the The exhaust brake is not operating properly constant throttle valves are malfunctioning Bring the vehicle to an authorized dealer for service 2 Bring the vehicle to an authorized dealer for service Problem Cruise Control Is Not Working One or more of the cruise control switches are damaged Replace the damaged switch Components of the PLD and or VCU control unit are Bring the vehicle to an authorized dealer for service damaged or not working properly All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 16 9 16 1 MECHANICAL TROUBLESHOOTING Problem The Battery Charge Indicator Light Does Not Come On When the Engine Is Not Running The bulb is damaged Change the bulb The circuit is broken Repair the break in the circuit Problem The Battery Charge Indicator Light Comes On When the Engine is Running Check the belt tension if necessary have an authorized The poly V belt is too loose dealer replace the belt tensioner The belt tensioner is damaged Have an authorized dealer replace the belt tensioner he polv V belt is worn or damaged Replace the belt The al i h ifi e alternator is damaged hasia Qamaged rectifier or Have an authorized dealer replace the alte
32. r Support Center 313 592 5800 All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 17 21 17 8 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER 17 8 VERIFICATION POWER WITH CHASSIS DYNAMOMETER The chassis dynamometer is a device for applying specific loads to a vehicle to determine if the vehicle will perform to published specifications and to permit a physical inspection for leaks of any kind It is an excellent method for detecting improper tune up misfiring injectors low compression and other malfunctions 17 8 1 Chassis Dynamometer Room Ventilation Recommendations For safe and accurate dynamometer readings the chassis dynamometer room must be properly ventilated 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 AM WARNING ENGINE EXHAUST To avoid injurv from inhaling engine exhaust alwavs operate the engine in a well ventilated area Engine exhaust is toxic If a vehicle is tested on a dynamometer located in an area 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 m
33. rnator voltage regulator Rev 2007 All information subject to change without notice 16 10 From Bulletin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION 17 LOW POWER CONCERN Section 17 1 17 2 17 3 17 4 17 5 17 6 17 7 17 8 Page FACTORS THAT AFFECT WHEEL HORSEPOWER 2 2 17 3 LOW HORSEPOWER INTERVIEW 17 6 AERATED RUE i L 17 13 RESTRICTED AIR CLEANER ELEMENT 17 15 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING lt 5 17 16 FAULTY EXHAUST SYSTEM dd 17 18 HIGH INLET AIR TEMPERATURE 17 20 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER 17 22 Rev 2007 All information subject to change without notice 17 2 From Bulletin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 17 1 FACTORS THAT AFFECT WHEEL HORSEPOWER The factors affecting wheel horsepower are listed in Table 17 1 To begin low horsepower diagnosis refer to section 17 2 Factors O Considerations Power Rating Is the correct power rating programmed into the PLD Is the driver aware of the effects that cruise power or the lack of cruise power has on perceived power Road Speed Setting Is the road speed s
34. s internal damage to the engine Bring the vehicle to an authorized dealer for service Rev 2007 All information subject to change without notice 16 6 From Bulletin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 6SE412 Problem tThe Engine Is in Emergency Running Mode constant speed 1 300 rpm The PLD or VCU control unit is damaged Bring the vehicle to an authorized dealer for service Problem The Coolant Temperature Is Above Normal Remedy The coolant level is too low Check for coolant leaks and repair as needed The poly V belt is loose Tighten or replace the poly V belt 246 Bring the vehicle to an authorized dealer for service reading correctly A 3 Clean the radiator Repair or replace the radiator if The radiator is damaged or dirty p p necessary The coolant pump is damaged Have an authorized dealer replace the coolant pump The thermostat is damaged Have an authorized dealer replace the coolant pump Bring the vehicle to an authorized dealer and have the fan hub checked The fan is not operating properly Bring the vehicle to an authorized 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 The coolant temperature gauge and or sensor is not reading correctly The thermostat is da
35. se a water spray mist fan in front of the vehicle to prevent overheating Running the dynamometer in manual mode instead of automatic mode allows for maximum control of the test process and may result in more consistent test results During the horsepower test make sure percent engine load is 100 and smoke limited is not active by monitoring them with a computer equipped with DDDL Select a transmission gear with a 1 1 gear ratio during the horsepower test Take horsepower reading at 1300 rpm and 1850 rpm Stabilize at rated speed for at least one minute before taking a final horsepower reading Compare the recorded horsepower to the appropriate minimum horsepower tables below for particular ratings All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 17 23 17 8 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER Note that the following charts are for vehicles with manual transmissions Vehicles with automatic transmissions i e equipped with torque converters will have slightly lower minimum horsepower values then listed in Table 17 3 272 Engine HP Rating Peak Torque 350 bhp 1900 RPM 1350 lb ft 1100 RPM 370 bhp 1900 1450 Ib ft B 1100 RPM 410 bhp 1900 1450 Ib ft B 1100 RPM 410 bhp 1900 1550 Ib ft
36. st brake valve is malfunctioning jiena an authorized dealer check the operation of the The engine performs poorly or does not develop full The remedies are listed in The Engine Performs Poorly power Does Not Develop Full Power All information subject to change without notice Rev 2007 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION From Bulletin 1 4000 07 16 5 16 1 MECHANICAL TROUBLESHOOTING Problem The Engine Performs Poorly Does Not Develop Full Power A Check the air restriction indicator Clean the intake air The air filter and or intake air svstem is clogged B is svstem and replace the air filter if necessarv The exhaust brake valve is malfunctioning e an authorized dealer check the operation of the The fuel filter is clogged Replace the filter element There are other problems with the fuel svstem Bring the vehicle to an authorized dealer for service The valves are not adjusted properly Check the valve lash See Th readin A e copant temperature sensoris damaged or reaging Bring the vehicle to an authorized dealer for service incorrectly The fuel i in A A f jomporalur Sensoris damaged or reading Bring the vehicle to an authorized dealer for service incorrectly h i il i i eh Emperaire sensatie damaged Bring the vehicle to an authorized dealer for service reading incorrectly The charge air emperature sensor idamaged or Bring the
37. tin 1 4000 07 6SE412 0702 Copyright 2007 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL For an example of the driver questionnaire see Figure 17 1 Engine Diagnostic Questionnaire Customer Name Contact Person LOW POWER POOR FUEL ECONOMY Does check engine light come on Yes No Does the engine miss run rough hard starting Miss Run Rough Hard Starting Power Loss sudden or has decreased with time Sudden Decreased with time Excessive engine exhaust smoke see 3 Yes No If yes what color Black Blue White Heard any unusual engine noise Yes No Power loss occurs on Foot Cruise Both Have injectors been replaced recently Yes No When was last tune up Mileage Date Comments ANY INTERMITTENT PROBLEMS Last time it happened Does the check engine light come on Yes No Does the problem occur only in damp or rainy conditions Yes No When the vehicle hits a bump or rough road Yes No Does the engine Miss Drop to idle Quit running Gauge Sweep Hard Starting Comments e g Does the driver do anything to correct the problem SMOKING Where is the smoke coming from What color is the smoke Blue Black White When does it smoke Start up Cold Eng Hot Eng Have you noticed any oil consumption Yes No Have you noticed a miss in the engine Yes No Was the smoke intermittent Start all at once Been getting worse over time Comments COOLANT LOSS Has the oil level risen Have you noticed any cool
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