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MBE4000 APPLICATION AND INSTALLATION

13.5

ENGINE HARNESS

The Engine Harness (EH) facilitates the communication of engine sensor input to the DDEC-ECU
(Figure 13-5 for the EGR engine).

Figure 13-5

A Typical MBE4000 EGR Engine Harness

All information subject to change without notice.

(Rev. 03/06)

13-7

7SA250 0603

Summary of Contents for MBE4000

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Page 3: ...or developing designing manufacturing and installing these systems including component qualification The equipment manufacturer is also responsible for furnishing equipment users complete service and safety information for these systems Detroit Diesel Corporation makes no representations or warranties regarding the information contained in installation of these ancillary systems or the preparation...

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Page 5: ...al contains the following information General information on safety precautions and on accessing installation drawings Specific component and accessory information on various production models Information on the electrical fuel exhaust lubrication cooling and air inlet systems All information subject to change without notice Rev 03 06 i 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 7: ...ON 4 3 4 1 1 MBE4000 ON HIGHWAY ENGINES 4 3 4 1 2 ENGINE AIR INLET CONNECTION FOR MBE EGR ENGINES 4 3 4 2 INSTALLATION REQUIREMENTS 4 4 4 2 1 DRY PAPER ELEMENT AIR CLEANERS 4 4 MEDIUM DUTY USE AIR CLEANER 4 5 HEAVY DUTY USE AIR CLEANER 4 6 EXTRA HEAVY DUTY USE 4 7 FOAM TYPE AIR CLEANERS 4 8 OIL BATH AIR CLEANERS 4 8 AUXILIARY PRECLEANERS 4 9 INLET SCREENS 4 9 RAIN CAPS AND INLET HOODS 4 10 WATER D...

Page 8: ...MUM TEMPERATURE RISE AMBIENT TO INTAKE MANIFOLD 4 24 CHARGE AIR COOLER SYSTEM RESTRICTION 4 25 4 5 TEST 4 25 5 EXHAUST SYSTEM 5 1 5 1 EXHAUST SYSTEM DESCRIPTION 5 3 5 1 1 TURBOCHARGER 5 4 5 2 INSTALLATION REQUIREMENTS 5 4 5 2 1 BACK PRESSURE 5 5 5 2 2 NOISE 5 6 5 2 3 FLEXIBLE FITTINGS 5 6 5 2 4 MATERIAL SPECIFICATIONS FOR PIPEWORK 5 6 5 2 5 MANIFOLDING OF ENGINES INTO A COMMON EXHAUST SYSTEM 5 6 5...

Page 9: ...7 7 6 CORE CONSTRUCTION 7 15 7 7 7 WATER PUMP INLET PRESSURE MAXIMUM STATIC HEAD 7 15 7 7 8 COOLANT FLOW RATE EXTERNAL PRESSURE DROP 7 15 7 7 9 MINIMUM COOLANT TEMPERATURE 7 16 7 7 10 SYSTEM PRESSURIZATION 7 16 7 7 11 COOLANTS 7 16 7 8 CHARGE AIR COOLING REQUIREMENTS 7 16 7 8 1 COOLING CAPABILITY 7 16 7 8 2 MAXIMUM PRESSURE LOSS 7 16 7 8 3 CLEANLINESS 7 17 7 8 4 LEAKAGE 7 17 7 9 END PRODUCT QUESTI...

Page 10: ...2 FAN DRIVES 7 33 BAFFLES TO PREVENT AIR RECIRCULATION 7 33 SHUTTERS 7 33 WINTERFRONTS 7 33 7 14 RADIATOR COMPONENT DESIGN 7 34 7 14 1 DOWN FLOW AND CROSS FLOW RADIATORS 7 34 HORIZONTAL RADIATOR 7 34 RAPID WARM UP DEAERATION TANK DOWN FLOW RADIATOR 7 35 REMOTE MOUNTED RADIATORS HEAT EXCHANGER 7 35 INTEGRAL TOP TANK 7 36 REMOTE TANK 7 39 RADIATOR BOTTOM TANK 7 40 COOLANT PRESSURE CONTROL CAPS AND R...

Page 11: ... OIL SELECTION 9 6 9 3 LUBRICATION FILTER 9 6 9 4 ENGINE COMPONENT OIL SUPPLY REQUIREMENTS 9 7 9 4 1 TURBOCHARGER LUBRICATION 9 7 9 4 2 AIR COMPRESSOR LUBRICATION 9 7 9 5 INSTALLATION REQUIREMENTS 9 7 9 5 1 SUPPLEMENTAL FILTRATION SYSTEMS 9 7 REMOTE MOUNT SUPPLEMENTAL OIL FILTERS 9 7 9 5 2 OIL SAMPLING VALVE 9 8 9 5 3 MECHANICAL OIL PRESSURE GAUGES 9 8 9 6 COMPONENT OPTIONS 9 8 9 6 1 OIL CHECKS AN...

Page 12: ...TANCE 10 13 11 MOUNTING SYSTEM 11 1 11 1 MOUNTING SYSTEM DESCRIPTION 11 2 11 1 1 THREE POINT MOUNTING 11 3 11 1 2 FOUR POINT MOUNTING 11 4 11 2 SOLID MOUNTING SYSTEMS 11 5 11 3 FLEXIBLE MOUNTING SYSTEMS 11 6 11 3 1 FLEXIBLE MOUNT SELECTION 11 6 METHOD A 11 7 METHOD B 11 8 11 4 INSTALLATION CHECK LIST 11 9 11 5 ENGINE SUPPORT 11 10 12 TORSIONAL ANALYSIS 12 1 12 1 OVERVIEW 12 2 12 2 MASS ELASTIC 12 ...

Page 13: ...SYSTEMS 18 1 18 1 OVERVIEW 18 2 18 2 CONSTANT THROTTLE VALVES WITH EXHAUST BRAKE 18 2 18 3 CONSTANT THROTTLE VALVES WITH TURBOBRAKE OPTIONAL 18 2 19 ACCESSORY DRIVES 19 1 19 1 FEPTO ACCESSORY DRIVES 19 2 19 2 REPTO ACCESSORY DRIVES 19 3 APPENDIX A ABBREVIATIONS ACRONYMS A 1 GLOSSARY G 1 INDEX INDEX 1 All information subject to change without notice Rev 03 06 ix 7SA250 0603 Copyright 2006 DETROIT D...

Page 15: ... Tap 5 10 Figure 6 1 Airflow Diagram Through Engine With EGR System 6 3 Figure 6 2 MBE4000 Engine with EGR 6 4 Figure 7 1 Thermostats Closed 7 4 Figure 7 2 Thermostats Open 7 5 Figure 7 3 Coolant Expansion 7 6 Figure 7 4 Thermostat and Related Parts 7 7 Figure 7 5 Rapid Warm up Cooling System Remote Tank Cross Flow and Down Flow Radiators 7 9 Figure 7 6 Rapid Warm up with Integral Top Tank 7 10 Fi...

Page 16: ...11 2 Four point Mounting with Front and Rear Bracket Sets 11 4 Figure 11 3 Transmissibility 11 8 Figure 11 4 Distance of Rear Mounts for Zero Bending Moments 11 10 Figure 11 5 Bending Moment for Fixed Mounting System 11 11 Figure 13 1 DDEC ECU Control Unit on Engine 13 3 Figure 13 2 The Vehicle Control Unit 13 4 Figure 13 3 NAFTA Architecture 13 5 Figure 13 4 Typical MBE4000 Vehicle Interface Harn...

Page 17: ...actors 7 29 Table 7 4 Top Tank Component Guidelines Standpipe s Baffle Vortex Baffle Fill Line and Connections Vent Line and Radiator Inlet 7 37 Table 7 5 Top Tank Component Guidelines Fill Neck Fill Neck Vent Hole and Coolant Level Sensor 7 38 Table 7 6 Component Design and Location Guidelines for the Remote Top Tank 7 40 Table 10 1 Minimum Battery Capacity for Acceptable Engine Cranking 10 4 Tab...

Page 19: ...ly operated constant throttle system and by either an exhaust brake after the turbocharger standard or a turbo brake The cylinder block has a replaceable cylinder liner The six individual cylinder heads are made of cast iron The cylinder head gasket is a three layer adjustment free seal with viton sealing elements The pistons are made of aluminum alloy with a shallow combustion chamber recess The ...

Page 21: ... area If operating an engine in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaust system or emission control system 2 1 STANDS Use safety stands in conjunction with hydraulic jacks or hoists Do not rely on either the jack or the hoist to carry the load 2 2 GLASSES Select appropriate safety glasses for the job Safety glasses must be worn when using tools such...

Page 22: ...ak leading to fire or an explosion If a cylinder should fall resulting in the gage end breaking off the sudden release of cylinder pressure will turn the cylinder into a dangerous projectile Observe the following precautions when using oxygen acetylene gas cylinders Always wear required safety shoes Do not handle tanks in a careless manner or with greasy gloves or slippery hands Use a chain bracke...

Page 23: ...VER recommended FIRE To avoid injury from fire check for fuel or oil leaks before welding or carrying an open flame near the engine 2 4 WORK PLACE Organize your work area and keep it clean PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids Eliminate the possibility of a fall by Wiping up oil spills Keeping tools and parts off the floor A fall could r...

Page 24: ...ndals or sneakers are not acceptable foot wear when installing an engine PERSONAL INJURY To avoid injury when working near or on an operating engine remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury 2 6 ELECTRIC TOOLS Improper use of electrical equipment can cause severe injury ELECTRICAL SHOCK To avoid injury from elect...

Page 25: ...engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure Fluids under pressure can have enough force to penetrate the skin PERSONAL INJURY To avoid injury from penetrating fluids do not put your hands in front of fluid under pressure Fluids under pressure can penetrate skin and clothing These fluids can...

Page 26: ...eutralize the acid Flush your eyes with water Get medical attention immediately Always disconnect the battery cable before working on the Detroit Diesel Electronic Controls system 2 10 FIRE Keep a charged fire extinguisher within reach Be sure you have the correct type of extinguisher for the situation The correct fire extinguisher types for specific working environments are listed in Table 2 1 Fi...

Page 27: ...heat Discard gloves after handling degraded fluoroelastomer parts A potential hazard may occur if these components are raised to a temperature above 600 F 316 C in a fire for example Fluoroelastomer will decompose indicated by charring or the appearance of a black sticky mass and produce hydrofluoric acid This acid is extremely corrosive and if touched by bare skin may cause severe burns the sympt...

Page 29: ...TION Section Page 3 1 ENGINE DESCRIPTION 3 3 3 2 MAJOR COMPONENT LOCATIONS FOR MBE4000 EGR ENGINES 3 4 3 3 ENGINE IDENTIFICATION 3 6 3 4 EMISSION LABEL 3 8 All information subject to change without notice Rev 03 06 3 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 30: ...ENGINE AND ACCESSORY IDENTIFICATION THIS PAGE INTENTIONALLY LEFT BLANK 3 2 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 31: ...ed four stroke direct injection diesel engines The cylinders are arranged inline See Figure 3 1 for the MBE4000 six cylinder EGR engine Figure 3 1 Typical MBE4000 Engine with EGR All information subject to change without notice Rev 03 06 3 3 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 32: ...R Cooler 2 Exhaust Manifold 3 piece 7 Reed Valves 3 EGR Hot Pipe 8 Air Temperature Sensor 4 EGR Shutoff Valve 9 Front Lifter Bracket 5 Throttle Figure 3 2 Right Front View of MBE4000 EGR Engine 3 4 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 33: ...Shutoff Valve hidden 3 Thermostat Housing 7 Crankcase Breather Hengst Filter 4 EGR Modulated Control Valve 8 Charge Air Mixer Figure 3 3 Left Front View of the MBE4000 EGR Engine All information subject to change without notice Rev 03 06 3 5 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 34: ...on the engine type plate located on the oil filter housing on the right hand side of the engine See Figure 3 4 and Figure 3 5 Figure 3 4 Location of Engine Type Plate Figure 3 5 Engine Type Plate Detail 3 6 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 35: ...er etched on the crankcase there is a ten digit number used for warranty and service that is found on the DDEC ECU label The ten digit number is derived from the fourteen digit number see Figure 3 6 Figure 3 6 Serial Number All information subject to change without notice Rev 03 06 3 7 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 36: ... with appropriate United States Environmental Protection Agency U S EPA and California Air Resources Board CARB emission standards An emission label is attached to the cylinder head cover as required by law See Figure 3 7 for the emission label Figure 3 7 Emission Label 3 8 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 37: ... Page 4 1 AIR INLET SYSTEM DESCRIPTION 4 3 4 2 INSTALLATION REQUIREMENTS 4 4 4 3 DESIGN GUIDELINES 4 14 4 4 TESTING REQUIREMENTS 4 19 4 5 TEST 4 25 All information subject to change without notice Rev 03 06 4 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 39: ...ing intake air This charge air is then cooled by an air to air intake manifold before flowing into the cylinders for improved combustion efficiency 4 1 1 MBE4000 ON HIGHWAY ENGINES All MBE4000 on highway engines have a single turbocharger which supplies filtered air through a remote CAC to the air intake manifold The MBE4000 CACs are generally located in front of or next to the engine radiator cor...

Page 40: ... application in which they are used are listed in Table 4 1 Type of Air Cleaner Application Light duty Marine engines Mobile and stationary engines in factories warehouses etc Cranes wheel mounted Medium duty Generator sets Air compressors pumps Cranes wheel mounted Heavy duty Trucks nonroad logging Tractors wheel agricultural Motor graders Tractors crawler small Scrapers Cranes shovels Extra Heav...

Page 41: ...nt Optional safety elements for increased reliability are available and may be included in these air cleaners See Figure 4 1 1 Body Assembly 6 Primary Element 2 Vacuator Valve 7 Safety Element 3 Cup Assembly 8 Nut Assembly Wing Nut and Washer Gasket 4 Clamp Assembly 9 Restriction Indicator Fitting Cap 5 Baffle Assembly 10 O ring Figure 4 1 Medium duty Air Cleaner All information subject to change ...

Page 42: ...precleaner but employ an oversized filter element to accomplish the same dust removal with similar service intervals Optional safety elements for increased reliability are available and may be included in these air cleaners 1 Dust Cup 8 Safety Element 2 Cup Clamp 9 Safety Signal 3 Body or Cup O ring 10 Primary Element 4 Lower Body Assembly 11 Gasket 5 Body Clamp 12 Access Cover 6 O ring 13 Wing Nu...

Page 43: ...st cups that open because of the weight of the dust when the engine stops Optional safety elements for increased reliability are available and may be included in these air cleaners See Figure 4 3 1 Bleed Tube 5 Housing 2 Positive Pressure Plumbing Kit 6 Outlet Nozzle 3 Positive Pressure Self cleaning Precleaner 7 Mounting Flange 4 Pamic Element Figure 4 3 Extra Heavy duty Air Cleaner All informati...

Page 44: ...erally do not have enough gradability for mobile nonroad applications NOTICE Air cleaner performance may be adversely affected by temperature extremes Oil pullover from improper usage or extreme vehicle tilt may cause engine runaway and damage The oil mist created by the filter may adversely effect turbocharger life and performance Oil bath air cleaners generally have lower efficiencies and greate...

Page 45: ...moval while servicing See Figure 4 4 Figure 4 4 Precleaner Centrifugal Action Precleaners may be used with the MBE4000 engines as long as the air inlet restriction requirements are met The use of a precleaner may necessitate the use of a larger air cleaner Inlet Screens An inlet screen may be used with an air cleaner when larger airborne material is encountered in an operating environment An inlet...

Page 46: ...failures in the intake parts A water drain should be positioned at the lowest point in the system A water collection trap may be necessary to overcome engine vacuum Drains may also be needed on the bottom of the air cleaner Inlet Silencers Appreciable reductions in noise levels can sometimes be achieved with the use of inlet silencers The installer should consult the supplier for specific recommen...

Page 47: ...power Poor fuel economy High combustion temperature Over heating Reduced engine life An air inlet restriction indicator must be fitted on the air intake system The operating setting of the indicator should correspond to the maximum permissible inlet restriction 5 5 kPa 22 in H2 O maximum for systems with dirty filters provided that it is connected to a tapping point close to the turbocharger inlet...

Page 48: ...cal but no closer than 12 7 mm 5 in Compensate for the added restriction incurred from piping between the cleaner and the turbocharger inlet when the restriction indicator fits to the air cleaner tapping of a remote mounted cleaner 4 12 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 49: ...imize radiated heat from these sources to the inlet system Pipework Material Specifications Aluminum or aluminized steel seamless tubing should be used The tube ends require a 0 09 in 2 3 mm minimum bead to retain hose and clamp connections Fiberglass piping between the air cleaner and the turbocharger compressor inlet is also acceptable DDC recommends that mitered elbows should have multiple sect...

Page 50: ... oil and lubricating oil on both internal and external surfaces Maximum Working Temperatures 105 C 220 F Working Pressure Up to 12 5 kPa 50 in H2O depression negative pressure Table 4 3 Hose Specifications for the Inlet Side of the Turbocharger 4 3 DESIGN GUIDELINES The installed inlet system must be designed to supply clean dry cool air to the engine with minimum restriction The system must also ...

Page 51: ... An air inlet restriction indicator must be installed on the air intake system The restriction of the air inlet system is equal to the sum of the individual restrictions in the system These include rain caps inlet hoods air cleaners and piping See Figure 4 8 Figure 4 8 Air Inlet System Calculation 4 3 3 INLET LOCATION Position the air cleaner inlet so that air is drawn from an area clear of water ...

Page 52: ...m minimum bead to retain hose and clamp connections Air system operating parameters such as heat rejection engine air flow air pressure maximum pressure drop minimum temperature loss and turbocharger compressor discharge temperature are found in the Technical Data section of this manual refer to section 14 Charge air cooler considerations include size cooling air flow restriction material specific...

Page 53: ...ressure loss using an adaptor plug on the inlet The charge air cooler is considered acceptable if it can hold 25 psi 172 kPa pressure with less than a 5 psi 34 5 kPa loss in 15 seconds after turning off the hand valve Size The size of the heat exchanger depends on performance requirements cooling air flow available and usable frontal area Using the largest possible frontal area usually results in ...

Page 54: ...al to minimize pipe length and pressure losses Leave access space between the cores when stacked in front of one another so debris may be removed Fan Systems The fan systems must provide sufficient air flow to cool both the air to air heat exchanger as well as the engine coolant radiator under all operating conditions A controlled fan drive system must be able to maintain a required air and water ...

Page 55: ...e area in the center of the grill should remain open at all times All monitoring warning and shutdown devices should be properly located and in good working condition 4 4 TESTING REQUIREMENTS A thorough evaluation of the air inlet system will include Complete descriptions and documentation of the system in the End Product Questionnaire EPQ form Adequate instrumentation Proper test preparation Accu...

Page 56: ...ng 5 0 kPa 20 in H2 O Combine four static pressure taps see Figure 4 9 to make a piezometer ring to measure static pressure in straight pipe sections Figure 4 9 Static Pressure Tap 4 20 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 57: ... to fire or an explosion If a cylinder should fall resulting in the gage end breaking off the sudden release of cylinder pressure will turn the cylinder into a dangerous projectile Observe the following precautions when using oxygen acetylene gas cylinders Always wear required safety shoes Do not handle tanks in a careless manner or with greasy gloves or slippery hands Use a chain bracket or other...

Page 58: ...he desired measurement location Figure 4 10 Piezometer Ring The instrumentation should be placed perpendicular to the plane of the bend where measurement on a bend is unavoidable 4 22 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 59: ...Figure 4 11 Typical Instrumentation Location 4 4 2 INLET SYSTEM RESTRICTION The maximum permitted inlet restriction for a system with a clean air cleaner is 10 in H2 O 2 5 kPa The maximum permitted inlet restriction for a system with a dirty air cleaner is 22 in H2 O 5 5 kPa All information subject to change without notice Rev 03 06 4 23 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 60: ...ent to Intake Manifold The maximum temperature differential between the ambient temperature and the temperature at the intake manifold needs to be determined See Figure 4 11 for temperature location the location description is listed in Table 4 4 Symbol Measurement Location Description T1 Air inlet temperature Within 5 in of the turbocharger T2 Compressor discharge temperature Within 5 in of the c...

Page 61: ...or in the manifold itself Table 4 5 Pressure Taps Connect a precision gauge between pressure taps P1 and P2 to determine pressure drop of the system Two precision gauges may be used as desired The maximum pressure drop for the MBE4000 engine is listed in the Technical Data section of this manual refer to section 14 4 5 TEST Thorough preparations prior to testing will ensure accurate results Confir...

Page 62: ...cation require no ram air Any questions regarding ram air should be directed to Detroit Diesel Application Engineering Sample data sheets for the air inlet and charge air system tests are given below see Figure 4 12 Figure 4 12 Air Inlet Data Sheet for Air to Air Charge Cooled Engine 4 26 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATI...

Page 63: ...Section Page 5 1 EXHAUST SYSTEM DESCRIPTION 5 3 5 2 INSTALLATION REQUIREMENTS 5 4 5 3 DESIGN REQUIREMENTS 5 7 5 4 TESTING REQUIREMENTS 5 8 All information subject to change without notice Rev 03 06 5 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 65: ...f Exhaust valves Exhaust manifold Turbocharger Exhaust piping Muffler Exhaust gases exit the cylinders through exhaust ports and the exhaust manifold These exhaust gases expand through the exhaust turbine and drive the turbocharger compressor impeller The gases are then released through the exhaust pipes and the muffler to the atmosphere All information subject to change without notice Rev 03 06 5...

Page 66: ...ble and within the limits specified for the engine The system should minimize radiated noise Adequate clearance must be provided for the complete exhaust system The exhaust must not pass too close to the filters fuel lines fuel injection pump starter alternators etc The minimum required exhaust pipe inner diameter I D for a MBE4000 engine is listed in the Technical Data section of this manual refe...

Page 67: ... usually causes excessive back pressure Small exhaust pipe diameter Excessive number of sharp bends in the system Long exhaust pipe between the manifold and muffler High muffler resistance Back pressure that is too high may result in Reduced power Poor fuel economy High combustion temperature Over heating Excessive smoke Reduced engine life The total back pressure must not exceed the maximum allow...

Page 68: ...and facilitates alignment of the engine with the exhaust system piping Exhaust pipe joints and connections should obviously be free from leaks NOTICE Never allow the engine manifold or turbocharger to support the weight of the exhaust system The turbine outlet uses a clamp see the installation drawing for details refer to section 15 5 2 4 MATERIAL SPECIFICATIONS FOR PIPEWORK The minimum required e...

Page 69: ...have some means of preventing water entry when not operating such as a rain cap 5 3 2 DRAINAGE The exhaust pipe can accumulate a considerable amount of condensed moisture especially when the pipe is long A condensate trap and drain may be needed at the lowest point in the system to avoid internal corrosion Use one of the following to prevent entry of rain and snow with vertical exhaust systems Fit...

Page 70: ...lankets on the turbocharger and exhaust manifold consult with Detroit Diesel Application Engineering 5 4 TESTING REQUIREMENTS A thorough evaluation of the exhaust system will include Complete descriptions and documentation of the system in the EPQ form Adequate instrumentation Proper test preparation Accurate tests Data analysis and documentation Diagnostics troubleshooting and corrective action i...

Page 71: ...measures in Hg to record the exhaust back pressure Use a piezometer ring to measure static pressure within 127 mm 5 in of the turbocharger discharge see Figure 5 2and Figure 5 3 Figure 5 2 Piezometer Ring All information subject to change without notice Rev 03 06 5 9 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 72: ...nt on a bend is unavoidable 5 4 2 MEASUREMENT OF EXHAUST TEMPERATURE Use a precision thermocouple and an appropriate read out device to measure temperatures Thermocouples should be located downstream of the pressure taps 5 10 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 73: ...ECIRCULATION Section Page 6 1 SYSTEM DESCRIPTION 6 3 6 2 EGR COOLER 6 4 6 3 EGR CONTROL VALVES 6 5 6 4 REED VALVES 6 5 6 5 EGR MIXER 6 5 All information subject to change without notice Rev 03 06 6 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 75: ...ses from the front three cylinders are routed from the exhaust manifold through the EGR cooler past control and reed valves and mixed with the intake manifold charge air The addition of cooled exhaust gases back into the combustion airflow reduces the peak in cylinder combustion temperature Less oxides of nitrogen NOx are produced at lower combustion temperatures The recycled exhaust gases are coo...

Page 76: ...Valve Figure 6 2 MBE4000 Engine with EGR 6 2 EGR COOLER The EGR system is equipped with a single pass cooler Exhaust gases from the first three cylinders are directed through the EGR shutoff valve and through the cooler and reed valves past the modulated EGR valve and the mixer and then back to the cylinder 6 4 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 D...

Page 77: ...rt to the engine The pressure of gases in the exhaust manifold changes over time peaking when exhaust valves open Exhaust gases pass through the reed valves during these pressure peaks The reed valves permit transport of exhaust gases only during the time when the exhaust gases pressure is greater than the charge air pressure 6 5 EGR MIXER The purpose of the mixer is to ensure good mixing of the c...

Page 79: ...NTS 7 13 7 8 CHARGE AIR COOLING REQUIREMENTS 7 16 7 9 END PRODUCT QUESTIONNAIRE 7 17 7 10 COOLING SYSTEM DESIGN CONSIDERATIONS 7 17 7 11 CHARGE AIR COOLING DESIGN GUIDELINES 7 24 7 12 HEAT EXCHANGER SELECTION 7 26 7 13 FAN SYSTEM RECOMMENDATIONS AND FAN SELECTION 7 27 7 14 RADIATOR COMPONENT DESIGN 7 34 7 15 DIAGNOSTICS AND TROUBLESHOOTING 7 53 7 16 MAINTENANCE 7 57 All information subject to chan...

Page 81: ... intake manifold Ambient air is drawn in through the air cleaner and piping to the exhaust driven turbocharger The turbo compresses the air which increases its temperature by about 300 F 150 C The charge air is then cooled by the air from the cooling fan as it passes through the CAC to the intake manifold 7 2 JACKET WATER COOLING SYSTEM When the engine is at normal operating temperature the coolan...

Page 83: ...MBE4000 APPLICATION AND INSTALLATION Figure 7 2 Thermostats Open All information subject to change without notice Rev 03 06 7 5 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 84: ...he coolant and air in the system starts to expand and build pressure The valve in the radiator pressure cap unseats and allows the trapped air to flow out the overflow tube See Figure 7 3 Figure 7 3 Coolant Expansion When the engine starts to cool down the air and coolant contract causing a void and creating a vacuum in the system The vacuum unseats another valve in the radiator pressure cap allow...

Page 85: ... all of the coolant in the system is recirculated through the engine and is directed back to the suction side of the water pump via an internal bypass tube As the coolant temperature rises above the start to open temperature the thermostat valves begin to open restricting the bypass system and allowing a portion of the coolant to circulate through the radiator When the coolant temperature reaches ...

Page 86: ...nates coolant flow through the radiator core during closed thermostat operation This reduces warm up time and maintains coolant temperature near the thermostat start to open value Having the deaeration tank internal or remote separated from the radiator core will accomplish this External vent and fill lines as well as internal standpipe s radiator core air vent are required in the deaeration tank ...

Page 87: ... AND INSTALLATION Figure 7 5 Rapid Warm up Cooling System Remote Tank Cross Flow and Down Flow Radiators All information subject to change without notice Rev 03 06 7 9 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 88: ...ARY AIR COOLED COOLER CORES Heat exchangers in addition to jacket water and charge air cooler radiators are quite often part of the total cooling system Heat exchangers such as air to oil air to air oil to air or others are to be used and mounted either in front of the radiator or behind it If auxiliary coolers are used greater restriction of air flow and increased heat load must be considered NOT...

Page 89: ...tting a denser charge of air to be delivered to the engine Cooling is accomplished by outside air directed past the cooling fins and core tubes of the CAC The intake air charge is routed to the cylinders by an intake manifold which directs the air to ports in the cylinder head through two intake valves per cylinder and into the cylinder At the beginning of the compression stroke each cylinder is f...

Page 90: ...e dense charge of air to be delivered to the engine Cooling is accomplished by incoming air flowing past the tubes and fins of the intercooler The compressed intake charge flowing inside the CAC core transfers the heat to the tubes and fins where it is picked up by the incoming outside air Powder coated painted untreated mild steel is unacceptable for piping Aluminum aluminized steel stainless ste...

Page 91: ...ent venting air bleeding to permit filling at a minimum continuous rate of 8 L min 2 gal min and on an interrupted basis using a 10 liter 2 3 gallon bucket Upon first indication of a full system the amount of coolant needed to complete the fill must not exceed the satisfactory drawdown amount This is also a requirement for interrupted fill Refer to section 7 7 5 for drawdown capacity information 7...

Page 92: ...nown in order to determine the expansion and deaeration volumes required in the top tank See Figure 7 8 Figure 7 8 Percent Increases in Volume for Water and Antifreeze Solution 7 14 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 93: ...t 7 7 7 WATER PUMP INLET PRESSURE MAXIMUM STATIC HEAD When the engine is operating at maximum engine speed fill cap removed and thermostat fully opened the water pump inlet pressure must not be lower than atmospheric pressure suction with a rapid warm up cooling system These requirements must be met to minimize water pump cavitation and corresponding loss in coolant flow Keep restrictions to the w...

Page 94: ...rosion Antifreeze concentration should not exceed 67 for ethylene glycol 50 for propylene glycol Detroit Diesel requires SCAs be added to all cooling systems at initial fill and be maintained at the proper concentration Follow SCA manufacturers recommendations Refer to Coolant Selections for Engine Cooling Systems 7SE0298 available on the DDC extranet 7 8 CHARGE AIR COOLING REQUIREMENTS Sufficient...

Page 95: ...appendix of this manual The short form may be used for ten or less units per year 7 10 COOLING SYSTEM DESIGN CONSIDERATIONS Many factors must be considered when designing the overall cooling system The design process can be broken down into two phases Consideration of heat rejection requirements Consideration of specific component design The following guidelines are presented as a systematic revie...

Page 96: ...on The jacket water and charge air heat must be dissipated in order to meet coolant and intake manifold rejection requirements The exhaust heat and radiated heat must be considered because both often have an effect on air temperature which affects fan and heat exchanger performance Limiting ambient temperature may occur at engine speeds other than maximum Coolant Flow The pump flow listed in the T...

Page 97: ...nstallations The heat rejected to the coolant generally increases when engine performance is reduced due to external conditions Engine performance is adversely affected by High air restrictions High exhaust back pressure High air inlet temperature Altitude Ambient Temperature The ambient temperature in which an engine will be operated must be considered when designing the jacket water cooled JWC a...

Page 98: ...by a cooling fan Fan noise is directly related to fan speed which affects air flow refer to section 7 13 Tilt Operations or Installations Cooling systems must perform satisfactorily at maximum tilt operation This is especially critical for applications where the engine must operate for extended periods on steep grades 7 10 4 SYSTEM COMPONENTS Total heat rejected to the coolant and air must be dete...

Page 99: ...t chosen for a cooling system can have an effect on the system performance Water pump output and heat transfer characteristics are different for water than for antifreeze because the fluids have different densities viscosities and thermal conductivity The heat exchanger manufacturer is the best source for determining what the difference in performance would be from one type of coolant to the next ...

Page 100: ...s are not recommended All lines must have a continuous downward slope without droops to ensure good cooling system draining and refilling capabilities Additional drains and vents may be required if this is not possible All vent to fill lines must have a continuous upward slope to the radiator top tank Locate a drain plug cock on the lowest portion of the cooling system to ensure complete draining ...

Page 101: ...r add on features such as cab heaters filters and auxiliary oil coolers Pumps are sensitive to inlet restrictions coolant temperature coolant type and aerated coolant Discharge flow can be seriously reduced and damaging cavitation can occur if the cooling system is not designed properly Water pump inlet restriction must be kept to a minimum to prevent cavitation This means radiators auxiliary oil ...

Page 102: ... restriction material specifications header tanks location and fan systems 7 11 1 SIZE The size of the heat exchanger depends on performance requirements cooling air flow available and usable frontal area Using the largest possible frontal area usually results in the most efficient core with the least amount of system pressure drop Consult your supplier to determine the proper heat exchanger for y...

Page 103: ...as practical to minimize pipe length and pressure losses Leave access space between the cores when stacked in front of one another so debris may be removed 7 11 6 PIPEWORK Give careful attention to the pipework and associated fittings used in the inlet system in order to minimize restriction and maintain reliable sealing Pipework length should be as short as possible in order to minimize the restr...

Page 104: ...oth radiators and charge air coolers Meet the following design criteria to achieve greatest efficiency for fan cooled applications Utilize the largest practical frontal area in order to minimize restriction to air flow Use square cores The square core allows maximum fan sweep area thus providing most effective fan performance Keep core thickness and fin density fins per unit length to a minimum Th...

Page 105: ...t fan diameter possible turning at the lowest speed to deliver the desired air flow are the most economical NOTE Fan blades should not extend beyond the radiator core Blades that reach beyond the core are of minimal or no benefit Other important considerations include Cooling air flow required by the radiator core Cooling air system total pressure drop Space available Noise level limit Fan drive l...

Page 106: ... fan even when engine mounted can receive air closer to ambient temperatures Proper fan spacing from the core and good shroud design are required so air flow is completely distributed across the core to obtain high efficiency A suction fan when mounted will generally have the concave side of the blade facing the engine whereas a blower fan will have the concave side facing the radiator see Figure ...

Page 107: ...reviewed with Detroit Diesel Application Engineering Increasing core thickness increases the restriction to air flow This condition causes fouling to occur faster Consider the following when analyzing fan performance Speed Static Pressure Horsepower The following fan law relationships are useful when interpreting basic fan curves Air flow varies directly with fan speed ft3 min2 ft3 min1 x r min2 r...

Page 108: ...efficient and noisy There are maximum tip speeds in the range of 18 000 to 23 000 feet per minute that the fan manufacturer based on his design Check with the fan manufacturer The system characteristics are defined by the air flow restrictions that are a result of Engine enclosure louvers Engine and accessories Fan guard Radiator core Charge air cooler if in tandem with radiator Oil cooler if in t...

Page 109: ... the shroud opening is dependent on the fan design as well as the many variables associated with an installation Different system performance may occur for the same fan positions in different applications due to air flow restriction and flow obstructions Consult the fan manufacturer for assistance in optimizing the fan positioning Keep fan tip to shroud clearance to a minimum because it influences...

Page 110: ...e well rounded entrance venturi shroud the ring shroud and the box shroud see Figure 7 10 The ring and box type shrouds are most common because they are easier to fabricate Figure 7 10 Fan Shroud Types Fan System Assemblies Do not exceed the design limits of any component when OEM components such as fans fan drives spacers etc are attached to Detroit Diesel supplied components fan hub and pulley a...

Page 111: ...r and poor fuel economy Shutters should open approximately 3 C 5 F before the thermostat start to open temperature The shutter control should sense engine water out before thermostat temperature and the probe must be fully submerged in coolant flow Winterfronts Winterfronts are not required under most operating conditions with a properly designed cooling system Some operators reduce the airflow th...

Page 112: ...ht limitations exist but deaeration thermal stratification adequate core tube coverage and freeze damage are generally more difficult to control Figure 7 11 Down Flow Radiator and Cross Flow Radiator Horizontal Radiator Horizontal radiators may be used in situations where space restrictions preclude the use of other types It is essential that vent lines go to the fill tank with the cap Consult DDC...

Page 113: ...g closed thermostat operation Prevent introduction of air into the cooling system during maximum tilt or angle operation Remote Mounted Radiators Heat Exchanger Consult an authorized distributor radiator supplier or DDC Application Engineering when remote i e non engine driven fans mounted radiators heat exchangers are being considered as many variables must be considered for each application The ...

Page 114: ... assist in the design of a new tank to critique existing tanks and to troubleshoot problem cooling systems See Figure 7 12 Figure 7 12 Rapid Warm up Down Flow Radiator Top Tank 7 36 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 115: ...the baffle and at the center of the tank This minimizes uncovering the fill opening and drawing air into the cooling system during vehicle operations Fill Line and Connections Make the engine connection as close to the water pump inlet as practical This will provide maximum head to the water pump and minimize heat migration to the radiator core resulting in quicker engine warm up Avoid connecting ...

Page 116: ...nes for top tank design critique or troubleshooting are Increasing top tank depth permits maximum usage of coolant volume and reduces tilt operation problems Consider hose fitting inside diameters when determining vent and fill line inside diameter requirements Low fill line flow velocity large inside diameter line will generally improve drawdown capacity and maintain higher pressure on the water ...

Page 117: ...t provide the same features as the ITT design The guidelines for the radiator inlet tank are listed in Table 7 6 Figure 7 13 Remote Surge Tank Design for Rapid Warm up Cooling System All information subject to change without notice Rev 03 06 7 39 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 118: ...ficult especially near the end of the fill because of small head differential Also equalization of the coolant level occurs during engine stop or low speed operation Table 7 6 Component Design and Location Guidelines for the Remote Top Tank Figure 7 14 Down Flow Radiator Inlet Tank Deaeration Line Boss Position Radiator Bottom Tank Consider the following guidelines when designing the radiator bott...

Page 119: ...ctions A well rounded coolant outlet exit area is preferred see Figure 7 16 to minimize restriction and aeration Figure 7 16 Radiator Outlet Contour Depth of the tank should be no less than the diameter of the outlet pipe to minimize restriction All information subject to change without notice Rev 03 06 7 41 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 120: ... coolant is hot Locate the pressure control device high in the deaeration tank above the hot coolant level to minimize coolant loss and dirt contamination of the relief valve seat HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron ...

Page 121: ...re upon cap removal if a separate pressure relief valve is used Inspect the valve cap periodically to ensure components are clean not damaged and in good operating order A 15psi pressure cap is required for most systems and applications Verify required minimum pressure cap rating by checking the Technical Data section of this manual refer to section 14 Consider higher pressure rated caps for opera...

Page 122: ...vel Sensors are required with MBE4000 engines Temperature Gauges Every temperature gauge should have sufficient markings to allow an operator to determine actual operating temperature The temperature range should go beyond 99 C 210 F so the operator will know if the maximum coolant temperature is being exceeded Maintain accuracy of 3 C 5 F to prevent inaccurate indication of either hot or cold run...

Page 123: ...e various coolant sensor devices can be seen in the following illustration see Figure 7 19 Figure 7 19 Nominal Settings For Coolant Temperature Control Devices 190 All information subject to change without notice Rev 03 06 7 45 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 124: ...re 7 21 only when adequate expansion drawdown and deaeration volume cannot be designed into the radiator or remote top tanks Figure 7 20 Cooling System Design Warm up Closed Thermostat 7 46 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 125: ...e increases as the engine coolant temperature rises The pressure valve in the pressure control cap will open due to this pressure causing coolant to flow into the coolant recovery tank See Figure 7 20 and Figure 7 21 All information subject to change without notice Rev 03 06 7 47 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 126: ...the pressure control cap when the coolant temperature decreases The total coolant volume decreases as the engine coolant temperature falls See Figure 7 22 Figure 7 22 Cooling System Design Cool down Closed Thermostat 7 48 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 127: ...et the following design criteria to achieve a properly functioning coolant recovery system Use an air tight pressure cap Install and maintain air tight seals on either ends of the line Ensure that the coolant level in the tank does not go below the level where the coolant recovery line connects to the recovery tank Do not visually check the recovery tank because it may give a false indication of t...

Page 128: ...air is not trapped at the top of the top tank See Figure 7 24 Figure 7 23 Acceptable Top Tank Design Figure 7 24 Unacceptable Top Tank Design Connect the deaeration line as high as possible to the top tank when using a coolant recovery system 7 50 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 129: ... Increase idle speed Avoid long term idle and or light load operation maintain minimum exhaust temperature Use under hood air intake for engine cold weather only Vehicle To maximize the available heat energy of the vehicle Use auxiliary heater On Off fan clutch Auxiliary oil coolers must not be located in radiator outlet tank Seal operator s compartment interior to eliminate any direct cold outsid...

Page 130: ...mation on coolant heaters can be obtained from the Detroit Diesel Application Engineering 7 14 4 MULTI DUTY CYCLE Cooling systems must perform satisfactorily under all operating modes Consideration must be given when an engine is used for prime power under several duty cycles such as cranes drill pumping rigs etc Cooling system must be sized for the maximum rated load 7 14 5 OTHER CONSIDERATIONS C...

Page 131: ...oot for engine overheat as follows 1 Check for inaccurate gauge warning or shutdown device insufficient coolant flow and inadequate heat transfer capabilities during coolant side investigation HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber ...

Page 132: ...ure Over under concentration of antifreeze or inhibitors corrosive water incorrect antifreeze or inhibitors Contamination Oil or other material depositing on heat transfer surfaces 5 Check for insufficient air flow The following are possible causes of insufficient air flow High restriction Plugged core damaged or bent fins shutters not opening correctly addition of bug screens winterfronts noise p...

Page 133: ...es for determining these deficiencies Defective thermostat Stuck open worn misaligned excessive leakage improper calibration incorrect start to open setting Insufficient engine heat rejection Excessive low speed and load or idle operation idle setting too low over concentration of antifreeze and or inhibitors cab and fuel heaters charge air fan removing heat faster than engine can supply Fixed fan...

Page 134: ...es Contamination of core tube surfaces deposits etc Fuel heaters plumbed in cab heater circuit 3 Check the following air side causes Low efficiency cores Improper air flow Excess outside air through core Core fins separated from tubes Core surface contamination dirt debris oil film etc Leaking air ducts Malfunctioning air flow control valves Undersized heater cores Poor distribution system Cab int...

Page 135: ...missing Hoses Plumbing Frayed damaged ballooning collapsing leaking Coolant Contaminated concentration Recirculation Baffles Missing not sealing If any of the above conditions are observed corrective action should be taken immediately Any time a coolant gauge warning shutdown or low level device is malfunctioning it should be fixed immediately A proper glycol ethylene propylene or extended life or...

Page 137: ...SYSTEM Section Page 8 1 FUEL SYSTEM DESCRIPTION 8 3 8 2 FUEL SYSTEM EQUIPMENT INSTALLATION GUIDELINES 8 5 8 3 FUEL SELECTION 8 10 All information subject to change without notice Rev 03 06 8 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 139: ...ilter secondary filter and through a check valve if included to the cylinder head Primary and secondary filters may be combined in some applications Fuel enters the EUP through the two fuel inlet filter screens located around the injector body Filter screens are used at the fuel inlet openings to prevent relatively coarse foreign material from entering the injector The DDEC ECU receives data such ...

Page 140: ...hematic diagram of a typical fuel system see Figure 8 1 Figure 8 1 MBE4000 Fuel System Schematic Diagram 8 4 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 141: ...orm powdery flakes that will quickly clog fuel filters and cause damage to the fuel pump and injectors Fuel tanks must be properly cleaned after manufacturing so no manufacturing debris gets into the fuel The fuel tank s must not be galvanized internally under any circumstances The fuel tank s or piping may be galvanized or painted on the outside only to prevent corrosion Design Baffles must be po...

Page 142: ...BE4000 engines A properly designed fuel tank may be seen in the following illustration see Figure 8 2 Figure 8 2 Properly Designed Fuel Tank Capacity Carefully choose the capacity of the fuel tank s to suit the specific engine installation Consideration should be given to length of operation without the need to refuel The design of tanks in mobile applications must include the supply pipe so that ...

Page 143: ...eights The fuel should be extracted at a point approximately 30 mm 1 2 in to 50 mm 2 in above the bottom edge of the tank passing through an 800 µm strainer With a raised tank 5 metres maximum e g in machinery the supply and return pipe must be provided with a shutoff and drainage valve as close to the engine as possible This prevents an overflow at the filter housing during maintenance work The f...

Page 144: ...ation is being used Do not modify or tamper with any fuel lines supplied with the engine The fuel inlet restriction cannot exceed 17 7 in Hg 600 mBar under any condition Design The lines leading from the fuel tank to the engine prefilter must be made from scale free steel piping or plastic i e polyamide 11 known as PA in accordance with DIN 7728 Steel pipes may have to be used depending on the amb...

Page 145: ...thstand a maximum suction of 17 7 in Hg 600 mBar without collapsing a pressure of 6 90 bar 100 psi without bursting and temperatures between 40 C 40 F and 149 C 300 F Size The fuel supply lines must be 10 mm ID or larger The return lines must be 10 mm ID or larger The minimum nominal diameter must be 12 mm ID 0 5 in if the pipe lengths exceeds 6 m The restrictions imposed between the tank and fuel...

Page 146: ...isfactory engine performance long engine life and acceptable exhaust emission levels For information on fuel selection refer to DDC publication 7SE270 Lubricating Oil Fuel and Filters 8 10 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 147: ...9 3 LUBRICATION FILTER 9 6 9 4 ENGINE COMPONENT OIL SUPPLY REQUIREMENTS 9 7 9 5 INSTALLATION REQUIREMENTS 9 7 9 6 COMPONENT OPTIONS 9 8 9 7 OPERATION AND MAINTENANCE 9 10 9 8 OIL FILTER CONFIGURATION 9 10 9 9 OIL CENTRIFUGE 9 10 All information subject to change without notice Rev 03 06 9 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 149: ... plumbing is kept to a minimum to avoid oil leakage The lubricating system consists of the following components Oil pump Pressure regulator valve Pressure relief valve Oil filters Oil filter adaptor Oil cooler Oil level dipstick Oil pan Ventilation A schematic of the MBE4000 lubricating system is shown in the following illustration see Figure 9 1 All information subject to change without notice Re...

Page 150: ...LUBRICATION SYSTEM Figure 9 1 Typical MBE4000 Lubrication System Schematic 9 4 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 151: ...l spray nozzles are installed in the block which provide a continuous spray of oil to the underside of the pistons From the main gallery oil is routed to passages in the cylinder head which deliver oil to the valve train components and injector followers Drains from the head return oil to the pan Oil for gear train components at the front of the engine is fed through drilled holes out of the main ...

Page 152: ...Lubricating Oils Fuel and Filters available on the DDC extranet 9 3 LUBRICATION FILTER The MBE4000 engine has a vertical oil filter attached to the engine see Figure 9 3 Figure 9 3 Vertical Oil Filter When the engine is installed the lubricating oil filter and the oil drain plug in the oil pan must be easily accessible see Figure 9 4 Figure 9 4 Engine Oil Drain Plug Oil Pan 9 6 All information sub...

Page 153: ...he fuel pump splined drive if equipped the compressor crankshaft and rod bearings cylinder walls and returns to the sump through the compressor drive opening in the rear of the gear case There is no external oil supply or return line 9 5 INSTALLATION REQUIREMENTS If any supplemental filtration systems are used or an oil sampling valve is desired the following installation requirements should be me...

Page 154: ... Distribution Center When the same engine configuration is used in more than one installation where the installation angles may vary it is critical that the proper oil gauge is used for each variant Detroit Diesel also provides a variety of oil fill options at various locations on the engine A rocker cover oil fill is standard on all MBE4000 engines Side mounted tube fill options are also availabl...

Page 155: ...fter engine shutdown while the oil is still warm This practice will minimize the possibility of coking the oil on the heater element Elements are most susceptible to oil coking when used on a cold engine The power density of the heater element should be kept below 4 Watts per square centimeter to prevent oil coking in extreme cold conditions 9 6 4 ENGINE OIL LEVEL SENSOR An optional Engine Oil Lev...

Page 156: ...utes after engine shutdown is required to achieve an accurate oil level measurement A twenty minute wait after shutdown is recommended to allow the oil to fully drain back to the pan from the overhead space 9 7 3 USED OIL ANALYSIS Please refer to the Technician s Guide of Used Lubricating Oil Analysis 7SE398 for a detailed procedural description and interpretation of analysis results 9 7 4 OIL DRA...

Page 157: ...LATION 10 ELECTRICAL SYSTEM Section Page 10 1 ELECTRICAL SYSTEM DESCRIPTION 10 2 10 2 INSTALLATION GUIDELINES 10 3 All information subject to change without notice Rev 03 06 10 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 158: ...system see Figure 10 1 typically consists of the following components Cranking motor and solenoid Battery charging alternator Alternator Voltage regulator generally integral to the alternator Storage battery s Ignition switch Figure 10 1 Engine Electrical System 10 2 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 159: ...nce free batteries Deep cycle batteries Filler Cap Batteries Filler cap batteries are lead acid with a high degree of antimony in the grid alloy These batteries require frequent servicing especially adding water and cleaning salts and corrosive deposits from the terminal posts Semi maintenance Free Batteries Servicing is reduced in the semi maintenance free batteries due to reduced amount of antim...

Page 160: ...able Engine Cranking Battery Mounting and Location Battery mounting boxes or carriers support the batteries and protect them from excess vibration road splash and other environmental conditions The battery carrier may be heated or cooled to keep the battery at optimum operating temperature 27 C 80 F The recommended battery carrier designs are Top crossbar Top mid frame Top picture frame Angled J b...

Page 161: ...MBE4000 APPLICATION AND INSTALLATION See Figure 10 2 Figure 10 2 Battery Retainers All information subject to change without notice Rev 03 06 10 5 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 162: ... for all applications Cantilever battery mountings are not recommended 10 2 2 CRANKING MOTOR The cranking motor is bolted to the flywheel housing NOTICE To prevent excessive overrun and damage to the drive and armature windings the switch should be opened immediately when the engine starts A cranking period should not exceed 30 seconds without stopping to allow the cranking motor to cool for at le...

Page 163: ...ause the starter to overheat and may reduce its life Cranking time should not exceed 30 seconds with a two minute cool down interval between cranking periods 10 2 3 ALTERNATOR The battery charging alternator provides a source of electrical current for maintaining the storage battery in a charged condition The alternator also supplies sufficient current to carry any other electrical load requiremen...

Page 164: ...rmation Because the regulator is contained within the alternator relying on the frame for ground return can result in incorrect voltage sensing by the regulator and as a result incorrect alternator output 10 8 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 165: ...can result in Improper alignment of pulleys Excessive vibration of mounting assembly components Improper alignment of pulleys causes excessive belt or pulley wear Society of Automotive Engineers SAE recommended practice should be followed with respect to pulley alignment and tolerances The pulley groove must be concentric with the bore and the pulley should be adequately balanced Fabricated sheet ...

Page 166: ...or 0 or larger cable sizes because of its added flexibility A full copper circuit is recommended for all installations because it maintains the lowest resistance and is the most trouble free Good cable routing is not too tight or loose is properly supported and avoids excessive heat abrasion and vibration Conduit or loom should be considered to protect cable where extreme heat or abrasion cannot b...

Page 167: ...nect the negative incoming cable ground to the negative terminal of the same battery Now the battery system is 12 volts Repeat if there is a second battery box Measure voltages for correct sizing as follows 1 Tighten nuts holding battery cables to solenoid and starter terminals NOTE Solenoid BAT terminal is at battery voltage when batteries are connected 2 Connect the positive carbon pile lead to ...

Page 168: ...resistance resistance should be less than the maximum allowable for this system If the measurement exceeds the maximum values see Figure 10 4 corrective measures such as cleaning the connections reducing the number of connections or increasing wire gage will have to be taken Figure 10 4 Cable Resistance 10 12 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DET...

Page 169: ...e cable resistance number found in step 2 Also add 0 0002 ohms for any contactors in the circuit 6 If this total resistance exceeds the value listed in Table 10 2 corrective action must be taken Magnetic Switch and Series Parallel Circuit Circuit Resistance 12 V system 0 048 ohm 24 V system 0 10 ohm Solenoid Switch Circuit 12 V system 0 0067 ohm 24 V system 0 030 ohm Starting Motor Circuit 12 V sy...

Page 171: ...UNTING SYSTEM DESCRIPTION 11 2 11 2 SOLID MOUNTING SYSTEMS 11 5 11 3 FLEXIBLE MOUNTING SYSTEMS 11 6 11 4 INSTALLATION CHECK LIST 11 9 11 5 ENGINE SUPPORT 11 10 All information subject to change without notice Rev 03 06 11 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 172: ...e engine and application Flexible mounts solid mounts and a combination of the two types of mounts represent the different mounting system configurations Flexible mountings enable the supporting structure to be isolated from engine vibration Solid mountings are used when the movement of an engine with flexible mounts is not acceptable A combination of solid and flexible mountings may be used based...

Page 173: ...ine flywheel housings have mounting pads At the rear of the engine a bracket is attached to each side of the flywheel housing with the driven mechanism flange mounted to the engine A standard design front mount provides two attaching points which are close enough together and are considered a single point See Figure 11 1 for a three point mounting with rear brackets and the bending moment less tha...

Page 174: ...m is readily adaptable to applying resilient mounts SeeFigure 11 2 Figure 11 2 Four point Mounting with Front and Rear Bracket Sets NOTE When installing and securing four point mounts ensure alignment and shimming is done first and that no twisting or binding can occur Ensure all bolt holes available are utilized Use high grade bolts and flat washers and apply recommended torque to secure mounts f...

Page 175: ...each flange apart With flanges together a 0 005 in gap is permitted for angular misalignment Concentricity also checked with dial indicators should be good within 0 005 in Make adjustments by shimming under one or more of the solid mounts Use isolators for instruments radiators etc attached to the top of the subbase to prevent damage caused by the vibrations that are transferred through the solid ...

Page 176: ... application However you still have to be prepared to furnish them the necessary information as follows 1 Name and description of the application and usage anticipated This includes a Stationary or mobile b On or off highway c Engine model d Number of cylinders e Four cycle f RPM of operation including idle speed g Configuration h Firing order i Crankshaft arrangement j HP and torque 2 Total weigh...

Page 177: ...eight and the CG Some mount manufacturers include safety factors up to three times the mount load rating to allow for forces due to engine torque and rugged terrain so weight only is normally sufficient to use for this calculation However if the power package will be subject to low gear high torque operation then the force due to torque must be added Consult the manufacturer to be sure 3 Refer to ...

Page 178: ...olation efficiency or 0 8 is acceptable 2 Determine transmissibility T T 1 0 I In this case T 1 0 0 8 0 2 3 Determine Fn by the following formula 4 With this Fn determine spring rate needed K from the formula where M W g W g weight at the mount point gravitational constant 5 Refer to the catalog for the desired mount that has that spring rate or close to it Recheck its suitability by repeating the...

Page 179: ... that the space between the mount and structure is enough to prevent shorting of the isolator 3 Ensure that there are no sound shorts direct contact of the engine with other components brackets pipes etc which are rigidly attached to the frame applications 4 For mounting systems other than three point the load at each mount should be balanced or adjusted to prevent excessive loads at the mountings...

Page 180: ...distance of rear mounts to achieve a zero bending moment at the rear of the cylinder block Figure 11 4 Distance of Rear Mounts for Zero Bending Moments 11 10 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 181: ...ne the bending moment at the rear of the cylinder block when engine mount locations are fixed Figure 11 5 Bending Moment for Fixed Mounting System All information subject to change without notice Rev 03 06 11 11 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 183: ...TION AND INSTALLATION 12 TORSIONAL ANALYSIS Section Page 12 1 OVERVIEW 12 2 12 2 MASS ELASTIC 12 2 All information subject to change without notice Rev 03 06 12 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 184: ...ow for all possible engine flywheel damper pulley combinations The forms to request a torsional analysis may be found at the end of this chapter 12 2 MASS ELASTIC MBE4000 specific mass elastic data is available This data can be requested from DDC for special use Mass elastic system data is confidential and must be handled with care To request this information contact DDC Application Engineering 12...

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Page 189: ...3 2 13 2 DDEC ECU ENGINE RESIDENT CONTROL UNIT 13 3 13 3 VEHICLE CONTROL UNIT ON HIGHWAY 13 4 13 4 VEHICLE INTERFACE HARNESS 13 6 13 5 ENGINE HARNESS 13 7 13 6 SYSTEM SENSORS 13 8 All information subject to change without notice Rev 03 06 13 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 190: ...e J1587 and J1939 Data Links where it can be read by minidiag2 The vehicle control system module is the Vehicle Control Unit DDEC VCU The harnesses connect the electronic control units to sensors and switches injectors and miscellaneous application devices like throttle controls instrument panel gages and lights For additional and in depth information about DDEC for MBE 900 and MBE4000 refer to DD...

Page 191: ...gure 13 1 DDEC ECU Control Unit on Engine The DDEC ECU processes the data received from the Vehicle Control Unit DDEC VCU for engine control management The data is then compared to the parameters stored in the DDEC ECU From these data quantity and timing of injection are calculated and the unit pumps are actuated accordingly through the solenoid valves All information subject to change without not...

Page 192: ...onment The mounting bracket is the responsibility of the OEM There must be maximum physical separation of the vehicle Interface harness VIH from other vehicle electrical systems Other electrical system wires should ideally be at least three feet away from the VIH and should not be parallel to the VIH This will eliminate coupling electromagnetic energy from other systems into the VIH 13 4 All infor...

Page 193: ...ning speed and speed limitation The DDEC VCU receives data from the operator accelerator pedal position switches various sensors and other electronic control units for example the anti lock brake system transmission controllers From this data instructions are computed for controlling the engine and transmitted to the DDEC ECU via the proprietary datalink All information subject to change without n...

Page 194: ...les The VIH must be completely detachable from the engine and all devices it connects to with locking weather proof connectors A schematic of a on highway VIH is shown in the following illustration see see Figure 13 4 Figure 13 4 Typical MBE4000 Vehicle Interface Harness 13 6 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 195: ...ess EH facilitates the communication of engine sensor input to the DDEC ECU Figure 13 5 for the EGR engine Figure 13 5 A Typical MBE4000 EGR Engine Harness All information subject to change without notice Rev 03 06 13 7 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 196: ...or locations on the MBE4000 engine 1 Intake Air Pressure Temperature Sensor 5 Engine Coolant Temperature Sensor 2 EGR Temperature Sensor 6 Barometric Pressure Sensor integrated into DDEC ECU 3 Camshaft Position Sensor on camshaft 7 Supply Fuel Temperature Sensor 4 Crankshaft Position Sensor 8 Engine Oil Pressure Temperature Sensor Figure 13 6 Sensor Location on the MBE4000 EGR Engine 13 8 All info...

Page 197: ...de of the charge air manifold behind the 2 cylinder head The Engine Oil Pressure Temperature Sensor is located at the base of the oil filter See Figure 13 6 for sensor locations on the MBE4000 engine NOTE The Engine Oil Level Sensor if used is located at the bottom of the oil pan All information subject to change without notice Rev 03 06 13 9 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 198: ...ENGINE ELECTRONIC CONTROLS THIS PAGE INTENTIONALLY LEFT BLANK 13 10 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 199: ...ND INSTALLATION 14 TECHNICAL DATA This information is available by contacting DDC Application Engineering All information subject to change without notice Rev 03 06 14 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 201: ...NSTALLATION 15 INSTALLATION DRAWINGS This information is available by contacting DDC Application Engineering All information subject to change without notice Rev 03 06 15 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 203: ...N AND INSTALLATION 16 OPTIONS This information is available by contacting DDC Application Engineering All information subject to change without notice Rev 03 06 16 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 205: ...VIRONMENTAL CONDITIONS Section Page 17 1 OVERVIEW 17 2 17 2 AIR INLET TEMPERATURE 17 2 17 3 EXHAUST BACK PRESSURE 17 3 17 4 ALTITUDE 17 3 All information subject to change without notice Rev 03 06 17 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 206: ...uel inlet restrictions fuel temperature and barometric pressure within the range of normal operational conditions 17 2 AIR INLET TEMPERATURE High inlet air temperature to the engine can cause loss of power and heat problems with the cooling system the lubricating oil and hydraulic oil systems This may be either due to high ambient temperatures or because the engine is being used inside a building ...

Page 207: ...k Pressure on Engine Power 17 4 ALTITUDE The loss of power is not normally important at altitudes of less than 150 m 500 ft above sea level The degree of power loss at higher altitudes is determined by the altitude and the fuel injection specification needed All information subject to change without notice Rev 03 06 17 3 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 208: ...EFFECTS OF ENVIRONMENTAL CONDITIONS THIS PAGE INTENTIONALLY LEFT BLANK 17 4 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 209: ...Section Page 18 1 OVERVIEW 18 2 18 2 CONSTANT THROTTLE VALVES WITH EXHAUST BRAKE 18 2 18 3 CONSTANT THROTTLE VALVES WITH TURBOBRAKE OPTIONAL 18 2 All information subject to change without notice Rev 03 06 18 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 210: ... oil pressure The exhaust brake is a pneumatically actuated butterfly valve located in the exhaust system downstream of the turbo It restricts the flow of exhaust gases out of the engine As a result pressure builds up in the exhaust system When the piston tries to expel gases from the cylinder during the exhaust stroke it now has to push against that pressure which absorbs horsepower When the brak...

Page 211: ...00 APPLICATION AND INSTALLATION Figure 18 1 Turbobrake Figure 18 2 Turbo Brake Off and On All information subject to change without notice Rev 03 06 18 3 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 213: ...STALLATION 19 ACCESSORY DRIVES Section Page 19 1 FEPTO ACCESSORY DRIVES 19 2 19 2 REPTO ACCESSORY DRIVES 19 3 All information subject to change without notice Rev 03 06 19 1 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 214: ... ft 854 N m 240 HP 179 kw Table 19 1 FEPTO Accessory Drive Limits NOTE The values listed are the maximum available at three degrees of shaft angle Any increase in the shaft angle has a direct negative effect on the available torque and horse power as well as the shaft life Installations using FEPTO drives require prior approval from Detroit Diesel Application Engineering Figure 19 1 Front Engine P...

Page 215: ...sition 1 243 CCW Spicer Compact 2000 or Elbe Series 0 100 95 3 75 Continuous 370 lb ft 500 N m Intermittent 531 lb ft 720 Nm 6 Only available on SAE 1 Flywheel Housing Table 19 2 REPTO Accessory Drives The REPTO is driven by the camshaft gear and is an integral part of a special SAE 1 flywheel housing All REPTO installations will require a torsional damper coupling installed at the flange of the d...

Page 216: ... DRIVES Figure 19 3 Typical MBE4000 REPTO Configuration Figure 19 4 REPTO Torsional Coupling 19 4 All information subject to change without notice Rev 03 06 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 217: ...ion for engines equipped with REPTO drives does not change See Figure 19 5 and Figure 19 6 Figure 19 5 REPTO Rear View Figure 19 6 REPTO Left Side View All information subject to change without notice Rev 03 06 19 5 7SA250 0603 Copyright 2006 DETROIT DIESEL CORPORATION ...

Page 218: ...analysis must include everything listed in Table 19 3 Cardan Shaft Driven Unit Name of manufacturer Name of manufacturer Make Make Model number or name Model number or name Stiffness deg lb ft Description of unit Inertia lb ft Moment of inertia in lb sec2 Length flange to flange Rated speed Shaft Drawing Continuous torque Peak Torque Horsepower Torsional coupling location Flange Drawing Table 19 3...

Page 219: ...r Minute Hg Mercury HP Horsepower I D Inner Diameter ITT Integral Top Tank JW Jacket Water JWC Jacket Water Cooled lb Pound mm Millimeters N m Newton meter NOx Oxides of Nitrogen OEM Original Equipment Manufacturer PTO Power Take off PWM Pulse Width Modulator REPTO Rear Engine Power Take off RFB Rear Face of Block RPM Revolutions per Minute SAE Society of Automotive Engineers SCA Supplemental Cool...

Page 221: ...r core is returned to the front of the core Either condition hinders cooling capability Air to Boil Temperature ATB The ambient temperature at which engine coolant out temperature reaches 212 F Air to Water Temperature ATW The differential between engine coolant out and ambient temperatures Ambient Temperature The environmental air temperature in which the unit operates Bleed Line s Line s strateg...

Page 222: ...ure approved by the engine manufacturer Coolant Flow Rate The rate of coolant flow through the cooling system and or radiator Coolant Recovery Bottle An add on coolant reserve tank that is used when radiator top tank and or remote deaeration tank can not be sized large enough to meet cooling system drawdown requirements Also known as an overflow bottle Cooling System A group of inter related compo...

Page 223: ...to the environment Fan Air Flow The rate of air flow that a fan can deliver at a given speed and static pressure Fill Line Used to rout coolant from the deaeration tank to the inlet of the water pump It is also called a shunt or make up line Fill Rate The coolant flow rate at which an empty cooling system can be completely filled without overflowing Heat Dissipation The amount of heat energy Btu t...

Page 224: ... neutralize acid using a laboratory test ASTM D 2896 or D 4739 TBN is important to deposit control in four stroke four cycle diesel engines and to neutralize the effects of high sulfur fuel in all diesel engines Temperature Stability or Drift The ability of the cooling system to maintain coolant temperature at light loads and or engine speed or long vehicle drift coasting An important system chara...

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Detroit Diesel MBE4000, Application And Installation Manual

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