Detroit Diesel MBE4000 Application And Installation Manual

ATTENTION

This document is a guideline for qualiﬁedpersonnel. Itisintendedtobeusedbyequipment

manufacturers and contains Detroit Diesel Corporation's preliminary recommendations for the

ancillary systems supporting the Detroit Diesel engines covered by this document. the equipment

manufacturer is responsible for 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 or distribution to equipment users. The

information in this manual is incomplete and is subject to change without notice.

MBE4000 APPLICATION AND INSTALLATION

ABSTRACT

This manual discusses the proper application and installation of the Detroit Diesel MBE4000

engine. This manual 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

ABSTRACT

ii All information subject to change without notice. (Rev. 03/06)

MBE4000 APPLICATION AND INSTALLATION

TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................................. 1- 1

2 SAFETY PRECAUTIONS ................................................................................................... 2- 1

2.1 STANDS .......................................................................................................................... 2- 1

2.2 GLASSES ....................................................................................................................... 2- 1

2.3 WELDING ....................................................................................................................... 2- 2

2.4 WORK PLACE ............................................................................................................... 2- 3

2.5 CLOTHING ...................................................................................................................... 2- 4

2.6 ELECTRIC TOOLS ......................................................................................................... 2- 4

2.7 AIR .................................................................................................................................. 2- 5

2.8 FLUIDS AND PRESSURE .............................................................................................. 2- 5

2.9 BATTERIES ....................................................................................................................2-6

2.10 FIRE ................................................................................................................................ 2- 6

2.11 FLUOROELASTOMER .................................................................................................. 2- 7

3 ENGINE AND ACCESSORY IDENTIFICATION ................................................................ 3- 1

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

4 AIR INLET SYSTEM ........................................................................................................... 4- 1

4.1 AIR INLET SYSTEM DESCRIPTION .............................................................................. 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 DRAINS ................................................................................................... 4-10

INLET SILENCERS .............................................................................................. 4-10

AIR CLEANER SELECTION ................................................................................ 4-11

4.2.2 RESTRICTION INDICATOR ....................................................................................... 4-11

4.2.3 PIPEWORK ................................................................................................................ 4-13

PIPEWORK MATERIAL SPECIFICATIONS ......................................................... 4-13

DIFFUSERS ......................................................................................................... 4-13

4.2.4 HOSE CONNECTIONS .............................................................................................. 4-14

4.3 DESIGN GUIDELINES .................................................................................................... 4-14

All information subject to change without notice. (Rev. 03/06) iii

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4.3.1 MAXIMUM AIR INLET FLOW .................................................................................... 4-15

4.3.2 AIR INLET SYSTEM RESTRICTION ......................................................................... 4-15

4.3.3 INLET LOCATION ...................................................................................................... 4-15

4.3.4 CHARGE AIR COOLER ............................................................................................ 4-16

RESTRICTION AND TEMPERATURE REQUIREMENTS ................................... 4-16

CLEANLINESS ..................................................................................................... 4-17

LEAKAGE ............................................................................................................. 4-17

SIZE ...................................................................................................................... 4-17

COOLING AIR FLOW RESTRICTION ................................................................. 4-17

MATERIAL ............................................................................................................ 4-18

HEADER TANKS .................................................................................................. 4-18

LOCATION ............................................................................................................ 4-18

FAN SYSTEMS ..................................................................................................... 4-18

SHUTTERS .......................................................................................................... 4-18

WINTERFRONTS ................................................................................................. 4-19

4.4 TESTING REQUIREMENTS ........................................................................................... 4-19

4.4.1 INSTRUMENTATION .................................................................................................. 4-19

TEMPERATURE MEASUREMENT ...................................................................... 4-19

PRESSURE MEASUREMENT ............................................................................. 4-20

LOCATION ............................................................................................................ 4-23

4.4.2 INLET SYSTEM RESTRICTION ................................................................................ 4-23

4.4.3 MAXIMUM TEMPERATURE RISE--AMBIENT TO TURBOCHARGER INLET .......... 4-24

4.4.4 AIR-TO-AIR SYSTEM EVALUATION TESTS ............................................................. 4-24

MAXIMUM 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

5.3 DESIGN REQUIREMENTS ........................................................................................... 5- 7

5.3.1 OUTLET LOCATION .................................................................................................. 5- 7

5.3.2 DRAINAGE ................................................................................................................. 5-7

5.3.3 MUFFLER LOCATION ................................................................................................ 5- 8

5.3.4 SYSTEM INSULATION ............................................................................................... 5- 8

5.4 TESTING REQUIREMENTS ........................................................................................... 5- 8

5.4.1 MEASUREMENT OF EXHAUST BACK PRESSURE ................................................ 5- 9

5.4.2 MEASUREMENT OF EXHAUST TEMPERATURE .................................................... 5-10

6 EXHAUST GAS RECIRCULATION .................................................................................... 6- 1

6.1 SYSTEM DESCRIPTION ................................................................................................ 6- 3

6.2 EGR COOLER ................................................................................................................ 6- 4

iv All information subject to change without notice. (Rev. 03/06)

MBE4000 APPLICATION AND INSTALLATION

6.3 EGR CONTROL VALVES ............................................................................................... 6- 5

6.4 REED VALVES ................................................................................................................ 6- 5

6.5 EGR MIXER .................................................................................................................... 6- 5

7 COOLING SYSTEM ........................................................................................................... 7- 1

7.1 COOLING SYSTEM DESCRIPTION .............................................................................. 7- 3

7.2 JACKET WATER COOLING SYSTEM ........................................................................... 7- 3

7.3 THERMOSTAT ................................................................................................................ 7- 7

7.3.1 ENGINE VENTING .................................................................................................... 7- 8

7.4 WATER PUMP ............................................................................................................... 7- 8

7.5 TYPES OF COOLING SYSTEMS ................................................................................... 7- 8

7.5.1 RAPID WARM-UP COOLING SYSTEM .................................................................... 7- 8

7.5.2 CONVENTIONAL COOLING SYSTEM ...................................................................... 7-10

7.5.3 AUXILIARY AIR-COOLED COOLER CORES ............................................................ 7-10

7.5.4 COOLANT HEATERS ................................................................................................. 7-10

7.6 AIR-TO-AIR CHARGE COOLING ................................................................................... 7-11

7.6.1 CHARGE AIR COOLER ............................................................................................. 7-12

7.7 COOLING SYSTEM PERFORMANCE REQUIREMENTS ............................................. 7-13

7.7.1 SYSTEM FILL ............................................................................................................. 7-13

7.7.2 SYSTEM DRAIN ......................................................................................................... 7-13

7.7.3 DEAERATION ............................................................................................................. 7-13

7.7.4 SYSTEM COOLANT CAPACITY ................................................................................ 7-14

7.7.5 DRAWDOWN CAPACITY ........................................................................................... 7-15

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 QUESTIONNAIRE ............................................................................... 7-17

7.10 COOLING SYSTEM DESIGN CONSIDERATIONS ........................................................ 7-17

7.10.1 COOLING SYSTEM REQUIREMENTS ..................................................................... 7-17

ENGINE OPERATING TEMPERATURE .............................................................. 7-17

7.10.2 ENGINE PERFORMANCE ......................................................................................... 7-18

ENGINE HEAT REJECTION ................................................................................ 7-18

COOLANT FLOW ................................................................................................. 7-18

HEAT TRANSFER CAPABILITIES ....................................................................... 7-18

7.10.3 ENVIRONMENTAL AND OPERATING CONDITIONS ............................................... 7-19

AMBIENT TEMPERATURE .................................................................................. 7-19

ALTITUDE ............................................................................................................. 7-20

SPACE CONSTRAINTS ....................................................................................... 7-20

NOISE LIMITS ...................................................................................................... 7-20

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TILT OPERATIONS OR INSTALLATIONS ........................................................... 7-20

7.10.4 SYSTEM COMPONENTS .......................................................................................... 7-20

ADDITIONAL HEAT LOADS TO COOLANT ........................................................ 7-20

ADDITIONAL HEAT LOADS TO AIR .................................................................... 7-21

COOLANT TYPE .................................................................................................. 7-21

PLUMBING .......................................................................................................... 7-21

AUXILIARY COOLANT FLOW PATH CIRCUITRY ............................................... 7-22

WATER PUMPS ................................................................................................... 7-23

7.11 CHARGE AIR COOLING DESIGN GUIDELINES ........................................................... 7-24

7.11.1 SIZE ............................................................................................................................ 7-24

7.11.2 COOLING AIR FLOW RESTRICTION ....................................................................... 7-24

7.11.3 MATERIAL ..................................................................................................................7-24

7.11.4 HEADER TANKS ........................................................................................................ 7-25

7.11.5 LOCATION ..................................................................................................................7-25

7.11.6 PIPEWORK ................................................................................................................ 7-25

7.12 HEAT EXCHANGER SELECTION .................................................................................. 7-26

7.13 FAN SYSTEM RECOMMENDATIONS AND FAN SELECTION ..................................... 7-27

7.13.1 BLOWER VS SUCTION FANS ................................................................................... 7-28

FAN PERFORMANCE .......................................................................................... 7-29

FAN POSITION ..................................................................................................... 7-31

FAN SHROUDS .................................................................................................... 7-32

FAN SYSTEM ASSEMBLIES ............................................................................... 7-32

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 RELIEF VALVES ...................... 7-42

THERMOSTAT ..................................................................................................... 7-44

COOLANT SENSOR DEVICES ........................................................................... 7-44

COOLANT RECOVERY SYSTEM ....................................................................... 7-46

7.14.2 COLD WEATHER OPERATING OPTIMIZATION ....................................................... 7-51

ENGINE ................................................................................................................ 7-51

VEHICLE .............................................................................................................. 7-51

COOLING SYSTEM ............................................................................................. 7-51

HEATER CIRCUIT ................................................................................................ 7-52

7.14.3 COOLANT HEATERS ................................................................................................. 7-52

7.14.4 MULTI-DUTY CYCLE ................................................................................................. 7-52

7.14.5 OTHER CONSIDERATIONS ...................................................................................... 7-52

7.15 DIAGNOSTICS AND TROUBLESHOOTING .................................................................. 7-53

vi All information subject to change without notice. (Rev. 03/06)

MBE4000 APPLICATION AND INSTALLATION

7.15.1 ENGINE OVERHEAT ................................................................................................. 7-53

TROUBLESHOOTING FOR ENGINE OVERHEAT .............................................. 7-53

7.15.2 COLD RUNNING ENGINE (OVERCOOLING) ........................................................... 7-55

7.15.3 POOR CAB HEATER PERFORMANCE .................................................................... 7-55

7.16 MAINTENANCE .............................................................................................................. 7-57

8 FUEL SYSTEM ................................................................................................................... 8- 1

8.1 FUEL SYSTEM DESCRIPTION ...................................................................................... 8- 3

8.2 FUEL SYSTEM EQUIPMENT/INSTALLATION GUIDELINES ........................................ 8- 5

8.2.1 FUEL TANK ................................................................................................................ 8- 5

MATERIAL ............................................................................................................ 8- 5

DESIGN ................................................................................................................ 8- 5

CAPACITY ............................................................................................................ 8- 6

POSITION ............................................................................................................. 8- 7

8.2.2 FUEL FILTER CONFIGURATION ............................................................................... 8- 8

8.2.3 FUEL LINES ............................................................................................................... 8- 8

DESIGN ................................................................................................................ 8- 8

MATERIAL ............................................................................................................ 8- 9

SIZE ...................................................................................................................... 8- 9

8.2.4 OPTIONAL DEVICES ................................................................................................. 8- 9

FUEL COOLER .................................................................................................... 8- 9

FUEL WATER SEPARATOR ................................................................................ 8- 9

8.3 FUEL SELECTION .......................................................................................................... 8-10

9 LUBRICATION SYSTEM ................................................................................................... 9- 1

9.1 LUBRICATION SYSTEM DESCRIPTION ....................................................................... 9- 3

9.2 LUBRICATION 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 AND FILLS ........................................................................................... 9- 8

9.6.2 OIL SUMPS ................................................................................................................ 9- 8

INSTALLATION REQUIREMENTS FOR OIL SUMPS ......................................... 9- 8

9.6.3 OIL IMMERSION HEATERS ...................................................................................... 9- 9

9.6.4 ENGINE OIL LEVEL SENSOR ................................................................................... 9- 9

9.7 OPERATION AND MAINTENANCE ............................................................................... 9-10

9.7.1 FIRST TIME START ................................................................................................... 9-10

9.7.2 OIL LEVEL MEASUREMENTS .................................................................................. 9-10

9.7.3 USED OIL ANALYSIS ................................................................................................. 9-10

9.7.4 OIL DRAIN INTERVALS ............................................................................................. 9-10

9.8 OIL FILTER CONFIGURATION ...................................................................................... 9-10

All information subject to change without notice. (Rev. 03/06) vii

TABLEOFCONTENTS

9.9 OIL CENTRIFUGE .......................................................................................................... 9-10

10 ELECTRICAL SYSTEM ...................................................................................................... 10- 1

10.1 ELECTRICAL SYSTEM DESCRIPTION ......................................................................... 10- 2

10.2 INSTALLATION GUIDELINES ........................................................................................ 10- 3

10.2.1 BATTERY ...................................................................................................................10-3

FILLER CAP BATTERIES .................................................................................... 10- 3

SEMI-MAINTENANCE FREE BATTERIES .......................................................... 10- 3

MAINTENANCE-FREE BATTERIES .................................................................... 10- 3

DEEP CYCLE BATTERIES .................................................................................. 10- 3

BATTERY CAPACITY ........................................................................................... 10- 4

BATTERY MOUNTING AND LOCATION ............................................................. 10- 4

10.2.2 CRANKING MOTOR .................................................................................................. 10- 6

10.2.3 ALTERNATOR ............................................................................................................ 10- 7

ALTERNATOR MOUNTING .................................................................................. 10- 9

10.2.4 GROUNDING REQUIREMENTS ............................................................................... 10- 9

10.2.5 WIRING ...................................................................................................................... 10-10

GUIDELINES FOR ELECTRICAL WIRING .......................................................... 10-10

CABLE LOSS TEST PROCEDURE ..................................................................... 10-11

MEASURING CIRCUIT RESISTANCE ................................................................. 10-12

CALCULATING CIRCUIT RESISTANCE ............................................................. 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 .............................................................................................................. 12-2

13 ENGINE ELECTRONIC CONTROLS ................................................................................. 13- 1

13.1 OVERVIEW ..................................................................................................................... 13- 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

14 TECHNICAL DATA ............................................................................................................. 14- 1

15 INSTALLATION DRAWINGS .............................................................................................. 15- 1

viii All information subject to change without notice. (Rev. 03/06)

MBE4000 APPLICATION AND INSTALLATION

16 OPTIONS ............................................................................................................................ 16- 1

17 EFFECTS OF ENVIRONMENTAL CONDITIONS .............................................................. 17- 1

17.1 OVERVIEW ..................................................................................................................... 17- 2

17.2 AIR INLET TEMPERATURE ........................................................................................... 17- 2

17.3 EXHAUST BACK PRESSURE ........................................................................................ 17- 3

17.4 ALTITUDE ....................................................................................................................... 17- 3

18 ENGINE BRAKE 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

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xAll information subject to change without notice. (Rev. 03/06)

MBE4000 APPLICATION AND INSTALLATION

LIST OF FIGURES

Figure 3-1 Typical MBE4000 Engine with EGR .................................................................. 3- 3

Figure 3-2 Right Front View of MBE4000 EGR Engine ...................................................... 3- 4

Figure 3-3 Left Front View of the MBE4000 EGR Engine .................................................. 3- 5

Figure 3-4 Location of Engine Type Plate .......................................................................... 3- 6

Figure 3-5 Engine Type Plate Detail ................................................................................... 3- 6

Figure 3-6 Serial Number ................................................................................................... 3- 7

Figure 3-7 Emission Label .................................................................................................. 3- 8

Figure 4-1 Medium-duty Air Cleaner .................................................................................. 4- 5

Figure 4-2 Heavy-duty Air Cleaner ..................................................................................... 4- 6

Figure 4-3 Extra Heavy-duty Air Cleaner ............................................................................ 4- 7

Figure 4-4 Precleaner Centrifugal Action ........................................................................... 4- 9

Figure 4-5 Rain Cap and Inlet Hood ................................................................................... 4-10

Figure 4-6 Altitude vs. Inlet Restriction .............................................................................. 4-12

Figure 4-7 Diffuser Conﬁgurations ...................................................................................... 4-13

Figure 4-8 Air Inlet System Calculation .............................................................................. 4-15

Figure 4-9 Static Pressure Tap ........................................................................................... 4-20

Figure 4-10 Piezometer Ring ................................................................................................ 4-22

Figure 4-11 Typical Instrumentation Location ....................................................................... 4-23

Figure 4-12 Air Inlet Data Sheet for Air-to-Air Charge Cooled Engine ................................. 4-26

Figure 5-1 Turbocharger Assembly .................................................................................... 5- 4

Figure 5-2 Piezometer Ring ................................................................................................ 5- 9

Figure 5-3 Static Pressure 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

Figure 7-7 Typical Charge Air Cooler ................................................................................. 7-12

Figure 7-8 Percent Increases in Volume for Water and Antifreeze Solution ...................... 7-14

Figure 7-9 Blower vs. Suction Fans ................................................................................... 7-28

Figure 7-10 Fan Shroud Types ............................................................................................. 7-32

Figure 7-11 Down Flow Radiator and Cross Flow Radiator ................................................. 7-34

Figure 7-12 Rapid Warm-up Down Flow Radiator Top Tank ................................................ 7-36

Figure 7-13 Remote Surge Tank Design for Rapid Warm-up Cooling System ..................... 7-39

Figure 7-14 Down Flow Radiator Inlet Tank Deaeration Line Boss Position ........................ 7-40

Figure 7-15 Coolant Inlet/Outlet Locations ........................................................................... 7-41

Figure 7-16 Radiator Outlet Contour .................................................................................... 7-41

Figure 7-17 Pressure Control Cap — Pressure Valve Open ................................................ 7-43

Figure 7-18 Pressure Control Cap — Vacuum Valve Open ................................................. 7-43

All information subject to change without notice. (Rev. 03/06) xi

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Figure 7-19 Nominal Settings For Coolant Temperature Control Devices — 190° ............... 7-45

Figure 7-20 Cooling System Design (Warm-up -- Closed Thermostat) ................................ 7-46

Figure 7-21 Cooling System Design (Stabilized Temperature -- Open Thermostat) ............ 7-47

Figure 7-22 Cooling System Design (Cool-down -- Closed Thermostat) ............................. 7-48

Figure 7-23 Acceptable Top Tank Design ............................................................................. 7-50

Figure 7-24 Unacceptable Top Tank Design ......................................................................... 7-50

Figure 8-1 MBE4000 Fuel System Schematic Diagram ..................................................... 8- 4

Figure 8-2 Properly Designed Fuel Tank ............................................................................ 8- 6

Figure 9-1 Typical MBE4000 Lubrication System Schematic ............................................. 9- 4

Figure 9-2 Typical MBE4000 Lubrication System ............................................................... 9- 5

Figure 9-3 Vertical Oil Filter ................................................................................................ 9- 6

Figure 9-4 Engine Oil Drain Plug, Oil Pan .......................................................................... 9- 6

Figure 10-1 Engine Electrical System .................................................................................. 10- 2

Figure 10-2 Battery Retainers .............................................................................................. 10- 5

Figure 10-3 Typical Cranking Motor Cross-section .............................................................. 10- 7

Figure 10-4 Cable Resistance .............................................................................................. 10-12

Figure 11-1 Three–point Mounting with Rear Bracket ......................................................... 11- 3

Figure 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 Harness .................................................... 13- 6

Figure 13-5 A Typical MBE4000 EGR Engine Harness ....................................................... 13- 7

Figure 13-6 Sensor Location on the MBE4000 EGR Engine ............................................... 13- 8

Figure 17-1 The Effects of Air Inlet Temperature .................................................................. 17- 2

Figure 17-2 The Effects of Exhaust Back Pressure on Engine Power ................................. 17- 3

Figure 18-1 Turbobrake ........................................................................................................ 18- 3

Figure 18-2 Turbo Brake Off and On .................................................................................... 18- 3

Figure 19-1 Front Engine Power Take-off, Left Side View .................................................... 19- 2

Figure 19-2 Front Engine Power Take-off, Front View ......................................................... 19- 3

Figure 19-3 Typical MBE4000 REPTO Conﬁguration .......................................................... 19- 4

Figure 19-4 REPTO Torsional Coupling ............................................................................... 19- 4

Figure 19-5 REPTO Rear View, ........................................................................................... 19- 5

Figure 19-6 REPTO, Left Side View ..................................................................................... 19- 5

xii All information subject to change without notice. (Rev. 03/06)

MBE4000 APPLICATION AND INSTALLATION

LIST OF TABLES

Table 2-1 The Correct Type of Fire Extinguisher ............................................................... 2- 6

Table 4-1 Air Cleaner Applications .................................................................................... 4- 4

Table 4-2 Air Inlet Restriction at Different Altitudes ........................................................... 4-11

Table 4-3 Hose Speciﬁcations for the Inlet Side of the Turbocharger ............................... 4-14

Table 4-4 Thermocouples .................................................................................................. 4-24

Table 4-5 Pressure Taps ................................................................................................... 4-25

Table 7-1 Maximum Engine Coolant Out Temperature ..................................................... 7-13

Table 7-2 Heat Exchanger Materials, Construction, and Design Choices ......................... 7-26

Table 7-3 Installed Fan Performance Factors ................................................................... 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

Table 10-2 Maximum Circuit Resistance ............................................................................. 10-13

Table 19-1 FEPTO Accessory Drive Limits ......................................................................... 19- 2

Table 19-2 REPTO Accessory Drives ................................................................................. 19- 3

Table 19-3 REPTO Installation Analysis Requirements ...................................................... 19- 6

All information subject to change without notice. (Rev. 03/06) xiii

TABLEOFCONTENTS

xiv All information subject to change without notice. (Rev. 03/06)

MBE4000 APPLICATION AND INSTALLATION

1INTRODUCTION

The MBE4000 engine is water-cooled, four-stroke, direct-injection diesel engines. The

six-cylinders are arranged inline. Each has a separate fuel injection pump (unit pump) with a short

injection line to the injection nozzle, which is located in the center of the combustion chamber.

The unit pumps are attached to the crankcase and are driven from the camshaft. Each cylinder

has two intake valves and two exhaust valves.

Charge-air cooling and an exhaust gas turbocharger are standard equipment on all MBE4000

engines.

The engine has a fully electronic control system, which regulates the fuel injection quantity and

timing using solenoid valves, allowing extremely low-emission operation.

Engine braking is controlled by a hydraulically-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 pistons

are cooled by oil spray nozzles.

The crankshaft is precision-forged with seven main bearings and eight custom-forged

counterweights, and a vibration damper at the front end.

The camshaft is made of induction-hardened steel and has seven main bearings. Each cylinder has

cams for intake and exhaust valves and a unit pump.

The valves are controlled by mushroom tappets, pushrods, and rocker arms. The intake valves are

opened and closed by a valve-guided bridge.

All information subject to change without notice. (Rev. 03/06) 1-1

INTRODUCTION

THIS PAGE INTENTIONALLY LEFT BLANK

1-2 All information subject to change without notice. (Rev. 03/06)

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Detroit Diesel MBE4000 Application And Installation Manual

Detroit Diesel MBE4000 Application And Installation Manual

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