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Detroit MBE 4000 Engine Application & Installation Manual

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Covers: Detroit MBE 4000 Engines Application and Installation
Pages: 226
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This manual discusses the proper application and installation of the Detroit Diesel MBE 4000 engine.

The following is a list of topics covered in the MBE 4000 Application and Installation Manual:

TABLE OF CONTENTS
1 INTRODUCTION
2 SAFETY PRECAUTIONS
2.1 STANDS
2.2 GLASSES
2.3 WELDING
2.4 WORK PLACE
2.5 CLOTHING
2.6 ELECTRIC TOOLS
2.7 AIR
2.8 FLUIDS AND PRESSURE
2.9 BATTERIES
2.10 FIRE
2.11 FLUOROELASTOMER
3 ENGINE AND ACCESSORY IDENTIFICATION
3.1 ENGINE DESCRIPTION
3.2 MAJOR COMPONENT LOCATIONS FOR MBE4000 EGR ENGINES
3.3 ENGINE IDENTIFICATION
3.4 EMISSION LABEL
4 AIR INLET SYSTEM
4.1 AIR INLET SYSTEM DESCRIPTION
4.1.1 MBE4000 ON-HIGHWAY ENGINES
4.1.2 ENGINE AIR INLET CONNECTION FOR MBE EGR ENGINES
4.2 INSTALLATION REQUIREMENTS
4.2.1 DRY PAPER ELEMENT AIR CLEANERS
MEDIUM-DUTY USE AIR CLEANER
HEAVY-DUTY USE AIR CLEANER
EXTRA HEAVY-DUTY USE
FOAM TYPE AIR CLEANERS .
OIL BATH AIR CLEANERS
AUXILIARY PRECLEANERS .
INLET SCREENS
RAIN CAPS AND INLET HOODS
WATER DRAINS
INLET SILENCERS
AIR CLEANER SELECTION
4.2.2 RESTRICTION INDICATOR
4.2.3 PIPEWORK
PIPEWORK MATERIAL SPECIFICATIONS
DIFFUSERS
4.2.4 HOSE CONNECTIONS
4.3 DESIGN GUIDELINES
4.3.1 MAXIMUM AIR INLET FLOW
4.3.2 AIR INLET SYSTEM RESTRICTION
4.3.3 INLET LOCATION
4.3.4 CHARGE AIR COOLER
RESTRICTION AND TEMPERATURE REQUIREMENTS
CLEANLINESS
LEAKAGE
SIZE
COOLING AIR FLOW RESTRICTION
MATERIAL
HEADER TANKS .
LOCATION
FAN SYSTEMS
SHUTTERS
WINTERFRONTS
4.4 TESTING REQUIREMENTS
4.4.1 INSTRUMENTATION
TEMPERATURE MEASUREMENT
PRESSURE MEASUREMENT
LOCATION
4.4.2 INLET SYSTEM RESTRICTION
4.4.3 MAXIMUM TEMPERATURE RISE–AMBIENT TO TURBOCHARGER INLET
4.4.4 AIR-TO-AIR SYSTEM EVALUATION TESTS
MAXIMUM TEMPERATURE RISE–AMBIENT TO INTAKE MANIFOLD
CHARGE AIR COOLER SYSTEM RESTRICTION
4.5 TEST
5 EXHAUST SYSTEM
5.1 EXHAUST SYSTEM DESCRIPTION
5.1.1 TURBOCHARGER
5.2 INSTALLATION REQUIREMENTS
5.2.1 BACK PRESSURE
5.2.2 NOISE
5.2.3 FLEXIBLE FITTINGS
5.2.4 MATERIAL SPECIFICATIONS FOR PIPEWORK
5.2.5 MANIFOLDING OF ENGINES INTO A COMMON EXHAUST SYSTEM
5.3 DESIGN REQUIREMENTS
5.3.1 OUTLET LOCATION
5.3.2 DRAINAGE
5.3.3 MUFFLER LOCATION
5.3.4 SYSTEM INSULATION
5.4 TESTING REQUIREMENTS
5.4.1 MEASUREMENT OF EXHAUST BACK PRESSURE
5.4.2 MEASUREMENT OF EXHAUST TEMPERATURE
6 EXHAUST GAS RECIRCULATION
6.1 SYSTEM DESCRIPTION
6.2 EGR COOLER

6.3 EGR CONTROL VALVES
6.4 REED VALVES
6.5 EGR MIXER
7 COOLING SYSTEM
7.1 COOLING SYSTEM DESCRIPTION
7.2 JACKET WATER COOLING SYSTEM
7.3 THERMOSTAT
7.3.1 ENGINE VENTING .
7.4 WATER PUMP
7.5 TYPES OF COOLING SYSTEMS
7.5.1 RAPID WARM-UP COOLING SYSTEM
7.5.2 CONVENTIONAL COOLING SYSTEM
7.5.3 AUXILIARY AIR-COOLED COOLER CORES
7.5.4 COOLANT HEATERS
7.6 AIR-TO-AIR CHARGE COOLING
7.6.1 CHARGE AIR COOLER
7.7 COOLING SYSTEM PERFORMANCE REQUIREMENTS
7.7.1 SYSTEM FILL
7.7.2 SYSTEM DRAIN
7.7.3 DEAERATION
7.7.4 SYSTEM COOLANT CAPACITY
7.7.5 DRAWDOWN CAPACITY
7.7.6 CORE CONSTRUCTION
7.7.7 WATER PUMP INLET PRESSURE/MAXIMUM STATIC HEAD
7.7.8 COOLANT FLOW RATE/EXTERNAL PRESSURE DROP
7.7.9 MINIMUM COOLANT TEMPERATURE .
7.7.10 SYSTEM PRESSURIZATION
7.7.11 COOLANTS
7.8 CHARGE AIR COOLING REQUIREMENTS
7.8.1 COOLING CAPABILITY
7.8.2 MAXIMUM PRESSURE LOSS
7.8.3 CLEANLINESS
7.8.4 LEAKAGE
7.9 END PRODUCT QUESTIONNAIRE
7.10 COOLING SYSTEM DESIGN CONSIDERATIONS
7.10.1 COOLING SYSTEM REQUIREMENTS
ENGINE OPERATING TEMPERATURE
7.10.2 ENGINE PERFORMANCE
ENGINE HEAT REJECTION
COOLANT FLOW
HEAT TRANSFER CAPABILITIES
7.10.3 ENVIRONMENTAL AND OPERATING CONDITIONS .
AMBIENT TEMPERATURE
ALTITUDE
SPACE CONSTRAINTS
NOISE LIMITS

TILT OPERATIONS OR INSTALLATIONS
7.10.4 SYSTEM COMPONENT
ADDITIONAL HEAT LOADS TO COOLANT
ADDITIONAL HEAT LOADS TO AIR .
COOLANT TYPE
PLUMBING .
AUXILIARY COOLANT FLOW PATH CIRCUITRY
WATER PUMPS
7.11 CHARGE AIR COOLING DESIGN GUIDELINES
7.11.1 SIZE
7.11.2 COOLING AIR FLOW RESTRICTION
7.11.3 MATERIAL
7.11.4 HEADER TANKS
7.11.5 LOCATION
7.11.6 PIPEWORK
7.12 HEAT EXCHANGER SELECTION
7.13 FAN SYSTEM RECOMMENDATIONS AND FAN SELECTION
7.13.1 BLOWER VS SUCTION FANS
FAN PERFORMANCE
FAN POSITION
FAN SHROUDS
FAN SYSTEM ASSEMBLIES
FAN DRIVES .
BAFFLES TO PREVENT AIR RECIRCULATION
SHUTTERS
WINTERFRONTS
7.14 RADIATOR COMPONENT DESIGN
7.14.1 DOWN FLOW AND CROSS FLOW RADIATORS
HORIZONTAL RADIATOR
RAPID WARM-UP DEAERATION TANK – DOWN FLOW RADIATOR
REMOTE MOUNTED RADIATORS/HEAT EXCHANGER
INTEGRAL TOP TANK
REMOTE TANK
RADIATOR BOTTOM TANK
COOLANT PRESSURE CONTROL CAPS AND RELIEF VALVES
THERMOSTAT
COOLANT SENSOR DEVICES
COOLANT RECOVERY SYSTEM
7.14.2 COLD WEATHER OPERATING OPTIMIZATION
ENGINE
VEHICLE
COOLING SYSTEM
HEATER CIRCUIT
7.14.3 COOLANT HEATERS
7.14.4 MULTI-DUTY CYCLE
7.14.5 OTHER CONSIDERATIONS
7.15 DIAGNOSTICS AND TROUBLESHOOTING

7.15.1 ENGINE OVERHEAT .
TROUBLESHOOTING FOR ENGINE OVERHEAT
7.15.2 COLD RUNNING ENGINE (OVERCOOLING) .
7.15.3 POOR CAB HEATER PERFORMANCE
7.16 MAINTENANCE
8 FUEL SYSTEM
8.1 FUEL SYSTEM DESCRIPTION
8.2 FUEL SYSTEM EQUIPMENT/INSTALLATION GUIDELINES
8.2.1 FUEL TANK
MATERIAL
DESIGN
CAPACITY
POSITION
8.2.2 FUEL FILTER CONFIGURATION
8.2.3 FUEL LINES
DESIGN
MATERIAL
SIZE
8.2.4 OPTIONAL DEVICES
FUEL COOLER
FUEL WATER SEPARATOR
8.3 FUEL SELECTION
9 LUBRICATION SYSTEM
9.1 LUBRICATION SYSTEM DESCRIPTION
9.2 LUBRICATION OIL SELECTION
9.3 LUBRICATION FILTER
9.4 ENGINE COMPONENT OIL SUPPLY REQUIREMENTS
9.4.1 TURBOCHARGER LUBRICATION
9.4.2 AIR COMPRESSOR LUBRICATION
9.5 INSTALLATION REQUIREMENTS
9.5.1 SUPPLEMENTAL FILTRATION SYSTEMS
REMOTE MOUNT SUPPLEMENTAL OIL FILTERS
9.5.2 OIL SAMPLING VALVE
9.5.3 MECHANICAL OIL PRESSURE GAUGES
9.6 COMPONENT OPTIONS
9.6.1 OIL CHECKS AND FILLS
9.6.2 OIL SUMPS
INSTALLATION REQUIREMENTS FOR OIL SUMPS
9.6.3 OIL IMMERSION HEATERS
9.6.4 ENGINE OIL LEVEL SENSOR
9.7 OPERATION AND MAINTENANCE
9.7.1 FIRST TIME START
9.7.2 OIL LEVEL MEASUREMENTS .
9.7.3 USED OIL ANALYSIS
9.7.4 OIL DRAIN INTERVALS
9.8 OIL FILTER CONFIGURATION

9.9 OIL CENTRIFUGE
10 ELECTRICAL SYSTEM
10.1 ELECTRICAL SYSTEM DESCRIPTION
10.2 INSTALLATION GUIDELINES
10.2.1 BATTERY
FILLER CAP BATTERIES
SEMI-MAINTENANCE FREE BATTERIES
MAINTENANCE-FREE BATTERIES
DEEP CYCLE BATTERIES
BATTERY CAPACITY
BATTERY MOUNTING AND LOCATION
10.2.2 CRANKING MOTOR
10.2.3 ALTERNATOR
ALTERNATOR MOUNTING
10.2.4 GROUNDING REQUIREMENTS
10.2.5 WIRING
GUIDELINES FOR ELECTRICAL WIRING
CABLE LOSS TEST PROCEDURE
MEASURING CIRCUIT RESISTANCE
CALCULATING CIRCUIT RESISTANCE
11 MOUNTING SYSTEM
11.1 MOUNTING SYSTEM DESCRIPTION
11.1.1 THREE-POINT MOUNTING
11.1.2 FOUR-POINT MOUNTING
11.2 SOLID MOUNTING SYSTEMS
11.3 FLEXIBLE MOUNTING SYSTEMS
11.3.1 FLEXIBLE MOUNT SELECTION
11.4 INSTALLATION CHECK LIST
11.5 ENGINE SUPPORT
12 TORSIONAL ANALYSIS
12.1 OVERVIEW
12.2 MASS ELASTIC
13 ENGINE ELECTRONIC CONTROLS
13.1 OVERVIEW
13.2 DDEC-ECU – ENGINE-RESIDENT CONTROL UNIT
13.3 VEHICLE CONTROL UNIT — ON-HIGHWAY
13.4 VEHICLE INTERFACE HARNESS
13.5 ENGINE HARNESS
13.6 SYSTEM SENSORS
14 TECHNICAL DATA
15 INSTALLATION DRAWINGS

16 OPTIONS
17 EFFECTS OF ENVIRONMENTAL CONDITIONS
17.1 OVERVIEW .
17.2 AIR INLET TEMPERATURE
17.3 EXHAUST BACK PRESSURE
17.4 ALTITUDE
18 ENGINE BRAKE SYSTEMS
18.1 OVERVIEW
18.2 CONSTANT-THROTTLE VALVES WITH EXHAUST BRAKE
18.3 CONSTANT-THROTTLE VALVES WITH TURBOBRAKE (OPTIONAL)
19 ACCESSORY DRIVES
19.1 FEPTO ACCESSORY DRIVES
19.2 REPTO ACCESSORY DRIVES
APPENDIX A: ABBREVIATIONS / ACRONYMS
GLOSSARY
INDEX

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