Detroit Diesel MBE4000 Guida utente

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

TABLEOFCONTENTS

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

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

TABLEOFCONTENTS

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)

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