Detroit Diesel Epa04 Mbe 4000 Workshop Manual by SharonRemicks

Detroit Diesel Epa04 Mbe 4000 Workshop Manual

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ABSTRACT

ThismanualprovidesinstructionforservicingtheMBE4000DieselEngine.Speciﬁcally,abasic overviewofeachmajorcomponentandthesystem,alongwiththerecommendationsforremoval, cleaning,inspection,criteriaforreplacement,repair,installation,andmechanicaltroubleshooting arecontainedinthismanual.

TRADEMARKINFORMATION

Loctite®isaregisteredtrademarkofHenkelCorporation.Wabco®isaregisteredtrademark ofAmericanStandard,Inc.Hengst®isaregisteredtrademarkofWalterHengstGMBH&Co. Perma-Lok®isaregisteredtrademarkofNationalStarchandChemicalInvestmentHolding Corporation.Henkel®isaregisteredtrademarkofHenkelCorporation.

ENGINEEXHAUST

Considerthefollowingbeforeservicingengines:

PERSONALINJURY

Dieselengineexhaustandsomeofitsconstituentsare knowntotheStateofCaliforniatocausecancer,birth defects,andotherreproductiveharm.

□ Alwaysstartandoperateanengineinawell ventilated area.

□

Ifoperatinganengineinanenclosedarea,ventthe exhausttotheoutside.

□ Donotmodifyortamperwiththeexhaustsystemor emissioncontrolsystem.

MBE4000SERVICEMANUAL

Allinformationsubjecttochangewithoutnotice.

MBE4000SERVICEMANUAL

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MBE4000SERVICEMANUAL TABLEOFCONTENTS GENERALINFORMATION......................................................................1 SCOPEANDUSEOFTHISMANUAL.............. ..................3 GENERALDESCRIPTION........................ ........3 ELECTRONICENGINECONTROLSYSTEM.........................................4 ENGINEBRAKINGPOWER....................................................................7 GENERALSPECIFICATIONSANDENGINEVIEWS.............................7 ENGINEMODELANDSERIALNUMBER......... ................13 EXHAUSTGASRECIRCULATION(EGR)SYSTEM...............................15 SAFETYINSTRUCTIONSANDPRECAUTIONS ....................................19 ENGLISHTOMETRICCONVERSION.............. ................28 DECIMALANDMETRICEQUIVALENTS.......... ................29 TORQUESPECIFICATIONS...................................................................31 1ENGINE 1.1CYLINDERHEADCOVER......................................................................1-3 1.2CYLINDERHEAD....................................................................................1-4 1.3CYLINDERBLOCK................ ................1-22 1.4EGRCYLINDERHEADANDBLOCK............... ................1-44 1.5EGRFRONTANDREARLIFTERBRACKETS.......................................1-47 1.6ENGINEBRAKE......................................................................................1-49 1.7FRONTRADIALSEAL.............. ................1-56 1.8REARRADIALSEAL................ ................1-60 1.9CRANKSHAFTSEALWEARSLEEVE.................................................... 1-63 1.10CRANKSHAFTASSEMBLY.....................................................................1-68 1.11FRONTCOVERHOUSING........ ................1-91 1.12CRANKSHAFTVIBRATIONDAMPER..................... 1-93 1.13FLYWHEEL..............................................................................................1-95 1.14RINGGEAR.............................................................................................1-104 1.15PILOTBEARING.......... .............1-108 1.16ENGINEBARRINGTOOL......................... ...........1-112 1.17FLYWHEELHOUSING............................................................................1-114 1.18PISTON,PISTONRING,ANDCONNECTINGROD............................... 1-116 1.19EGRPISTON,PISTONRING,ANDCONNECTINGROD......................1-140 1.20VALVES................. ..................1-143 1.21EGRVALVES ........................................................................................... 1-162 1.22ROCKERARM.........................................................................................1-167 1.23CAMSHAFTANDCAMSHAFTPOSITIONSENSOR..............................1-171 1.24EGRCAMSHAFT..................................................................................... 1-181 1.AADDITIONALINFORMATION..................................................................1-183 2FUELSYSTEM 2.1INJECTORUNITPUMP........................................................................... 2-3 2.2EGRINJECTORUNITPUMP..................................................................2-15 Allinformationsubjecttochangewithoutnotice. DDC-SVC-MAN-0023 Copyright©2009DETROITDIESELCORPORATION iii

MBE4000SERVICEMANUAL 2.3HIGHPRESSUREFUELLINEANDTRANSFERTUBE.........................2-16 2.4FUELINJECTORNOZZLE......................................................................2-26 2.5EGRFUELINJECTORNOZZLE.............................................................2-34 2.6PROTECTIVESLEEVE........... .........2-35 2.7DDEC-ELECTRONICCONTROLUNIT.......... .........2-39 2.8FUELHEATEXCHANGER......................................................................2-44 2.9FUELFILTER....... .........2-47 2.10FUELFILTERHOUSING......... .........2-50 2.11FUELFILTERBRACKET.........................................................................2-54 2.12FUELPUMP.............................................................................................2-57 2.13FUELPUMPDRIVE.................................................................................2-61 2.14FUELSYSTEMINSPECTION.... .........2-65 2.AADDITIONALINFORMATION..................................................................2-73 3LUBRICATIONSYSTEM 3.1LUBRICATIONSYSTEMDESCRIPTION....... ...................3-3 3.2OILPAN...................................................................................................3-5 3.3PISTONOILSPRAYNOZZLE(S)............................................................3-11 3.4CAMSHAFTLUBRICATIONSPRAYER............ .........3-17 3.5OILPUMPANDSUMPPIPE........ ......3-19 3.6OILFILTER..............................................................................................3-27 3.7OILHEATEXCHANGER/FILTERHOUSING..........................................3-29 3.8OILPRESSURE/TEMPERATURESENSOR.... .........3-34 3.AADDITIONALINFORMATION..... .........3-37 4COOLINGSYSTEM 4.1COOLINGSYSTEM............... ...................4-3 4.2COOLANTPUMP....................................................................................4-7 4.3EGRCOOLANTPUMP............................................................................4-18 4.4FRONTIDLERANDTENSIONERSUPPORT................... ......4-19 4.5THERMOSTAT............. ..............4-22 4.6EGRTHERMOSTATHOUSING..............................................................4-27 4.7COOLANTTEMPERATURESENSOR....................................................4-29 4.AADDITIONALINFORMATION.................... 4-31 5FUEL,LUBRICATINGOIL,ANDCOOLANT 5.1FUEL.................. ...................5-3 5.2LUBRICATINGOIL..................... 5-5 5.3COOLANT................................................................................................5-7 5.AADDITIONALINFORMATION..................................................................5-13 6AIRINTAKESYSTEM 6.1INTAKEMANIFOLD.................................................................................6-3 6.2CHARGEPRESSURE/TEMPERATURESENSOR .......6-5 6.3TURBOCHARGER........................ 6-6 6.AADDITIONALINFORMATION..................................................................6-17 7EXHAUSTSYSTEM 7.1EXHAUSTMANIFOLD............................................................................. 7-3 7.2EXHAUSTBRAKEASSEMBLY...............................................................7-6 Allinformationsubjecttochangewithoutnotice. iv DDC-SVC-MAN-0023 Copyright©2009DETROITDIESELCORPORATION

MBE4000SERVICEMANUAL 7.3EGREXHAUSTMANIFOLD....... ................7-14 7.4EGRCOOLERANDCOOLERSUPPORTBRACKET............................7-26 7.5EGRCONTROLVALVE,GASOUTLETPIPE,ANDGASMIXER..........7-47 7.6EPV(ELECTRONICPROPORTIONALVALVE)ANDWABCO®AIR SOLENOIDVALVE.......... .............7-54 7.7HENGSTBREATHERFILTER.................................................................7-58 7.AADDITIONALINFORMATION....................... ......7-67 8ELECTRICALEQUIPMENT 8.1DRIVEBELTS..........................................................................................8-3 8.AADDITIONALINFORMATION....................... ......8-15 9POWERTAKE-OFF 9.1FRONTENGINEPOWERTAKE-OFF(FEPTO) ................9-3 9.2REARENGINEPOWERTAKE-OFF(REPTO)... ................9-7 10SPECIALEQUIPMENT 10.1AIRCOMPRESSORFLANGE....... .............10-3 10.2AIRCOMPRESSOR................................................................................10-5 10.AADDITIONALINFORMATION..................................................................10-11 11OPERATIONANDVERIFICATION 11.1PREPARATIONFORAFIRSTTIMESTART...........................................11-3 11.2STARTINGTHEENGINE........................................................................11-8 11.3RUNNINGTHEENGINE.......... ...11-11 11.4STOPPINGTHEENGINE......... ................11-13 12ENGINETUNE-UP 12.1VALVELASHCHECKING........... ................12-3 12.2ADJUSTINGVALVELASH......................................................................12-9 13PREVENTIVEMAINTENANCE 13.1SCHEDULEDINTERVALS........................ ...........13-3 14ENGINESTORAGE 14.1PREPARINGENGINEFOR STORAGE...................... 14-3 15TROUBLESHOOTING THEELECTRONICENGINECONTROL SYSTEM 15.1ELECTRONICENGINECONTROLSYSTEM..... .............15-3 16GENERALMECHANICALTROUBLESHOOTING 16.1MECHANICALTROUBLESHOOTING.................................................... 16-3 17LOWPOWERCONCERN 17.1FACTORSTHATAFFECTWHEELHORSEPOWER..............................17-3 17.2LOWHORSEPOWERINTERVIEW..................... 17-6 17.3AERATEDFUEL......... .............17-13 17.4RESTRICTEDAIRCLEANERELEMENT...............................................17-15 17.5RESTRICTEDORCRACKEDCHARGEAIRCOOLERORLEAKING INTAKEMANIFOLD.................. ................17-16 17.6FAULTYEXHAUSTSYSTEM....................... ..................17-18 Allinformationsubjecttochangewithoutnotice. DDC-SVC-MAN-0023 Copyright©2009DETROITDIESELCORPORATION v

MBE4000SERVICEMANUAL

.........17-20 17.8VERIFICATIONOFPOWERWITHCHASSISDYNAMOMETER...........17-22 INDEX.................................................................................................Index-1 Allinformationsubjecttochangewithoutnotice. vi DDC-SVC-MAN-0023 Copyright©2009DETROITDIESELCORPORATION

17.7HIGHINLETAIRTEMPERATURE..............

GENERALINFORMATION SectionPage SCOPEANDUSEOFTHISMANUAL............... ..................3 GENERALDESCRIPTION.........................................................................3 ELECTRONICENGINECONTROLSYSTEM............................................4 ENGINEBRAKINGPOWER.......... ..................7 GENERALSPECIFICATIONSANDENGINEVIEWS................................7 ENGINEMODELANDSERIALNUMBER.................................................13 EXHAUSTGASRECIRCULATION(EGR)SYSTEM.......... 15 SAFETYINSTRUCTIONSANDPRECAUTIONS......................................19 ENGLISHTOMETRICCONVERSION......................................................28 DECIMALANDMETRICEQUIVALENTS..................... 29 TORQUESPECIFICATIONS...................................................................... 31

Allinformationsubjecttochangewithoutnotice.

MBE4000SERVICEMANUAL

SCOPEANDUSEOFTHISMANUAL

Thismanualcontainscompleteinstructionsonoperation,adjustment(tune-up),preventive maintenance,andrepair(includingcomplete overhaul)fortheMBE4000engine.Thismanual waswrittenprimarilyforpersonsservicingand overhaulingtheengine.Inaddition,thismanual containsalloftheinstructionsessentialtotheoperatorsandusers.Basicmaintenanceand overhaulproceduresarecommontoallMBE4000engines,andapplytoallenginemodels.

Thismanualisdividedintonumberedsections.Sectiononecoverstheengine(lessmajor assemblies).Thefollowingsectionscoveracompletesystemsuchasthefuelsystem,lubrication system,orairsystem.Eachsectionisdividedintosubsectionswhichcontaincomplete maintenanceandoperatinginstructionsforaspeciﬁcenginesubassembly.Eachsectionbegins withatableofcontents.Pagesandillustrationsarenumberedconsecutivelywithineachsection. Informationcanbelocatedbyusingthetableofcontentsatthefrontofthemanualorthetableof contentsatthebeginningofeachsection.Informationonspeciﬁcsubassembliesoraccessories withinthemajorsectionislistedimmediatelyfollowingthesectiontitle.

GENERALDESCRIPTION

TheMBE4000Enginedescribedinthismanualisa water-cooled,four-stroke,directinjection dieselengine.Thecylindersarearrangedinline.Eachcylinderhasaseparatefuelinjectionpump (unitpump)withashortinjectionlinetotheinjectionnozzle,whichislocatedinthecenterof thecombustionchamber.Theunitpumpsareattachedtothecrankcaseandaredrivenfromthe camshaft.Eachcylinderhastwointakevalvesandtwoexhaustvalves.

Charge-aircoolingandanexhaustgasturbochargerarestandardequipmentonallMBE4000 engines.

Theenginehasafullyelectroniccontrolsystem,whichregulatestheinjectionquantityandtiming usingsolenoidvalves,allowingextremelylow-emissionoperation.Thecontrolsystemconsistsof anengine-residentpumpandnozzlecontrolunit(theDDEC-ECU)andavehiclecontrolunit(the DDEC-VCU).Thetwoareconnected byaproprietarydatalink.

Enginebrakingiscontrolledbya pneumatically-operatedexhaustbrakeontheturbochargerand byaconstant-throttlesystem.Forgreaterbrakingpower,anoptionalturbobrakeisavailable. Thecylinderblockhasintegratedoilandwaterchannels.Theuppersectionofthecylinderbore isinduction-hardened.Thesixindividualcylinderheadsaremadeofcastiron.Thecylinderhead gasketisanadjustment-freesealwithrubbersealingelements.

Thepistonsaremadeofaluminumalloywithringcarriersandashallowcombustionchamber recess.Thepistonsarecooledbyoilspraynozzles.

Thecrankshaftisprecision-forgedwithsevenmainbearingsandeightcustom-forgedcounter weights,andavibrationdamperatthefrontend.

Thecamshaftismadeofinduction-hardenedsteel andhassevenmainbearings.Eachcylinderhas camsforintakeandexhaustvalvesandaunitpump.

Thevalvesarecontrolledbymushroomtappets,pushrods,androckerarms.Theintakeand exhaustvalvesareopenedandclosedbyavalve-guidedbridge.

MBE4000SERVICEMANUAL

Thereisaforce-feedlubricatingoilcircuitsuppliedbyagear-typeoilpump.Thispumpis positionedattherearoftheoilpananddrivenbygearsfromthecrankshaft.Theoil heat exchangerislocatednearthefrontofthecrankcaseontheright-handsideneartheturbocharger.

Thegear-typefuelpumpislocatednearthefrontofthecrankcaseonthelefthandside.Thepump isdrivenfromtheforwardendofthecamshaft.

Theaircompressor,withapower-steeringpumpattached,isdrivenbyagearonthecamshaft.

Theengineiscooledbyaclosedsystemusingrecirculatedcoolant;temperatureisregulated automaticallybyathermostat.

Therearethreedrivebelts,eachwithitsownautomaticbelttensioner.Thealternatorandcoolant pump(andanyotheraccessories)aredrivenbyamaindrivebelt.Thefanandtheairconditioner compressorareeachdrivenbytheirowndrivebelt.

ELECTRONICENGINECONTROLSYSTEM

Theengineisequippedwithafullyelectroniccontrolsystem.Besidestheengineanditsrelated sensors,thissystemiscomposedoftheDDEC-ECU,or enginecontrolunit,andtheDDEC-VCU, orvehiclecontrolunit.Thetwocontrolunitsareconnectedbyaproprietarydatalinkthrough whichallnecessarydataandinformationcanbeexchanged.TheDDEC-VCUthenbroadcasts allinformationontheJ1587andJ1939datalinks,whereitcanbereadbyminidiag2,Nexiq™ DiagnosticDataReader(DDR),orDetroitDieselDiagnosticLink®(DDDL)PCsoftware.

TheDDEC-ECUmonitorsboththeengineandthedatalink.Whenamalfunctionorother problemisdetected,thesystemselectsan appropriateresponse;forexample,theemergency runningmodemaybeactivated.

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MBE4000SERVICEMANUAL

DDEC-ECU—Engine-ResidentControlUnit

TheDDEC-ECUcontrolunitislocatedontheleft-handsideoftheengine.SeeFigure1.The DDEC-ECUprocessesthedatareceivedfromtheDDEC-VCU,forexamplethepositionofthe acceleratorpedal,enginebrake,etc.Thesedataareevaluatedtogetherwiththedatafromthe sensorsontheengine,suchas,chargeandoilpressureandcoolantand fueltemperature.The dataisthencomparedtothecharacteristicmapsorlinesstoredintheDDEC-ECU.Fromthese data,quantityandtimingofinjectionarecalculatedandtheunitpumpsareactuatedaccordingly throughthesolenoidvalves.

MBE4000SERVICEMANUAL

Figure1DDEC-ECUControlUnitLocation NOTE: ToobtainareplacementDDEC-ECU,allthedatagivenontheDDEC-ECUlabelare required.

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DDEC-VCU—VehicleControlUnit

Thevehiclecontrolunit(DDEC-VCU)communicateswithotherelectroniccontrolunitsinstalled onthevehicleovertheJ1587datalink.SeeFigure2.WithintheDDEC-VCU,setsofdatafor speciﬁcapplicationsarestored.Theseincludeidlespeed,maximumrunningspeed,andspeed limitation.

MBE4000SERVICEMANUAL

Figure2VehicleControlUnit(DDEC-VCU) TheDDEC-VCUreceivesdatafromthefollowingsources: □ Theoperator(acceleratorpedalposition,enginebrakeswitch) □ Otherelectroniccontrolunits(forexample,theantilockbrakesystem) □ TheDDEC-ECUcontrolunit(datasuchasoilpressureandcoolanttemperature)

Allinformationsubjecttochangewithoutnotice.

Fromthesedata,instructionsarecomputedforcontrollingtheengineandtransmittedtothe DDEC-ECUviatheproprietarydatalink.TheDDEC-VCUcontrolsvarioussystems,forexample, communicationswiththedatalink,theenginebrake,andtheconstant-throttlevalves.Ifthe enginecontrolsystemdetectsafault,theappropriatefaultcodeisbroadcastonthedatalink andcanbereadusingminidiag2.Whenthereisafault,thecodeforthecontrolunitreporting thefaultcanbereaddirectlyonthedisplay.

ENGINEBRAKINGPOWER

ExhaustBrake/Constant-ThrottleValves

Toincreasebrakingperformance,theengineisequippedwithanexhaustbrakeonthe turbochargerinconjunctionwithconstant-throttlevalvesonthecylinderhead.

NOTE:

Theconstant-throttlevaluesareactivatedbyengineoilpressure. Theexhaustback-pressureisusedbytheexhaustbraketoincreasebrakingperformance.

OptionalTurboBrake

Forhighbrakingoutput,theMBE4000enginecanbeequippedwithanoptionalturbobrake. Theturbobrakeincreasestheairmass ﬂowthroughtheenginetoprovideupto600brake horsepower.Theturbobrakecanbeoperatedeithermanuallyorautomatically,throughthe cruisecontrolfunction.

Becausethechargeairpressureismaintainedatahighlevelduringbraking,fullthrottleresponse isavailableimmediately,iftheoperatordesiresit,withoutanyturbolag.

Theturbobrakeismaintenance-free,highlyreliable,andaddsvirtuallynoweighttotheengine.

GENERALSPECIFICATIONSANDENGINEVIEWS

ForageneralviewoftheMBE4000engine, showingmajorcomponents,seeFigure3forthe left-handside,andseeFigure4fortheright-handside.

ForageneralviewoftheMBE4000engine,showingportsand ﬂuidlines,seeFigure5forthe left-handsideandseeFigure6fortheright-handside.

ForageneralviewoftheMBE4000engine,showingsensorlocations,seeFigure7.Twosensors arenoteasilyvisiblefromtheleft-handsideoftheengine:thechargepressure/temperature sensor,locatedontheright-hand sideofthechargeairmanifold,andtheoilpressure/temperature sensorlocatedatthebaseoftheoil ﬁlter.

MBE4000SERVICEMANUAL

MBE4000SERVICEMANUAL 1.FrontCamshaftCover8.PowerSteeringPump 2.ThermostatHousing9.DDEC-ECUControlUnit 3.CoolantPump 10.FuelHeatExchanger 4.Charge-Air(Intake)Manifold 11.OilPan 5.EngineTrimCover 12.FuelFilter 6.CrankcaseBreather 13.FuelPump 7.AirCompressor 14.AirConditionerCompressor Figure3LeftSide,MajorEngineComponents Allinformationsubjecttochangewithoutnotice. 8 DDC-SVC-MAN-0023 Copyright©2009DETROITDIESELCORPORATION

MBE4000SERVICEMANUAL 1.Starter8.Alternator 2.ExhaustBrakeValve9.OilFilter 3.ExhaustBrakeCylinder 10.OilFillTube 4.ExhaustManifold 11.OilHeatExchanger 5.CylinderHeadCover 12.OilDipstick 6.Fan 13.Turbocharger 7.BeltTensioner Figure4RightSide,MajorEngineComponents Allinformationsubjecttochangewithoutnotice. DDC-SVC-MAN-0023 Copyright©2009DETROITDIESELCORPORATION 9

MBE4000SERVICEMANUAL 1.FuelSpillLine5.CoolantLine(toaircompressor) 2.ThermostatOutlet6.HydraulicLine(topowersteeringpump) 3.ChargeAirInlet7.ElectronicEngineHarnessConnector 4.OpenBreatherTube8.FuelFeedLine Figure5LeftSide,PortsandLines Allinformationsubjecttochangewithoutnotice. 10 DDC-SVC-MAN-0023 Copyright©2009DETROITDIESELCORPORATION

MBE4000SERVICEMANUAL 1.OilDrainPlug5.TurbochargerOutletPipe 2.TurboOilReturnLine6.Dipstick 3.Constant-ThrottleInlet7.OilFillCap 4.ExhaustBrakeValveOutlet8.CoolantPumpInletPipe Figure6RightSide,PortsandLines

MBE4000SERVICEMANUAL 1.IntakeManifoldPressure/TemperatureSensor5.BarometricPressureSensor(integratedinto DDEC-ECU) 2.TDCSensor(oncamshaft)6.FuelTemperatureSensor 3.CrankAnglePositionSensor7.OilPressure/TemperatureSensor 4.CoolantTemperatureSensor Figure7SensorLocations Allinformationsubjecttochangewithoutnotice. 12 DDC-SVC-MAN-0023 Copyright©2009DETROITDIESELCORPORATION Detroit Diesel Epa04 Mbe 4000 Workshop Manual Full download:

This is the cut pages sample. Download all 631 page(s) at: ManualPlace.com

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