Detroit Diesel Unit Fuel Injectors & Unit Pump Technicians Guide Manual – PDF DOWNLOAD

Description

Detroit Diesel Unit Fuel Injectors & Unit Pump Technicians Guide Manual – PDF DOWNLOAD

DESCRIPTION:

Detroit Diesel Unit Fuel Injectors & Unit Pump Technicians Guide Manual – PDF DOWNLOAD

INTRODUCTION :

• This technicians guide explains the fuel injection system operation in current on-highway,
  four-cycle Detroit Diesel®Corporation engines. Series 50®, Series 60®, MBE 900, and MBE 4000
  engines are the models covered in this guide. The main emphasis of this guide is on the unit
  injector and the unit pump.
• The heart of the diesel engine is the fuel injection system. It has the vital function of
  communicating with the Electronic Control Module (ECM) and pumping a measured quantity
  of fuel into each cylinder at precisely the right moment. This is achieved by Detroit Diesel
  Corporation’s electronic control technology: Detroit Diesel Electronic Controls (DDEC®). The
  unit injector does all this with simple design and few parts. The benefits are low unit cost and
  minimal maintenance cost. The advantage of the 30,000 psi fuel injection pressure capability is
  high velocity injection which translates into excellent penetration and atomization. As a result
  of the ability to control injection spray, exhaust emissions and fuel consumption parameters are
  optimized. These features help make the most efficient use of each ounce of fuel, minimizing
  smoke, NOx, and HC emissions.

TABLE OF CONTENTS:

Detroit Diesel Unit Fuel Injectors & Unit Pump Technicians Guide Manual – PDF DOWNLOAD

1 INTRODUCTION ………………………………………………………………………………………………….. 1-1
1.1 DIESEL FUEL SYSTEM OVERVIEW ………………………………………………………………….. 1-1
1.1.1 SERIES 50/60 ELECTRONIC UNIT INJECTOR ……………………………………………….. 1-5
1.1.2 MBE 900 AND MBE 4000 UNIT PUMP AND NOZZLE ………………………………………. 1-10
2 SAFETY……………………………………………………………………………………………………………… 2-1
2.1 GENERAL SAFETY PRECAUTIONS TO OBSERVE WHEN WORKING ON THE
ENGINE ………………………………………………………………………………………………………….. 2-2
2.1.1 EXHAUST (START/RUN ENGINE) ………………………………………………………………….. 2-2
2.1.2 ITEMS UNDER TENSION ……………………………………………………………………………… 2-3
2.1.3 WORK PLACE ……………………………………………………………………………………………… 2-3
2.1.4 FLUIDS AND PRESSURE ……………………………………………………………………………… 2-4
2.1.5 GLASSES ……………………………………………………………………………………………………. 2-5
2.1.6 FIRE ……………………………………………………………………………………………………………. 2-5
2.1.7 BATTERIES …………………………………………………………………………………………………. 2-6
2.1.8 CLOTHING ………………………………………………………………………………………………….. 2-7
2.1.9 AIR ……………………………………………………………………………………………………………… 2-7
3 INSPECTION AND REMOVAL OF SYSTEMS ………………………………………………………… 3-1
3.1 SERIES 50/60 UNIT INJECTOR INSPECTION/REMOVAL …………………………………….. 3-1
3.2 MBE 900 UNIT PUMP INSPECTION/REMOVAL ………………………………………………….. 3-2
3.3 MBE 4000 UNIT PUMP INSPECTION/REMOVAL ………………………………………………… 3-3
4 FUEL………………………………………………………………………………………………………………….. 4-1
4.1 FUEL ADDITIVES …………………………………………………………………………………………….. 4-1
4.2 AIR IN FUEL ……………………………………………………………………………………………………. 4-1
4.3 FUEL CETANE NUMBER ………………………………………………………………………………….. 4-1
4.4 FUEL FILTRATION ……………………………………………………………………………………………. 4-2
4.5 FUEL STABILITY ……………………………………………………………………………………………… 4-3
4.6 FUEL SULFUR CONTENT ………………………………………………………………………………… 4-3
4.7 FUEL TEMPERATURE ……………………………………………………………………………………… 4-3
4.8 FUEL WATER CONTAMINATION ……………………………………………………………………….. 4-3
5 ELECTRONIC CONTROL SYSTEMS …………………………………………………………………….. 5-1
5.1 DDEC ABBREVIATIONS AND TERMS ……………………………………………………………….. 5-1
5.2 DDEC AND PRO-LINK OPERATIONS ………………………………………………………………… 5-3
5.2.1 RETRIEVING AND CLEARING CODES ………………………………………………………….. 5-3
5.2.2 UNIT INJECTOR CALIBRATION UPDATE ……………………………………………………….. 5-4
5.2.3 SNAPSHOT SEQUENCE ………………………………………………………………………………. 5-4
5.3 DDEC FOR MBE 900 AND MBE 4000 ENGINES …………………………………………………. 5-5
5.4 FUEL-RELATED ELECTRONIC FAULT CODES ………………………………………………….. 5-5
5.4.1 FLASH CODE 37 – FUEL PRESSURE SENSOR/FUEL RESTRICTION SENSOR
VOLTAGE HIGH ……………………………………………………………………………………………. 5-5
5.4.2 FLASH CODE 38 – FUEL PRESSURE SENSOR/FUEL RESTRICTION SENSOR
VOLTAGE LOW …………………………………………………………………………………………….. 5-6
All information subject to change without notice. i
7SE500 0409 Copyright © 2004 DETROIT DIESEL CORPORATION
TABLE OF CONTENTS
5.4.3 FLASH CODE 47 – AIR/FUEL PRESSURE HIGH ……………………………………………… 5-6
5.4.4 FLASH CODE 48 – AIR/FUEL PRESSURE LOW ………………………………………………. 5-6
5.4.5 FLASH CODE 61 – INJECTOR RESPONSE TIME LONG ………………………………….. 5-7
5.4.6 FLASH CODE 71 – INJECTOR RESPONSE TIME SHORT ………………………………… 5-7
5.4.7 FLASH CODE 77 – ISOLATED FUEL ………………………………………………………………. 5-7
6 FAILURE MODES ………………………………………………………………………………………………… 6-1
6.1 NORMAL INJECTOR ………………………………………………………………………………………… 6-2
6.2 SEIZED INJECTOR ………………………………………………………………………………………….. 6-3
6.3 BROKEN INJECTOR FOLLOWER SPRING AND DAMAGED STATOR WITH BROKEN
STATOR SCREWS ……………………………………………………………………………………………. 6-4
6.4 LOOSE STOP PLATE SCREW …………………………………………………………………………… 6-5
6.5 MISSING STOP PLATE SCREW ………………………………………………………………………… 6-6
6.6 CRACKED INJECTOR BODY FAILURE ………………………………………………………………. 6-7
6.7 BROKEN SOLENOID TERMINAL SCREW FAILURE ……………………………………………. 6-8
6.8 FAILED OR BLOWN SPRAY TIP FAILURE ………………………………………………………….. 6-9
6.9 LOW PRESSURE PLUG LEAK ………………………………………………………………………….. 6-10
6.10 HIGH PRESSURE PLUG LEAK …………………………………………………………………………. 6-11
6.11 BLACK OR GRAY SMOKE PROBLEM ………………………………………………………………… 6-12
6.12 WHITE SMOKE PROBLEM ……………………………………………………………………………….. 6-12
7 INJECTORO-RINGS……………………………………………………………………………………………. 7-1
8 FUEL SYSTEM TESTS …………………………………………………………………………………………. 8-1
8.1 SERIES 50/60 DDEC CYLINDER CUTOUT TEST ………………………………………………… 8-1
8.2 SERIES 50/60 FAULTY FUEL INJECTOR TEST …………………………………………………… 8-4
8.3 SERIES 50/60 DDEC IMPROPER INJECTOR CALIBRATION TEST ………………………. 8-4
8.4 SERIES 50/60 DDEC HIGH PRESSURE FUEL TEST …………………………………………… 8-6
8.5 SERIES 50/60 DDEC INSUFFICIENT FUEL FLOW TEST …………………………………….. 8-7
8.6 MBE CYLINDER CUTOUT TEST ……………………………………………………………………….. 8-8
8.7 MBE 900 DOWNSTREAM (AFTER SECONDARY FILTER) PRESSURE TEST ……….. 8-8
8.8 MBE 900 FLOW TEST AT NOZZLE HOLDER ………………………………………………………. 8-9
8.9 MBE 900 FLOW TEST AT FUEL FILTER ……………………………………………………………… 8-9
8.10 MBE 900 UPSTREAM PRESSURE TEST ………………………………………………………….. 8-11
8.11 MBE 900 INJECTOR LEAK TEST ………………………………………………………………………. 8-12
GLOSSARY ……………………………………………………………………………………………………………………. G-1

IMAGES PREVIEW OF THE MANUAL:

DETROIT DIESEL UNIT FUEL INJECTORS & UNIT PUMP TECHNICIANS GUIDE MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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