Mack ASET AC Diesel Engine Maintenance Manuals

Manuals and User Guides for Mack ASET AC Diesel Engine Maintenance. We have 1 Mack ASET AC Diesel Engine Maintenance manual available for free PDF download: Service Manual

Mack ASET AC Service Manual (536 pages)

Brand: Mack | Category: Engine | Size: 49 MB

Table of Contents
7
Introduction
14
Safety Information
15
Advisory Labels
15
Service Procedures and Tool Usage
16
Explanation of Numerical Code
18
Conversion Chart
19
About the Mack Aset™ Ac Diesel Engine
22
Heater Core and Optional Fuel Heater Hose Connection Revisions
22
Visual Identification
24
Engine Model Identification
25
Engine Information Plate
25
Engine Serial Number Identification
27
Description and Operation
28
Engine Design Features
29
ASET™ AC Engine Technologies
30
ASET™ AC (CEGR) Engine Features and Components
32
MACK Fuel Filtration System
54
Electronic Unit Pumps (EUP)
55
Engine Brake
56
Camshaft
66
Valve Train
66
Low-Pressure Fuel System
73
High-Pressure Fuel System
76
High-Pressure Fuel Injection Lines
77
Fuel Injector Assemblies
77
Cylinder Block
78
Crankshaft
80
Block Heater
80
Cylinder Head
81
Cylinder Head Gasket
82
Gear Train
83
Air Compressor
84
Power Steering Pump
84
Vibration Damper Hub
84
Front Cover
85
Lubrication System
86
Glossary of Terms
93
Component Locator
96
Component Location Views
97
ASET™ AC Engine
97
Troubleshooting
100
Engine Symptom Diagnosis for Mack Aset™ Engines
101
V-MAC III Diagnostics
101
Camshaft Timing and Lobe Lift Checks
112
Camshaft Timing Check
112
Camshaft Lobe Lift Check
112
Chassis-Mounted Charge Air Cooling Tests
113
General Information
113
Special Tool Required
113
CMCAC Troubleshooting
113
CMCAC Pressure Test
114
Restriction Pressure Test
115
Core Inspection
116
CMCAC Preventive Maintenance
116
Cylinder Head and Cylinder Block Leak Test Procedure
117
Cylinder Head and Head Gasket Check - in Chassis
117
Cylinder Head Fuel Passages Leak Check - in Chassis
118
Cylinder Block/Cylinder Head Coolant Passages Leak Check - in Chassis
118
Cylinder Head Oil Passage Leak Check - out of Chassis
120
Cylinder Head Coolant Passage Leak Check - out of Chassis
121
Cylinder Block Coolant Passage Leak Check - out of Chassis
122
Engine Brake Tests (Mack Powerleash™)
124
Operational Tests
124
Electrical Troubleshooting
125
MACK Powerleash™ Checks (Hydraulic/Mechanical)
126
MACK Powerleash™ Troubleshooting Guide
128
Removal and Inspection of MACK Powerleash™ Engine Brake Components
130
Engine Brake Tests (J-Tech™)
132
Operational Tests
132
Electrical Troubleshooting
133
J-Tech™ Checks (Hydraulic/Mechanical)
134
J-Tech™ Troubleshooting Guide
137
Maintenance
140
Lubrication System Maintenance for Aset™ Engines
141
Crankcase Breather Element Cleaning
141
Oil Level Check
142
Oil and Filter Change Procedure
143
Fuel Filter Element Replacement for Aset™ Ac Engines
147
Primary/Secondary Fuel Filter Change
147
Coolant Conditioner Element Replacement for Aset™ Engines
150
Coolant Conditioner Replacement
150
Oil Coalescing Air Filter Replacement
150
Drive Belt Replacement and Tensioning for Aset™ Ac Engines
151
General Information
151
Automatically Tensioned System
152
Repair Instructions, Part 1
154
Engine Removal
155
General Instructions
155
Removal from Vehicle
155
Engine Disassembly
158
General Instructions
158
Filter Element Removal
158
Dipstick Tube Removal
159
Oil Cooler and Oil Filter Mounting Bracket Assembly Removal
159
Oil Coalescing Air Filter Removal
160
Mounting Engine in Stand
161
Alternator Removal
163
Engine Electronic Control Unit (EECU) and Cooling Plate Removal
163
EGR Gas Tube Removal
165
EGR Cooler Removal
167
EGR Mixer Tube Removal
168
Thermostat Housing Removal
169
Oil Supply Lines Removal
170
EGR Valve Removal
172
Water Pump Housing Removal
173
VTG Position Control Valve Removal
175
Coolant Manifold Removal
176
Air Inlet Manifold Removal
176
Turbocharger Removal
176
Fuel Nozzle Inlet Tube Assembly Removal
177
Exhaust Manifold Removal
178
Engine Wiring Harness Removal
178
Electronic Unit Pump (EUP) Removal
179
Air Compressor Removal
180
Cylinder Head Cover and Spacer Removal
182
Rocker Arm, Valve Yoke and Push Rod Removal
183
Revised Rocker Arm Shift Mounting Bolts
185
Nozzle Holder Removal
186
Cylinder Head Assembly Removal
186
Vibration Damper and Crankshaft Hub Removal
188
Oil Pan Removal
188
Oil Pump Removal
190
Front Cover Removal
191
Auxiliary Shaft Removal
191
Camshaft Removal
192
Piston and Connecting Rod Assembly Removal
193
Flywheel Removal
195
Flywheel Housing Removal
196
Main Bearing Cap Removal
196
Crankshaft Removal
198
Cylinder Block Reconditioning
198
Special Tools Required
198
Piston Cooling Spray Nozzle Removal
198
Cylinder Sleeve Removal
199
Cleaning and Inspection
200
Cylinder Sleeve Counterbore
203
Cup Plug Replacement
207
Pipe Plug Replacement
207
H-Ring Replacement
208
Camshaft Bushing Replacement
210
Auxiliary Shaft Bushing Replacement
214
Cylinder Sleeve Installation
218
Piston Cooling Spray Nozzle Installation
221
Cylinder Block Dowel Pin Replacement
224
Crankshaft and Flywheel Bench Procedures
226
General Information
226
Crankshaft Inspection
226
Crankshaft Dowel Pin Replacement
226
Crankshaft Gear Replacement
227
Crankshaft Wear Ring Installation
228
Flywheel Inspection and Resurfacing
230
Auxiliary Shaft and Camshaft Bench Procedures
232
Auxiliary Shaft Inspection
232
Camshaft Inspection
232
Connecting Rod and Piston Bench Procedures
236
Connecting Rod Inspection and Reconditioning
236
Piston Inspection and Cleaning
239
Piston Ring Replacement
239
Assembling Connecting Rod to Piston
242
Cylinder Head Overhaul
243
Special Tools Required
243
Inlet and Exhaust Valve Removal
243
Cylinder Head Cleaning and Inspection
247
Fire Ring Groove Cutting
248
Valve Guide Replacement
251
Valve Seat Insert Replacement
254
Valve Spring Inspection
260
Injection Nozzle Holder Insert Replacement
261
Valve Yoke Guide Pin Replacement
263
Cylinder Head Cup Plug Replacement
264
Cylinder Head Pipe Plug Replacement
265
Inlet and Exhaust Valve Inspection
266
Inlet and Exhaust Valve Installation
267
Valve Rocker Arm Shaft Bench Procedures
273
Rocker Arms
273
Valve Rocker Arm Shaft Disassembly (With/Without Engine Brake)
275
Inspection
276
Valve Rocker Arm Shaft Reassembly (Without Engine Brake)
277
Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake)
279
Valve Rocker Arm Shaft Reassembly (with MACK Powerleash™ Engine Brake)
281
Lubrication System Bench Procedures
286
Oil Cooler Assembly Reconditioning
286
Oil Pump Reconditioning
286
Cooling System Components Bench Procedures
292
Oil Cooler Reconditioning
292
EGR Cooler Reconditioning
292
Water Pump Reconditioning
292
Fuel System Component Bench Procedures
293
Electronic Unit Pump (EUP) Inspection
293
Installation of Electronic Unit Pump Plunger Spring and Seat
293
Fuel Injector Nozzle Cleaning
296
Vtg System Bench Procedures
297
VTG Control Valve Solenoid Replacement
297
Engine Reassembly
299
General Instructions
299
Crankshaft Installation
299
Main Bearing Cap Installation
300
Piston and Connecting Rod Installation
306
Flywheel Housing Installation
311
Crankshaft Rear Oil Seal Installation
314
Flywheel Installation
317
Valve Lifter Installation
318
Camshaft Installation
320
Camshaft Core Plug Installation
321
Camshaft Idler Gear Installation
321
Auxiliary Shaft Installation
322
Oil Pump Installation
323
Front Cover Installation
324
Crankshaft Front Seal Installation
325
Crankshaft Hub Installation
326
Vibration Damper Installation
326
Oil Pan Installation
327
Cylinder Head Installation
329
Exhaust Manifold Installation
332
Nozzle Holder Assembly Installation
333
Push Rod Installation
336
Valve Yoke Installation
337
Rocker Arm and Engine Brake Installation
341
Cylinder Head Cover and Spacer Installation
347
Oil Fill Tube/Dipstick Installation
349
Air Compressor Installation
349
Electronic Unit Pump (EUP) Installation
351
Engine Wiring Harness Installation
352
Fuel Nozzle Inlet Tube Assembly Installation
352
Turbocharger Installation
355
Coolant Manifold Installation
356
Air Inlet Manifold Installation
357
VTG Position Control Valve Installation
357
Water Pump Housing Installation
358
EGR Valve Installation
361
Oil Supply Lines Installation
363
Thermostat Housing Installation
366
EGR Mixer Tube Installation
369
EGR Cooler Installation
370
EGR Gas Tube Installation
371
EECU and Cooling Plate Installation
373
Coolant Conditioner Installation
375
Alternator Installation
376
Removing Engine from Engine Stand
376
Oil Coalescing Air Filter Installation
377
Oil Cooler and Oil Filter Mounting Bracket Assembly Installation
377
Dipstick Tube Installation
379
Engine Installation
379
General Instructions
379
Engine Installation into Vehicle
379
Repair Instructions, Part 2
384
In-Chassis Part/Component Procedures
385
Electronic Unit Pump Replacement (In-Chassis)
385
Unit Pump Removal
385
Tappet Guide Pin and Tappet Bore Inspection
386
Salvaging a Damaged EUP Tappet Bore
386
Tappet Installation
387
Unit Pump Installation
387
Camshaft Replacement (In-Chassis)
389
Preliminary Steps
389
Camshaft/Lifter Removal
389
Cleaning and Inspection of Cylinder Block
391
Camshaft Installation
392
Camshaft Idler Gear Installation
393
Exhaust Valve Yoke Pin and Valve Rotator Inspection and Replacement Criteria (In-Chassis)
395
Valve Lifter H-Ring Dislodgement and Alignment Inspections (In-Chassis)
397
H-Ring Dislodgement Inspection
398
H-Ring Alignment Inspection
398
H-Ring Dislodgement Check and Alignment Verification
399
Eecu and Sensor Service Procedures (In-Chassis)
400
Engine Electronic Control Unit (EECU) and Cooling Plate Removal
400
EECU and Cooling Plate Installation
402
Sensors Installation and Adjustment
403
Cooling System Service Procedures (In-Chassis)
404
Thermostat Replacement
404
Water Pump Housing Assembly Removal and Installation
409
Coolant Conditioner Adapter Removal and Installation
414
Egr System Service Procedures (In-Chassis) for Aset™ Ac Engine
415
Preliminary Steps
415
EGR Gas Tube(S) Removal and Installation
415
EGR Cooler Removal and Installation
421
EGR Valve Removal and Installation
425
EGR Valve Heat Shields Removal and Installation
429
EGR Gas Mixer Tube Removal and Installation
430
MASS Flow System Replacement Instructions
433
Final Assembly
434
Vtg Turbocharger Service Procedures
435
Preliminary Steps
435
VTG Position Control Valve Removal and Installation
435
Turbocharger Removal
437
Turbocharger Installation (Includes Pre-Lubing Procedures)
439
VTG Actuator Removal and Installation
441
VTG Actuating System Calibration
448
Turbocharger Wheel Speed Sensor Replacement
452
Repair Instructions, Part 3
454
Engine Setup and Adjustments
455
Fuel Injection Timing
455
Valve Adjustment
455
Valve Adjustment Procedure
456
Electronic Unit Pump (EUP) Calibration
473
Engine Speed and Position Sensors Installation and Adjustment
473
Engine Speed Sensor
473
Engine Position Sensor
474
Other Engine-Mounted Sensors
474
Engine Final Preparation and Operational Check
475
Filter Element Installation
475
Engine Lubrication System
475
Turbocharger
476
Cooling System
476
Fuel System
477
Engine Operational Check
478
Rebuilt Engine Run-In Procedures
478
General Instructions
478
Run-In Check
478
Specifications
480
Aset™ Ac Engine Mechanical Specifications
481
Performance Specifications
481
Material and Dimensional Data
482
Engine Component Torque Specifications
491
Specification Footnotes
501
Aset™ Engine Assembly Lubricants and Sealants
503
Aset™ Ac Engine Drive Belt Specifications
504
Schematic & Routing Diagrams
506
Aset™ Ac Engine Systems Schematics
507
Cooling System Flow Diagrams
507
Lubrication System Flow Diagrams
508
Fuel System Flow Diagrams
509
Accessory Drive Belt Routings
512
Special Tools & Equipment
514
Aset™ Engine Special Tools
515
Special Tools for Engine Overhaul
515
V-MAC III Special Tools
518
Appendix
520
Fastener Identification
521
Fastener Selection and Installation
521
Fastener Sizes and Types
522
Torque Wrench Use
523
Using an Adapter in Combination with a Torque Wrench
523
Turbocharger Failure and Actions Required to Avoid Repeat Failure
524
Cleaning Oil from the Charge Air Cooler
525
Cleaning the Intake Air System
525
Cleaning the Turbocharger Oil Supply Line, Changing the Engine Oil and Pre-Lubricating the Turbocharger Following a Failure
526
Pre-Lubricating a Turbocharger after Sitting Idle for an Extended Period of Time
527
Index
528

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