Mack E-TECH SB-210-034 Engine Accessory Manuals

Manuals and User Guides for Mack E-TECH SB-210-034 Engine Accessory. We have 1 Mack E-TECH SB-210-034 Engine Accessory manual available for free PDF download: Service Manual

Mack E-TECH SB-210-034 Service Manual

Mack E-TECH SB-210-034 Service Manual (365 pages)

Brand: Mack | Category: Engine | Size: 30 MB

Table of Contents

Table of Contents
10
Introduction

17
Identification

25
- Engine Model Identification
  26
  - Engine Information Plate
    26
  - Engine Serial Number Identification
    28
Description & Operation

29
- E-Tech™ Engine Design Features
  30
  - Electronic Unit Pumps
    30
  - V-Mac III
    32
  - Belt Drive System
    40
  - J-Tech™ Engine Brake
    40
  - Camshaft
    43
  - Valve Train
    43
  - Low-Pressure Fuel System
    48
  - Fuel Filtration System
    50
  - High-Pressure Fuel System
    51
  - High-Pressure Fuel Injection Lines
    52
  - Fuel Injector Assemblies
    52
  - Cylinder Block
    53
  - Crankshaft
    56
  - Block Heater for Front (Water Pump) Location
    56
  - Cylinder Head
    57
  - Cylinder Head Gasket
    59
  - Gear Train
    60
  - Air Compressor
    61
  - Power Steering Pump
    61
  - Vibration Damper Hub
    61
  - Front Cover
    62
  - Centri-Max® Oil Filter Breather Vent
    63
  - Lubrication System
    63
- Glossary of Terms
  71
Troubleshooting

73
- Engine Symptom Diagnosis
  74
  - V-MAC III Diagnostics
    74
- Camshaft Timing and Lobe Lift Checks
  82
  - Camshaft Timing Check
    82
  - Camshaft Lobe Lift Check
    82
- Chassis-Mounted Charge Air Cooling Tests
  83
- Maintenance
  
  103
  - Belt Drive System Tensioning
    104
    
    Automatically Tensioned System
    104
    
    Manually Tensioned System
    104
  - Filter Element Replacement
    105
    
    General Information
    105
    
    Crankcase Breather Filter Cleaning
    106
    
    Oil Filter Element Replacement
    106
    
    Fuel Filter Replacement
    109
    
    Coolant Conditioner Replacement
    110
- Repair Instructions
  
  111
  - Engine Removal
    112
    
    General Instructions
    112
    
    Removal from Vehicle
    112
  - Engine Disassembly
    115
    
    Filter Element Removal
    115
    
    General Instructions
    115
    
    Oil Cooler and Oil Filter Mounting Bracket Assembly Removal
    117
    
    Mounting Engine in Stand
    119
    
    Alternator Removal
    121
    
    Engine Electronic Control Unit (EECU) Removal
    121
    
    Fuel Filter Adapter Assembly Removal
    123
    
    Coolant Conditioner Element Removal
    124
    
    Oil Cooler-To-Water Pump Inlet Line Removal
    125
    
    Thermostat Removal
    126
    
    Coolant Manifold Removal
    127
    
    Air Inlet Manifold Removal
    128
    
    Water Pump Removal
    128
    
    Fuel Nozzle Inlet Tube Assembly Removal
    129
    
    Turbocharger Removal
    129
    
    Exhaust Manifold Removal
    130
    
    Engine Electronic Control Unit (EECU) and Cooling Plate Removal
    131
    
    Engine Wiring Harness Removal
    131
    
    Electronic Unit Pump (EUP) Removal
    132
    
    Oil Fill Tube Removal
    132
  - Air Compressor Removal
    133
  - Valve Cover and Spacer Removal
    134
  - Rocker Arm, Valve Yoke and Push Rod Removal
    135
  - Nozzle Holder Removal
    137
  - Cylinder Head Assembly Removal
    138
  - Vibration Damper and Crankshaft Hub Removal
    139
  - Oil Pan Removal
    139
  - Oil Pump Removal
    141
  - Front Cover Removal
    142
  - Auxiliary Shaft Removal
    143
  - Camshaft Removal
    144
  - Piston and Connecting Rod Assembly Removal
    145
  - Flywheel Removal
    147
  - Flywheel Housing Removal
    148
  - Main Bearing Cap Removal
    149
  - Crankshaft Removal
    150
  - Cylinder Block Reconditioning
    150
    
    Piston Cooling Spray Nozzle Removal
    150
    
    Special Tools Required
    150
    
    Cylinder Sleeve Removal
    151
    
    Cleaning and Inspection
    152
    
    Cylinder Sleeve Counterbore
    153
    
    Cup Plug Replacement
    158
    
    H-Ring Replacement
    159
    
    Pipe Plug Replacement
    159
    
    Camshaft Bushing Replacement
    161
    
    Auxiliary Shaft Bushing Replacement
    164
    
    Cylinder Sleeve Installation
    168
    
    Piston Cooling Spray Nozzle Installation
    173
    
    Cylinder Block Dowel Pin Replacement
    175
  - Crankshaft and Flywheel Bench Procedures
    177
    
    Crankshaft Inspection
    177
    
    General Information
    177
    
    Crankshaft Dowel Pin Replacement
    178
    
    Crankshaft Gear Replacement
    179
    
    Crankshaft Wear Ring Installation
    180
    
    Flywheel Inspection and Resurfacing
    183
  - Auxiliary Shaft and Camshaft Bench Procedures
    184
    
    Auxiliary Shaft Inspection
    184
    
    Camshaft Inspection
    184
  - Connecting Rod and Piston Bench Procedures
    189
    
    Connecting Rod Inspection and Reconditioning
    189
    
    Piston Inspection and Cleaning
    192
    
    Piston Ring Replacement
    193
    
    Assembling Connecting Rod to Piston
    196
  - Cylinder Head Overhaul
    197
    
    Inlet and Exhaust Valve Removal
    197
    
    Special Tools Required
    197
    
    Cylinder Head Inspection
    201
    
    Fire Ring Groove Cutting
    201
    
    Valve Guide Replacement
    204
  - Valve Seat Insert Replacement
    207
  - Valve Spring Inspection
    212
  - Injection Nozzle Holder Insert Replacement
    213
  - Valve Yoke Guide Pin Replacement
    214
  - Cylinder Head Cup Plug Replacement
    215
  - Cylinder Head Pipe Plug Replacement
    216
  - Valve Replacement
    218
  - Valve Rocker Arm Shaft Bench Procedures
    222
    
    Inspection
    222
    
    Rocker Arms
    222
    
    Valve Rocker Arm Shaft Disassembly (Without/With Engine Brake)
    222
    
    Valve Rocker Arm Shaft Reassembly (Without Engine Brake)
    223
    
    Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake)
    225
  - Lubrication System Bench Procedures
    227
    
    Oil Cooler Assembly Reconditioning
    227
    
    Oil Pump Reconditioning
    227
  - Cooling System Components Bench Procedures
    231
    
    Oil Cooler Reconditioning
    231
    
    Water Pump Reconditioning
    234
  - Fuel System Components Bench Procedures
    235
    
    Electronic Unit Pump (EUP) Inspection
    235
    
    Installation of Electronic Unit Pump Plunger Spring and Seat
    235
    
    Fuel Injector Nozzle Cleaning
    237
  - Engine Reassembly
    238
    
    Crankshaft Installation
    238
    
    General Instructions
    238
    
    Main Bearing Cap Installation
    240
    
    Piston and Connecting Rod Installation
    246
    
    Flywheel Housing Installation
    250
    
    Crankshaft Rear Oil Seal Installation
    254
    
    Flywheel Installation
    256
    
    Camshaft Installation
    258
    
    Valve Lifter Installation
    258
    
    Camshaft Core Plug Installation
    259
    
    Camshaft Idler Gear Installation
    260
    
    Auxiliary Shaft Installation
    261
    
    Oil Pump Installation
    262
    
    Front Cover Installation
    263
    
    Crankshaft Front Seal Installation
    264
    
    Crankshaft Hub Installation
    265
    
    Vibration Damper Installation
    265
    
    Oil Pan Installation
    266
    
    Cylinder Head Installation
    268
    
    Exhaust Manifold Installation
    271
    
    Nozzle Holder Assembly Installation
    273
    
    Push Rod Installation
    275
    
    Valve Yoke Installation
    276
    
    Rocker Arm and Engine Brake Installation
    277
    
    Valve Cover and Spacer Installation
    280
    
    Oil Fill Tube Installation
    281
    
    Engine Ecu/Cooling Plate Installation
    282
    
    Air Compressor Installation
    283
    
    Electronic Unit Pump Installation
    284
    
    Engine Wiring Harness Installation
    285
    
    Fuel Nozzle Inlet Tube Assembly Installation
    285
    
    Turbocharger Installation
    286
    
    Water Pump Installation
    287
    
    Oil Cooler and Oil Filter Mounting Bracket Installation
    288
    
    Coolant Manifold Installation
    290
    
    Air Inlet Manifold Installation
    292
    
    Thermostat, Housing and Seal Installation
    292
    
    Coolant Conditioner Installation
    294
    
    Fuel Filter Adapter Assembly Installation
    294
    
    Engine ECU Installation
    296
    
    Oil Cooler-To-Water Pump Inlet Line Installation
    296
    
    Alternator Installation
    297
    
    Removing Engine from Engine Stand
    297
    
    Plate-Type Oil Cooler and Oil Filter Mounting Bracket Assembly Installation
    298
    
    Engine Installation
    300
    
    Engine Installation into Vehicle
    300
    
    General Instructions
    300
    
    Electronic Unit Pump (EUP) Replacement
    302
    
    In-Chassis Part/Component Procedures
    302
    
    Camshaft Replacement (Engine in Chassis)
    304
    
    Engine Brake Control Valve Replacement
    309
    
    Valve Lifter H-Ring Installation Check
    311
    
    Engine Setup and Adjustments
    313
    
    Fuel Injection Timing
    313
    
    Valve Yoke, Valve Lash and Engine Brake Adjustments
    313
    
    Engine Speed and Position Sensors Installation and Adjustment
    320
    
    Electronic Unit Pump (EUP) Calibration
    321
    
    Engine Final Preparation and Operational Check
    322
    
    Engine Lubrication System
    322
    
    Filter Element Installation
    322
    
    Turbocharger
    322
    
    Cooling System
    323
    
    Engine Operational Check
    323
    
    Fuel System
    323
    
    General Instructions
    324
    
    Rebuilt Engine Run-In Procedures
    324
    
    Run-In Check
    324
Specifications

325
- E-Tech™ Engine Mechanical Specifications
  326
  - Performance Specifications
    326
  - Material and Dimensional Data
    327
  - E-Tech™ Component Torque Specifications
    335
  - Specification Footnotes
    344
- E-Tech™ Engine Lubricant and Sealant Specifications
  345
- Fastener Torque
  346
  - Fastener Selection and Installation
    346
  - Fastener Sizes and Types
    347
- Schematics & Diagrams
  
  349
  - Engine System Schematics (Fluids Flow)
    350
    
    Cooling System Flow Diagram
    350
    
    Lubrication System Flow Diagram
    351
    
    Fuel System Flow Diagram
    352
- Special Tools & Equipment
  
  353
  - E-Tech™ Engine Special Tools
    354
    
    Special Tools for Engine Overhaul
    354
    
    V-MAC III Special Tools
    357
- Index
  
  359

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