SERVICE BULLETIN - Jacobs Vehicle Systems
Contents
1. Perform the Following Bulletin 757GB59C This engine brake unit contains all the ESB 200 2002 288 01 latest upgrades No further component upgrades are necessary Perform normal diagnostic procedures when engine brake performance issues are encountered Refer to Additional Service Notes 1 on page 8 Tune Up Kits these kits are used for general engine brake tune ups and overhauls they are not to be used for warrantable repairs Engine Brake Model Engine Brake Assembly Part No Applicable Kit Part No 680B 757GB654 front and 757GB53 rear 4559 18678 690 690A and 690B 757GB58 A B C and 757GB59 A B C 4559 31180 Service Bulletins The following is a list of service bulletins that apply to the J Tech Engine Brake Service Bulletin No Bulletin Title SB 213 027 Valve Yoke Guide Pin Rotator and Slave Piston Spring Breakage Engines Equipped With J Tech Engine Brake SB 213 030 Flange Style Jam Nuts for Rocker Arm and Valve Yoke Adjusting Screws E Tech Engines SB 213 032 Valve Lifter Camshaft and other Valve Train Changes E Tech Engines SB 266 012 J Tech Model 690 Oil Supply Screw SB 266 013 J Tech Engine Brake With Top Oil Supply Port for External Oil Line SB 266 015 Converting J Tech 757GB58 Series Engine Brake Units to Top Oil Feed ESB 200 2002 288 01 Tie In for New Jake Brake Reset Screws and Slave Piston Springs Product Improvement Program2. 21427 Piston master 4559 11283 Valve control CO NI oa A wo N 4559 18756 Spring inner control valve 4559 28149 Collar control valve 4559 28189 Spring outer control valve 4559 12991 Ring retaining control valve 4559 1024614 Solenoid valve 4559 20229 Seal upper 4559 01082 Seal center 691GC226A Check valve fitting oil supply top 4559 24862 Ring retaining accumulator and slave piston 4559 24861 Retaining washer accumulator and slave piston 4559 30764 Spring accumulator 4559 30752 Accumulator piston 4559 11395 Jam nut reset screw 1 2 20 4559 32053 Screw reset 4559 21423 Piston slave 4559 30860 Single spring slave piston 142GC243M Flanged jam nut actuating pin adjusting screw 421GC41CM Actuating pin adjusting screw 891GC223M Yoke valve 4559 25132 Screw oil check WD WO WD WS WD W vl NINI GT A GW WY DW WI avj W W WI W W DM WI vj Ww 4559 24223 Solenoid lead wire NOTE The solenoid lower seal part No 4559 01083 is not used with engine brake models 690A or 690B This seal is not shown in figure 3 nor is it listed in the above parts list SB 266 017 Page 7 of 9 Additional Service Notes 1 ASET engines are equipped with either the 757GB59B or 757GB59C engine brakes and there are no
3. information and installation instructions 449GC237M Seal EGR tube flange 682GC512M Mixer tube 446GC2149 O ring mixer tube 670GC5125 BRV tube required for AC 400 AC 380 410 AC 427 and AC 460 engines 63AX1771 Fitting oil supply at oil filter mounting bracket 63AX3657 Elbow fitting 90 degree oil supply at oil filter mounting bracket 63AX1741 Connector fitting straight at 90 degree elbow fitting 744GB348P2 Hose assembly oil supply pedestal to 4 way fitting 796AX6F Convoluted tubing 12 304 8 mm length for 744GB384P2 hose assembly 497GB383 4 way fitting assembly NOTE prior to installing this fitting it will be neces sary to remove the existing threaded top head bolt at the rear cylinder head bolt position No 19 and install it at the front cylinder head bolt position No 16 These two head bolts must be switched and torqued to 205 lb ft 278 Nem 744GB43 Hose assembly oil supply 4 way fitting to 3 way fitting 9032 131X4 Block off plug must be ordered through the vendor ship direct system 421GC2124M2 Cylinder head cover engine brake spacer hold down bolts 616GC275M2 Cylinder head cover engine brake spacer hold down studs SB 266 017 Page 9 of 9
4. BULLETIN NUMBER SB 266 017 DATE 8 25 03 MODEL ASET E Tech E7 Also applies to Mack Trucks Australia ENGINE BRAKE SERVICE INFORMATION SUMMARY E TECH AND ASET WITH J TECH AND E7 WITH JACOBS ENGINE BRAKES This bulletin provides a summary of service information concerning Jacobs engine brakes on E7 E Tech and ASET engines NOTE Jacobs Vehicle Systems Regional Managers are available to assist with product training service training and troubleshooting engine brakes used on MACK engines To request technical assistance from Jacobs please contact Jacobs Vehicle Systems directly at 1 800 876 5253 or contact a MACK District or Regional Service Manager Engine Brake Retrofit Kits The following kits are used to install an engine brake on a non brake engine Engine Brake Retrofit Kit Engine Model Part No Engine Brake Part No E7 215SB207B 757GB54 front 757GB53 rear E Tech 215SB327 757GB59C ASET AI AMI 215SB327 757GB59C ASET AC 215SB327 757GB59C For E Tech engines kit part No 215SB327 is recommended Any remaining stock of kit part No 215SB293A B or C can be used as long as the brake supplied in kit is part No 757GB59B or C If not update brake to 757GB59C using kit part No 215SB321 J Tech Engine Brake Service Kit Applications Service Kit Part No Kit Description 4559 28190 Control Valve Update Kit The control valves originally included in this kit
5. Line Kit Includes all components excluding the two steel oil feed lines part No 8609 82000 necessary for the installation of the engine brake external oil supply lines refer to Additional Service Notes 1 and 2 on page 8 Service bulletin SB 266 015 outlines the procedures for converting an bottom fed engine brake unit to a dual feed J Tech Engine Brake Action Items The following instructions apply when addressing an engine brake drop out condition or complaints of poor performance Engine Brake Having Housing Refer to Service Model Part No Perform the Following Bulletin 757GB58A B or C Convert housing to top oil feed and SB 266 015 install J Tech Service Kit part No 215SB321 SB 266 017 Page 2 of 9 Engine Brake Model Having Housing Part No 757GB59 Perform the Following For engine serial Nos ON0077 through 0R3258 build date range July 3 through October 2 2000 install external oil line kit part No 57GC522P2 refer to Additional Service Note 1 on page 6 and inspect the reset screw for the presence of 032053A stamped next to the screwdriver slot If the screws are part No 032053A the brake has the 215SB321 kit parts If the reset screws are any other part number install kit part No 215SB321 following all the instructions outlined in bulletin SB 213 027 refer to Additional Service Notes 4 and 5 on page 8 757GB59A For engine serial Nos OR3259 thr
6. Tech and ASET ngines with reset screw 032053A Refer to the applicable engine service manual for the correct engine brake lash settings Glossary of Terms Poor Brake Performance During an engine braking event the engine sounds like the brake is functioning properly but retarding power is limited Engine Brake Drop Out A more severe form of poor engine brake performance An intermittent failure of multiple cylinders to perform the braking function then random cycling between braking and not braking Slave Lash Setting For the J Tech engine brake slave lash is the gap measured between the bottom surface of the engine brake slave piston and the top surface of the engine brake actuator pin For the engine brake used on E7 engines it is the gap measured between the slave piston and the top of the valve yoke SB 266 017 Page 5 of 9 J Tech Parts Part numbers for the engine brake individual components are as follows reference assembly model 690B 757GB59C d o lD j d 268902a Exploded View Figure 1 J Tech Engine Brake Unit Page 6 of 9 SB 266 017 Qty per assembly Part No 417GC310AM Description Adjusting screw rocker arm 4559 21437 Spherical locknut 4559 21740 Screw retaining master piston return spring 4559 16505 Washer retaining flat spring and control valve 4559 13158 Spring master piston return 4559
7. are now obsolete This kit has been terminated Service bulletin SB 266 011 has been cancelled For engine brake units needing the control valves replaced individual parts are available through the MACK Parts System Refer to page 6 and 7 for an exploded view of an engine brake unit along with a list of part numbers SB 266 017 Page 1 of 9 SERVICE PUBLICATIONS ALLENTOWN PA 18105 MACK TRUCKS INC 2003 Service Kit Part No Kit Description 4559 30950 J Tech Conversion Kit This kit is obsolete and has been terminated The individual parts originally contained in this kit however are available through the MACK Parts System Refer to page 6 and 7 for an exploded view of an engine brake unit along with a list of part numbers Service bulletin SB 266 015 outlines the primary solution to engine brake performance and drop out issues When addressing a performance drop out issue on a dual fed engine brake unit and diagnostic procedures indicate a faulty component use the individual parts as required 215SB320 J Tech Reset Screw Slave Piston This kit has been terminated and superseded Spring and Valve Yoke Adjusting by kit part No 215SB321 Screw Update Kit 215SB321 J Tech Reset Screw Slave Piston Supersedes kit part No 215SB320 Applies to Spring and Actuating Pin Adjusting Product Improvement Programs PI550 and Screw Update Kit P1552 and also service bulletin SB 266 015 57GC522P2 External Oil
8. e through the MACK Parts System These screws are needed when an earlier engine brake is being upgraded to the latest 757GB59C configuration J Tech Installation on Non Brake ASET AC Al and AMI Engines If it is desired to install a J Tech engine brake on a non brake equipped ASET engine the components listed in the following charts will be required Installation instructions are given in the ASET Engine Service Manual 5 109 Parts Required for ASET Al and AMI Engines Qty Part No Description 215SB327 Kit J Tech ASET 160AX574 BRV hose required for Al 427 and Al 460 engines 35AX1604 Spacer stand off for BRV tube required for Al 427 and Al 460 engines 27AM12 Bolt stand off spacer retaining M10 x 1 5 x 100 mm long 421GC2124M2 Bolts cylinder head cover engine brake spacer hold down 616GC275M2 Studs cylinder head cover engine brake spacer hold down NOTE The total quantity of cylinder head cover engine brake spacer hold down studs and bolts required per engine is twelve A quantity of 14 is listed in the table above however to cover the various bolt and stud combinations that may be encountered on any given engine SB 266 017 Page 8 of 9 Parts Required for ASET AC Engines Qty Part No 215SB327 Description Kit J Tech installation 206MS55M or 206MS52DM Mass Flow System MFS refer to service bulletin SB 214 022 for
9. issues to resolve To upgrade a non brake ASET engine with a J Tech engine brake use kit part No 215SB327 Currently ASET engines use external oil lines to supply oil to the engine brake units These lines however are not necessary with current production cylinder blocks and will be eliminated in the near future External oil lines are not required for any engine replacement basic engine short block or service block having a cylinder block part number given in service bulletin SB 211 018 Improvements were made to the engine block beginning with E Tech engine serial No 2D0001 3 02 which improved oil pressure allowing the elimination of the external oil lines to the engine brake units External oil lines were eliminated from production beginning with E Tech engine serial No 2N2969 7 30 02 Installation of the high volume oil pump part Nos 315GC466M and 315GC466MxX is no longer recommended unless it is used as a very last resort when all other corrective actions have failed to resolve the performance and or drop out issues including the appropriate troubleshooting procedures outlined in the applicable engine service manual An engine brake unit already updated to the latest configuration can be identified by the part number 032053A part number should be legible stamped on the reset screw and by the engine brake ID plates being 757GB59B or C Actuating pin adjusting screws part No 421GC41CM are availabl
10. ough 0V0113 build date range October 2 through November 14 2000 replace existing top oil feed check valve fitting part No 691GC226 with current fitting part No 691GC226A and inspect the reset screw for the presence of 032053A stamped next to the screwdriver slot If the screws are part No 032053A the brake has the 215SB321 kit parts If the reset screws are any other part number install kit part No 215SB321 following all the instructions outlined in bulletin SB 213 027 refer to Additional Service Notes 4 and 5 on page 8 For engine serial Nos 0V0114 through 2R2728 build date range November 14 2000 through September 25 2002 inspect the reset screw for the presence of 032053A stamped next to the screwdriver slot If the screws are part No 032053A the brake has the 215SB321 kit parts If the reset screws are any other part number install kit part No 215SB321 following all the instructions outlined in bulletin SB 213 027 refer to Additional Service Notes 3 and 5 on page 8 Refer to Service Bulletin SB 213 027 SB 266 013 757GB59B This engine brake unit contains all the latest upgrades No further component upgrades are necessary Perform normal diagnostic procedures when engine brake performance issues are encountered Refer to Additional Service Notes 1 on page 8 SB 266 017 Page 3 of 9 ESB 200 2002 288 01 Engine Brake Having Housing Refer to Service Model Part No
11. s The following Product Improvement Programs apply to J Tech ngine brakes on E Tech engines Product Improvement Program Affected Engines E Tech engines manufactured J Tech Engine Brake Component January 1 2002 through Improvements September 25 2002 engine serial Nos 2A0001 through 2R2728 All E Tech engines J Tech Engine Brake Component manufactured October 1 2000 Improvements through December 31 2001 engine serial Nos 0R3259 through 1Y2113 SB 266 017 Page 4 of 9 Service Tools e 4559 18280 Oil Pressure Test Kit Includes an oil pressure test gauge used for diagnosing performance problems with all Jacobs engine brake models e 4559 25084 Slave Piston Removal Tool Used to compress and safely remove the slave piston springs e 4559 22161 MACK Engine Brake Tool Kit Contains thickness gauges and slave piston removal tool necessary for servicing Jacobs engine brakes on all MACK engines e Thickness Gauges Used for setting engine brake slave lash 4559 22001 0 060 thickness gauge for E7 engines 4559 20521 0 080 thickness gauge for E7 engines 4559 14177 0 085 thickness gauge for E7 engines 4559 21327 0 100 thickness gauge for E7 engines Standard Thickness Gauge 0 017 for E Tech ngines with any reset screw other than part No 032053A Standard Thickness Gauge 0 021 for E
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