Mack Truck E7 Engine Overhaul Operator’s Manual 5-101 – PDF DOWNLOAD
FILE DETAILS:
Mack Truck E7 Engine Overhaul Operator’s Manual 5-101 – PDF DOWNLOAD
Language : English
Pages : 303
Downloadable : Yes
File Type : PDF
Size: 30 MB
TABLE OF CONTENTS:
Mack Truck E7 Engine Overhaul Operator’s Manual 5-101 – PDF DOWNLOAD
SAFETY INFORMATION iii
Advisory Labels iv
Service Procedures and Tool Usage v
EXPLANATION OF NUMERICAL CODE vii
EXPLANATION OF 3-DIGIT NUMERICAL CODE viii
ABOUT THIS MANUAL ix
200 GENERAL INFORMATION 1-1
INTRODUCTION 1-2
ENGINE MODEL IDENTIFICATION 1-3
Engine Information Plate 1-3
LUBRICANTS AND SEALANTS 1-5
OVERHAUL PART REPLACEMENT 1-6
200 SPECIFICATIONS 2-1
SPECIFICATIONS 2-2
Improved Design 2-2
Engine General Specifications 2-2
Engine Features 2-2
Good Shop Practice — Fasteners 2-4
Performance Specifications (Oil Pressure and Intake Manifold Temperature) 2-4
FASTENER TORQUE 2-5
Fastener Selection and Installation 2-5
Fastener Sizes and Types 2-6
TORQUE SPECIFICATIONS 2-7
Torque Specifications for Critical Fasteners 2-7
Torque Specifications for Hose Clamps 2-10
Torque Specifications for Pipe Plugs 2-11
Torque Specifications for Non-Critical Fasteners 2-11
FITS AND LIMITS 2-14
Fits and Limits 2-14
METRIC MISMATCH 2-20
Inch Thread vs Metric Thread Fastener Combinations Contributing to
Thread Stripping 2-20
Inch Thread vs Metric Thread Fastener Combinations Contributing to
Assembly Weakness 2-21
Incompatible Metric vs Metric Fastener Systems 2-21
CONVERSION FACTORS 2-21
SPECIAL TOOLS 2-22
Special Tool List 2-22
V-MAC Tools 2-24
200 ENGINE REMOVAL 3-1
GENERAL 3-2
Vehicle Preparation 3-2
Engine Removal 3-2
200 ENGINE DISASSEMBLY 4-1
GENERAL 4-2
[219 EV] CENTRI-MAX™ AND SPIN-ON FILTER ELEMENTS 4-2
MOUNTING ENGINE IN STAND 4-3
Special Tools Required 4-3
[271 CB] ALTERNATOR 4-5
[215 HB] FAN ASSEMBLY 4-5
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[231 PB] FUEL FILTER ADAPTER ASSEMBLY 4-6
[215 LD] COOLANT CONDITIONER ELEMENT 4-7
[215 NU] THERMOSTAT 4-8
[214 HD] AIR INLET MANIFOLD 4-9
[215 NK] COOLANT MANIFOLD 4-9
[215 DW & 219 EP] OIL COOLER AND OIL FILTER HOUSING ASSEMBLY 4-10
[215 SW] WATER PUMP 4-11
[214 SD] TURBOCHARGER 4-11
[222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY 4-12
[214 EG] EXHAUST MANIFOLD 4-13
[213 JB] VALVE COVER AND RISER 4-13
[213 LP, NV & LH] ROCKER ARM, VALVE YOKE AND PUSH ROD 4-14
[222 KG] NOZZLE HOLDER 4-15
Special Tool Required 4-15
[213 EV] CYLINDER HEAD ASSEMBLY REMOVAL 4-16
[212 RB & RH] VIBRATION DAMPER AND CRANKSHAFT HUB 4-17
[261 CK] AIR COMPRESSOR 4-17
[221 GP] INJECTION PUMP 4-19
[221 CD] ECONOVANCE 4-20
V-MAC Equipped Engines 4-20
[211 NB] OIL PAN 4-20
[219 MU] OIL PUMP 4-22
[211 RP] TIMING GEAR COVER 4-23
[212 CV] AUXILIARY DRIVESHAFT 4-24
[213 CH] CAMSHAFT 4-24
[212 NP & LQ] PISTON AND CONNECTING ROD ASSEMBLY 4-25
[212 UC] FLYWHEEL 4-27
[211 HD] FLYWHEEL HOUSING 4-28
[211 JA] MAIN BEARING CAP 4-28
[212 HP] CRANKSHAFT 4-30
[219 RV] PISTON COOLING SPRAY NOZZLE 4-30
[212 NC] CYLINDER SLEEVE 4-31
Special Tool Required 4-31
200 BENCH PROCEDURES 5-1
[211 DB] CYLINDER BLOCK 5-2
Cylinder Sleeve Counterbore 5-2
[212 CV] AUXILIARY DRIVESHAFT 5-5
Description 5-5
Inspection 5-5
[212 LP] CONNECTING RODS 5-5
Description 5-5
Special Tools Required 5-7
Inspection 5-7
Wrist Pin Repair 5-7
[212 HP] CRANKSHAFT 5-9
Description 5-9
Inspection 5-10
[212 HA] Crankshaft Dowel Pin Replacement 5-10
[212 HV] Crankshaft Gear 5-12
[212 UB] FLYWHEEL 5-13
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[212 NP] PISTONS 5-13
Description 5-13
Special Tools Required 5-14
Disassembly 5-14
Inspection 5-15
[212 NV] PISTON RINGS 5-15
Keystone Ring Groove Check 5-15
Ring Installation 5-17
[212 LP & NP] CONNECTING ROD ASSEMBLY TO PISTON 5-17
[213 CH] CAMSHAFT 5-18
Description 5-18
Disassembly 5-18
Inspection 5-20
Assembly 5-20
[213 EV] CYLINDER HEADS 5-22
Description 5-22
Special Tools Required 5-24
[213 NB] Inlet and Exhaust Valve Removal 5-25
[213 EX] Cylinder Head Inspection 5-27
[213 EH] Fire Ring Groove 5-27
[213 EP] Valve Guides 5-30
[213 FB] Inlet and Exhaust Valve Seat Inserts 5-33
[213 MB] Valve Springs 5-38
[213 GB] Injection Nozzle Holder Insert 5-38
[213 FH] Valve Yoke Guide Pins 5-39
[213 FP] Cylinder Head Cup Plugs 5-41
Cylinder Head Pipe Plugs 5-42
[213 NB] INLET AND EXHAUST VALVES 5-43
Inspection 5-43
Valve Identification 5-43
Inlet and Exhaust Valve Installation 5-45
[213 LV] VALVE ROCKER ARM SHAFT 5-47
Inspection 5-47
Rocker Arms 5-47
Valve Rocker Arm Shaft Assembly (Except Jacobs Engine Brake) 5-47
Valve Rocker Arm Shaft Assembly (with Jacobs Engine Brake) 5-49
Dynatard Engine Brake Solenoid 5-51
[266 KD] DYNATARD ENGINE BRAKE 5-51
Dynatard Overload Protection (E7 Engines with Dynatard) 5-51
Dynatard Overload Protection System 5-52
[266] JACOBS ENGINE BRAKE 5-53
[266] ENGINE BRAKE SWITCH AND BRACKET ASSEMBLY 5-53
Description 5-53
Adjustment (E7 Mechanically Governed Engine with Engine Brake) 5-53
[215 DW] OIL COOLER ASSEMBLY 5-54
Description 5-54
Disassembly 5-55
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Inspection 5-56
Assembly 5-56
[215 SW] WATER PUMP 5-57
[219 MU] OIL PUMP 5-57
Disassembly 5-57
Inspection 5-58
Improved “Fast Ratio” Auxiliary Driveshaft 5-61
Assembly 5-62
[221 CD] ECONOVANCE 5-62
Econovance Control Valve Assembly 5-62
Econovance Disassembly 5-63
Cleaning and Inspection 5-64
Econovance Assembly 5-64
[221 KU] INJECTION PUMP DRIVE HUB 5-64
Description 5-64
Special Tools Required 5-64
Cleaning 5-65
Installation of Drive Hub (Mechanically Governed Engines) 5-65
Installation of Drive Hub (V-MAC Engines) 5-66
[222 KG] INJECTOR NOZZLES 5-67
Nozzle Cleaning 5-67
200 ENGINE ASSEMBLY 6-1
GENERAL 6-2
[211 DB] CYLINDER BLOCK 6-2
Special Tools Required 6-2
Cleaning and Inspection 6-2
Cup Plug Replacement 6-3
Pipe Plug Replacement 6-4
[213 CC] Camshaft Bushings 6-5
[212 CB] Auxiliary Driveshaft Bushing Replacement 6-9
[212 NC] CYLINDER SLEEVE 6-11
Description 6-11
Special Tools Required 6-11
Installation 6-11
[219 RV] PISTON COOLING SPRAY NOZZLE 6-14
Description 6-14
Special Tools Required 6-14
Installation 6-14
Piston Cooling Nozzle Spray Positioning 6-15
[211 HA] CYLINDER BLOCK DOWEL PINS 6-17
Description 6-17
Special Tools Required 6-17
Removal 6-17
Installation 6-17
[212 HP] CRANKSHAFT 6-19
Installation 6-19
[212 HH] MAIN BEARING CAP 6-20
Special Tool Required 6-20
Installation 6-20
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[212 NP & 212 LP] PISTONS AND CONNECTING RODS 6-23
Description 6-23
Special Tools Required 6-23
Installation 6-24
[211 HD] FLYWHEEL HOUSING 6-26
Description 6-26
Inspection 6-26
Dowel Pins 6-26
Capscrews (Flywheel Housing) 6-27
Installation 6-29
Runout 6-30
[212 JH] CRANKSHAFT WEAR RING 6-31
Special Tools Required 6-31
Removal 6-31
Installation 6-31
Wear Ring with Double-Lip Teflon Seal (Automatic Transmission) 6-32
[212 JH] CRANKSHAFT REAR OIL SEAL 6-33
Installation 6-33
[212 VC] FLYWHEEL (E7 ENGINE WITHOUT POINTER ON TIMING COVER) 6-35
Description 6-35
Installation 6-36
[213 CH] CAMSHAFT 6-37
Description 6-37
Special Tools Required 6-37
Inspection 6-37
Installation (Engine in Stand) 6-38
Installation (Engine in Chassis) 6-39
[212 CV] AUXILIARY DRIVESHAFT 6-41
Inspection 6-41
Installation 6-41
[219 MU] OIL PUMP 6-42
Description 6-42
Installation 6-43
[211 RP] TIMING GEAR COVER 6-44
[211 SB] TIMING GEAR COVER SEAL 6-45
Special Tool Required 6-45
Installation 6-45
[221 GP] FUEL INJECTION PUMP INSTALLATION 6-45
[212 RH] CRANKSHAFT HUB 6-45
Inspection 6-45
Installation 6-45
[212 RB] VIBRATION DAMPER 6-46
Description 6-46
Inspection 6-46
Installation 6-46
[211 NB] OIL PAN 6-46
Description (Isolating Oil Pan Gasket on E7 Engines) 6-46
Oil Pan Installation 6-50
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[213 EV] CYLINDER HEADS 6-51
Description 6-51
Installation 6-52
[222 KG] NOZZLE HOLDER ASSEMBLY 6-55
Description 6-55
Special Tool Required 6-55
Installation 6-55
[213 LH] VALVE LIFTER PUSH RODS 6-57
Inspection 6-57
Identification 6-57
Installation 6-58
[213 NV] VALVE YOKES 6-58
Description 6-58
Installation 6-58
[213 LP] ROCKER ARMS 6-59
Description 6-59
Installation (Non-Brake and Dynatard Equipped Engines) 6-59
Installation (Jake Brake-Equipped Engines) 6-59
Brake Housing Installation 6-60
[213 JB] VALVE COVER 6-61
Description 6-61
Installation 6-61
[214 EG] EXHAUST MANIFOLD 6-62
Description 6-62
Installation 6-62
[215 NK] COOLANT MANIFOLD 6-64
Inspection 6-64
Installation 6-64
[261 CK] AIR COMPRESSOR 6-65
Installation 6-65
[221 CD] ECONOVANCE 6-66
Installation 6-66
[221 GP] FUEL INJECTION PUMP 6-66
Installation 6-66
[222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY 6-70
Installation 6-70
[214 SC] TURBOCHARGER 6-72
Installation (Includes Pre-Lubing Procedures) 6-72
[215 NU, NG & LD] THERMOSTAT, THERMOSTAT HOUSING, THERMOSTAT SEAL
AND COOLANT CONDITIONER 6-73
[214 HD] AIR INLET MANIFOLD 6-75
[231 PB] FUEL FILTER ADAPTER ASSEMBLY 6-75
Installation 6-75
[215 SW] WATER PUMP 6-76
Installation 6-76
[215 DW & 219 EP] OIL COOLER AND OIL FILTER HEAD 6-77
Assembling a New Oil Filter Adapter 6-77
Installation 6-78
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[271 CB] ALTERNATOR 6-80
Installation 6-80
Fan Belt(s) 6-80
200 SETUP AND ADJUSTMENTS 7-1
[213 NB] VALVE YOKE AND VALVE LASH ADJUSTMENTS
(NON-JAKE BRAKE ENGINE AND DYNATARD EQUIPPED) 7-2
Description 7-2
Special Tool Required 7-2
Locating and Marking Flywheel Valve Adjustment Markings 7-2
Valve Yoke Adjustment 7-3
Inlet Valve Adjustment 7-5
Exhaust Valve Adjustment 7-5
Continuation of Adjustments 7-6
[213 NB] VALVE YOKE, VALVE LASH AND SLAVE PISTON ADJUSTMENTS
(JACOBS BRAKE ENGINE) 7-6
Description 7-6
Housing Identification 7-7
Special Tools Required 7-8
Valve Yoke 7-8
Slave Piston, Inlet Valve and Exhaust Valve Lash Adjustments 7-9
Inlet Valve Adjustment 7-9
Exhaust Valve Adjustment 7-9
Slave Piston Adjustment 7-10
Continuation of Adjustments 7-11
[221 GP] INJECTION PUMP FIXED-TIMING PROCEDURES 7-11
Description 7-11
Special Tools Required 7-13
Setting Static Fuel Injection Pump Timing 7-13
Fuel Injection Pump Driven Gear Installation 7-15
Checking Pump-to-Engine Timing 7-18
Fuel Injection Pump Access Cover Installation 7-18
Fuel Injection Pump Pre-Lubrication 7-19
Timing Event Marker (TEM) Installation 7-20
[212 NP] LOCATING PISTON TOP DEAD CENTER (TDC) 7-21
E7 Series Engines with Front Timing Indicators 7-21
Special Tool Required 7-21
Locating Piston TDC 7-21
200 ENGINE INSTALLATION & TESTING 8-1
INSTALLATION 8-2
Description 8-2
Removing Engine from Engine Stand 8-2
Engine Installation into Vehicle 8-2
Filter Element Installation 8-3
FINAL PREPARATION 8-4
Lubrication 8-4
Engine Operational Check 8-5
REBUILT ENGINE RUN-IN PROCEDURES 8-5
Description 8-5
Run-In Check 8-5
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[233 FA] CHASSIS-MOUNTED CHARGE AIR COOLING 8-6
Description 8-6
Special Tool Required 8-6
CMCAC Troubleshooting 8-6
CMCAC Pressure Test 8-7
Restriction Pressure Test 8-8
Core Repair 8-8
CMCAC Preventive Maintenance 8-9
200 TROUBLESHOOTING 9-1
CAMSHAFT TIMING CHECK 9-10
CAMSHAFT LOBE LIFT CHECK 9-10
PROPER FIRE RING/CYLINDER SLEEVE-TOP COMBINATIONS 9-11
General Information 9-11
Engines Built Prior to 1993 9-11
Engines Built from June 1993 to Present (3L Serial Number and Later) 9-12
Cylinder Head and Cylinder Block Leak Test Procedure 9-13
200 APPENDIX 10-1
E7 ENGINE SERIAL NUMBERS, JACOBS BRAKE APPLICATION 10-2
E7 LUBRICATION SYSTEM 10-3
E7 COOLING SYSTEM 10-4
INDEX 11-1
DESCRIPTION:
Mack Truck E7 Engine Overhaul Operator’s Manual 5-101 – PDF DOWNLOAD
SAFETY INFORMATION:
Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation. The following list of general shop safety practices can help technicians avoid potentially hazardous situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood.
- Perform all service work on a flat, level surface. Block wheels to prevent vehicle from rolling.
- DO NOT wear loose fitting or torn clothing. Remove any jewelry before servicing vehicle.
- ALWAYS wear safety glasses and protective shoes. Avoid injury by being aware of sharp corners and jagged edges.
- Use hoists or jacks to lift or move heavy objects.
- NEVER run engine indoors unless exhaust fumes are adequately vented to the outside.
- Be aware of hot surfaces. Allow engine to cool sufficiently before performing any service or tests in the vicinity of the engine.
- Keep work area clean and orderly. Clean up any spilled oil, grease, fuel, hydraulic fluid, etc.
- Only use tools that are in good condition, and always use accurately calibrated torque wrenches to tighten all fasteners to their specified torques. In instances where procedures require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions.
This manual is intended to assist the technician in properly overhauling MACK E7 engines. The manual is divided into nine major sections. Working on the E7 engine is not difficult, but like most present-day precision equipment, it requires proper tools and knowledge.
- The overhaul procedures are separated into three sections: engine disassembly, bench procedures and engine assembly. Each section contains detailed procedures that must be followed in the order specified. If a step calls for a procedure that has already been described earlier in the manual, you will be referred to the section where the original procedure appeared.
- This manual covers the overhaul of an engine once it is removed from the vehicle, but also gives instructions for removing the engine from a nonspecified chassis. The new E7 is the most fuel-efficient diesel engine MACK has ever produced. This engine provides higher horsepower ratings, better fuel economy, increased durability and improved serviceability.
- In addition, the E7 still easily meets all applicable emissions standards. All this, coupled with the latest manufacturing techniques and equipment, makes the new E7 the highestquality MACK engine ever made. Externally, all E7 engine models look the same.
- However, Mack Trucks, Inc. has made many major internal design changes to comply with current and future EPA emission standards. To properly identify the E7 engine model year, refer to the engine information plate and the following pages of this section for additional engine plate information.
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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