Mack Truck Mechanical Marine Engine M-E7 Operating Maintenance & Service Manual(5-108) – PDF DOWNLOAD
FILE DETAILS:
Mack Truck Mechanical Marine Engine M-E7 Operating Maintenance & Service Manual(5-108) – PDF DOWNLOAD
Language : English
Pages : 331
Downloadable : Yes
File Type : PDF
Size: 30.4 MB
DESCRIPTION:
Mack Truck Mechanical Marine Engine M-E7 Operating Maintenance & Service Manual(5-108) – PDF DOWNLOAD
INTRODUCTION
Service Procedures and Tool Usage
- Anyone using a service procedure or tool not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuals deviating in any manner from the instructions provided assume all risks of consequential personal injury or damage to equipment involved.
- Also note that particular service procedures may require the use of a special tool(s) designed for a specific purpose. These special tools must be used in the manner described, whenever specified in the instructions.
INTRODUCTION
MackPower™, 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 marine engine operation
The following list of general 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
- DO NOT wear loose-fitting or torn clothing. Remove any jewelry before servicing.
- ALWAYS wear safety glasses and proper shoes. Avoid injury by being aware of sharp corners and jagged edges.
- When the boat is in the water, always close the sea water seacock prior to working on the raw water system to avoid sinking the boat. Reopen sea water seacock when work is complete.
- Use hoists or jacks to lift or move heavy objects.
- NEVER run engine 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 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
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mack Truck Mechanical Marine Engine M-E7 Operating Maintenance & Service Manual(5-108) – PDF DOWNLOAD
INTRODUCTION 1
SAFETY INFORMATION 2
Advisory Labels 2
Service Procedures and Tool Usage 3
CONVERSION CHART 5
EXPLANATION OF NUMERICAL CODE 8
ABOUT THE MARINE ENGINE AND ITS SERVICE 9
OPERATION OF MACKPOWER™ MARINE ENGINES 10
Engine Operating Instructions 10
VISUAL IDENTIFICATION 15
ENGINE MODEL IDENTIFICATION 16
Engine Information Plate 16
COMPONENT LOCATOR 17
ENGINE DESIGN FEATURES AND COMPONENT LOCATOR 18
TROUBLESHOOTING 25
ENGINE SYMPTOM DIAGNOSIS 26
Engine Will Not Crank 26
Engine Cranks — Will Not Start 26
Engine Misfires 27
Engine Stalls at Low Speeds 28
Erratic Engine Speed 28
Low Power 29
Engine Will Not Achieve No-Load Governed RPM 30
Excessive Engine Vibration 30
Excessive Black or Gray Smoke 30
Excessive Blue or White Smoke 31
Excessive Fuel Consumption 31
Excessive Oil Consumption 32
Engine Overheats 32
High Exhaust Temperature 33
Low Engine Oil Pressure 33
Engine Oil in Coolant 34
Coolant in Engine Oil 34
Low Compression 34
Excessive Crankcase Pressure 34
CAMSHAFT TIMING CHECK 35
CAMSHAFT LOBE LIFT CHECK 35
CYLINDER HEAD AND CYLINDER BLOCK LEAK TEST PROCEDURES 36
Cylinder Head and Head Gasket Check 36
Cylinder Head Fuel Passages Leak Check 37
Cylinder Head Oil Passage Leak Check 37
Cylinder Head Coolant Passage Leak Check (Off Engine) 39
Cylinder Block Coolant Passage Leak Check (Cylinder Heads Removed) 40
Raw Water Pump Impeller Troubleshooting Guide 41
MAINTENANCE 43
MARINE ENGINE SERVICE INTERVALS 44
GENERAL MAINTENANCE REQUIREMENTS 45
Turbocharger and Exhaust Connections 45
Belt Drive System Maintenance 45
Blow-By Recirculation Unit 46
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TABLE OF CONTENTS
v
Engine Oil Maintenance Requirements 48
Fuel System Maintenance 51
Cooling System Maintenance 54
AFTERCOOLER MAINTENANCE 57
Cleaning Aftercooler Internal Components 57
RAW WATER PUMP 62
Raw Water Pump Maintenance 62
GEAR OIL COOLER 65
General Information 65
HEAT EXCHANGER MAINTENANCE 66
General Information 66
ZINC REPLACEMENT 70
General Information 70
BATTERY/CHARGING SYSTEM MAINTENANCE 72
BATTERY 72
BATTERY CHARGING ALTERNATOR 73
REPAIR INSTRUCTIONS 75
ENGINE REMOVAL 76
Vessel Preparation 76
Removal Procedure 76
ENGINE DISASSEMBLY 78
General 78
Injection Pump Shutdown Solenoid Removal 78
Starter Motor Removal 78
Starter Magnetic Relay Removal 79
Filter Element Removal 80
Heat Exchanger to Oil Cooler Coolant Tube Removal 81
Mounting Engine in Stand 81
Alternator Removal 84
Blow-By Recirculation Vacuum Regulator and Breather Hose Removal 84
Engine Cooling System Vent Line Removal 85
Blow-By Recirculation Unit (AIRSEP®) Removal 86
Raw Water Pump Removal 87
Fuel Filter Adapter and Coolant Conditioner Adapter Assembly Removal 88
LDA Acceleration Smoke Control Line Removal 90
Exhaust Mixer/Exit Pipe (If Equipped) Removal 91
Turbocharger Removal 92
Fuel Nozzle Inlet Tube Assembly Removal 95
Injection Pump Throttle Return to Idle Mechanism 98
Engine Oil Fill Tube Removal 98
Exhaust Manifold Removal 99
Heat Exchanger Removal 100
Gear Oil Cooler Removal 101
Aftercooler Removal 101
Thermostat Removal 103
Coolant Manifold Removal 104
Air Inlet Manifold Removal 105
Oil Cooler and Oil Filter Housing Assembly Removal 105
Water Pump Removal 106
Fuel Injection Pump Removal 106
Valve Cover Removal 108
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vi
TABLE OF CONTENTS
Injector Nozzle Holder Removal 108
Rocker Arm, Valve Yoke and Push Rod Removal 109
Cylinder Head Assembly Removal 110
Vibration Damper and Crankshaft Hub Removal 111
Oil Pan Removal 111
Oil Pump Removal 113
Timing Gear Cover Removal 114
Auxiliary Driveshaft Removal 115
Camshaft Removal 116
Piston and Connecting Rod Assembly Removal 117
Flywheel Removal 119
Flywheel Housing Removal 119
Main Bearing Cap Removal 120
Crankshaft Removal 121
CYLINDER BLOCK RECONDITIONING 121
Piston Cooling Spray Nozzle Removal 121
Cylinder Sleeve Removal 122
Cylinder Sleeve Counterbore Repair 123
Cylinder Block Core Plug and Camshaft and Auxiliary Shaft Bushing Replacement 126
Cylinder Sleeve Installation 134
Piston Cooling Spray Nozzle Installation 137
Cylinder Block Dowel Pins 139
AUXILIARY DRIVESHAFT AND CAMSHAFT INSPECTION 140
Auxiliary Driveshaft 140
Camshaft 141
CRANKSHAFT INSPECTION 145
Description 145
Inspection 145
Crankshaft Wear Ring Installation 146
Crankshaft Dowel Pin Replacement 148
Crankshaft Gear 148
CONNECTING ROD AND PISTON INSPECTION 149
Connecting Rods 149
Pistons 152
Piston Rings 153
Assembling Connecting Rod to Piston 156
CYLINDER HEAD OVERHAUL 157
Cylinder Heads 157
Inlet and Exhaust Valves 176
Valve Rocker Arm Shaft 178
LUBRICATION SYSTEM COMPONENTS INSPECTION 181
Oil Cooler Assembly Inspection and Repair 181
Oil Pump Inspection and Repair 184
COOLING SYSTEM COMPONENTS INSPECTION 188
Water Pump Inspection (Fresh Water) 188
Gear Oil Cooler Inspection 188
Heat Exchanger Inspection 189
Raw Water Pump Inspection and Overhaul 190
FUEL SYSTEM COMPONENTS INSPECTION 196
Injection Pump Drive Hub 196
Injector Nozzle Inspection and Cleaning 199
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TABLE OF CONTENTS
vii
ENGINE REASSEMBLY 200
General Instructions 200
Crankshaft Installation 200
Main Bearing Cap Installation 202
Piston and Connecting Rod Installation 207
Flywheel Housing Installation 211
Crankshaft Rear Oil Seal Installation 214
Flywheel Installation 216
Camshaft Installation 217
Auxiliary Driveshaft Installation 218
Oil Pump Installation 220
Timing Gear Cover Installation 221
Crankshaft Front Seal Installation 221
Crankshaft Hub Installation 222
Vibration Damper Installation 222
Oil Pan Installation 223
Cylinder Head Installation 227
Push Rod Installation 230
Valve Yoke Installation 230
Rocker Arm Installation 231
Nozzle Holder Assembly Installation 232
Valve Cover Installation 234
Fuel Injection Pump Installation 234
Water Pump Installation 240
Air Inlet Manifold Installation 241
Coolant Manifold Installation 241
Thermostat, Housing and Seal Installation 242
Gear Oil Cooler Installation 244
Heat Exchanger Installation 245
Aftercooler Installation 246
Exhaust Manifold Installation 247
Engine Oil Fill Tube Installation 248
Injection Pump Throttle Return to Idle Mechanism Installation 248
Fuel Nozzle Inlet Tube Assembly Installation 249
Fuel Filter Adapter and Coolant Conditioner Adapter Assembly Installation 252
Turbocharger Installation 254
Exhaust Mixer/Exit Pipe (If Equipped) Installation 259
LDA Acceleration Smoke Control Line Installation 259
Engine Cooling System Vent Line Installation 260
Raw Water Pump Installation 261
Blow-By Recirculation Unit (AIRSEP®) Installation 262
Blow-By Recirculation Vacuum Regulator and Breather Hose Installation 263
Injection Pump Shutdown Solenoid Installation 264
Starter Magnetic Relay Installation 266
Alternator Installation 266
Removing Engine from Engine Stand 267
Filter Element Installation 267
Starter Motor Installation 268
Heat Exchanger to Oil Cooler Coolant Tube Installation 268
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TABLE OF CONTENTS
ENGINE INSTALLATION 269
General Instructions 269
Installation Procedure 269
ENGINE SETUP AND ADJUSTMENTS 270
Valve Yoke and Valve Lash Adjustments 270
Injection Pump Fixed-Timing Procedures 273
Locating Piston Top Dead Center (TDC) 279
FINAL PREPARATION AND OPERATIONAL CHECK 281
Systems Check and Lubrication 281
Engine Operational Check 283
REBUILT ENGINE RUN-IN PROCEDURES 284
Description 284
Run-In Check 284
SPECIFICATIONS 285
ENGINE GENERAL SPECIFICATIONS 286
Engine Features 286
PERFORMANCE SPECIFICATIONS 288
FITS AND LIMITS 289
TORQUE SPECIFICATIONS 295
M-E7 Component Torque Specifications 295
Torque Specifications for Hose Clamps 298
Oetiker Stepless Spring Clamps 298
Torque Specifications for Pipe Plugs 299
Specification Footnotes 299
Torque Specifications for Non-Critical Fasteners 300
ENGINE LUBRICANT AND SEALANT REQUIREMENTS 303
SCHEMATIC & ROUTING DIAGRAMS 305
ENGINE FLOW DIAGRAMS 306
Lubrication System Flow Diagram 306
Cooling System Flow Diagram 307
Fuel System Flow Diagram 308
SPECIAL TOOLS & EQUIPMENT 309
SPECIAL TOOLS 310
Special Tools for Engine Overhaul 310
INDEX 313
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