Mack MP7 Manuals

Manuals and User Guides for Mack MP7. We have 3 Mack MP7 manuals available for free PDF download: Service Manual, Operator's Handbook Manual, Body Builder Instructions

Mack MP7 Service Manual (364 pages)

Brand: Mack | Category: Engine | Size: 37.95 MB

Table of Contents
5
Introduction

12
- Safety Information
  13
  - Advisory Labels
    13
  - Service Procedures and Tool Usage
    14
- Explanation of Numerical Code
  16
- Conversion Chart
  17
- About the Mack Mp7 Engine
  20
  - Service Precautions Summary
    24
Visual Identification

26
- Mp7 Engine Model Identification
  27
  - Engine Information Plate
    27
  - Engine Serial Number Identification
    28
Description and Operation

30
- Mp7 Engine Design Features
  31
  - Engine Variants
    31
  - Engine Components
    31
  - Lubrication System
    43
  - Crankcase Ventilation
    45
  - Fuel System
    46
  - Powerleash™ Engine Brake
    51
  - Exhaust Gas Recirculation System
    53
  - Exhaust Aftertreatment System
    55
  - Variable Geometry Turbocharger
    60
  - Cooling System
    61
  - Engine Management System
    62
- Glossary of Terms
  65
Component Locator

68
- Mp7 Engine Component Location Views
  69
Troubleshooting

74
- Engine Symptom Diagnosis
  75
  - Troubleshooting Technique
    75
  - Noise and Vibration
    76
- Engine Checks and Tests
  77
  - Special Tools
    77
  - Camshaft Sensor Depth, Check
    80
  - Camshaft Timing, Check
    81
  - Crankcase Ventilation, Check
    81
  - Cylinder Head, Pressure Test
    82
  - Cylinder Liner and Piston Wear, Check
    83
  - EGR Cooler, Pressure Test
    85
  - Engine Compression, Test
    86
  - Flywheel Housing Runout, Check
    88
  - Oil Cooler, Pressure Test
    89
  - Rocker Arm, Check
    90
  - Thermostat, Check
    93
  - Valve Guide Wear, Check
    94
- Maintenance
  
  96
  - Lubrication System Maintenance
    97
    
    Oil Level Check
    97
    
    Special Tool
    97
    
    Oil and Filter Change Procedure
    98
    
    Crankcase Ventilation System
    99
  - Fuel Filter Replacement
    100
    
    Fuel Filter Change
    100
  - Cooling System Maintenance
    102
    
    Coolant Drain Outlets
    102
    
    Coolant Filter
    102
    
    Special Tool
    102
  - Exhaust Aftertreatment System Maintenance
    103
    
    Special Tools
    103
    
    Diesel Particulate Filter
    104
    
    Aftertreatment Fuel Injector (AFI)
    109
  - Drive Belt Replacement and Tensioning
    112
    
    General Information
    112
    
    Automatically Tensioned System
    113
- Repair Instructions, Part 1
  
  114
  - Engine Removal
    115
    
    General Instructions
    115
    
    Special Tools
    115
    
    Removal
    116
  - Engine Disassembly
    119
    
    Special Tools
    119
    
    General Instructions
    122
    
    Mounting the Engine on a Repair Stand
    122
    
    Cylinder Head (Valve) Cover Removal
    123
    
    Engine Wiring Harness Removal - External
    123
    
    Camshaft Gear and Vibration Damper Removal
    124
    
    Engine Wiring Harness Removal - Internal
    124
    
    Timing Gear Cover Removal
    124
    
    Rocker Arm Shaft and Engine Brake Removal
    125
    
    Valve Yoke (Bridge) Removal
    126
    
    Camshaft Removal
    127
    
    Unit Injector Removal
    128
    
    Starter Removal
    133
    
    EGR Hot Pipe (Cooler Inlet) Removal
    134
    
    Turbocharger Removal
    134
    
    EGR Valve Removal
    135
    
    EGR Cooler Removal
    136
    
    Exhaust Manifold Removal
    137
    
    Oil Filter Housing Removal
    138
    
    Coolant Pipe Removal
    139
    
    Cooling Duct Cover and Oil Cooler Removal
    140
    
    Fan Drive, Idler and Fan Bracket Removal
    142
    
    EGR Crossover (Cooler Outlet) Pipe Removal
    143
    
    EGR Mixer Removal
    143
    
    EGR Venturi Housing Removal
    143
    
    Fuel Lines and Fuel Filter Housing Removal
    144
  - EECU and Cooling Plate Removal
    145
  - Inlet Manifold Removal
    146
  - Tandem Pump (Fuel and Power Steering) Removal
    147
  - Air Compressor Removal
    147
  - Flywheel and Pilot Bearing Removal
    148
  - Power Take-Off (PTO) Assembly Removal
    148
  - Flywheel Housing Removal
    149
  - Crankshaft Rear Seal Removal
    150
  - Timing Gear Train Removal
    150
  - Timing Gear Plate Removal
    152
  - Alternator and Refrigerant Compressor Removal
    152
  - Thermostat and Cover Removal
    153
  - Coolant Pump Removal
    153
  - Cylinder Head Removal
    154
  - Crankshaft Vibration Damper and Fan Pulley Removal
    157
  - Crankshaft Front Cover Removal
    157
  - Crankshaft Front Seal Removal
    158
  - Oil Fill Pipe and Dipstick Retainer Removal
    158
  - Oil Pan Removal
    158
  - Front Engine Support Removal
    159
  - Oil Pump and Valve Housing Removal
    159
  - Block Stiffener Plate Removal
    161
  - Piston and Connecting Rod Assembly Removal
    162
  - Main Bearing Cap Removal
    163
  - Crankshaft Removal
    164
  - Cylinder Block Reconditioning
    165
    
    Tools and Equipment
    165
    
    Cylinder Liner Removal
    166
    
    Piston Cooling Spray Nozzle Removal
    166
    
    Cylinder Block Cleaning and Inspection
    167
    
    Cylinder Liner Height Measurement
    168
    
    Cylinder Liner Installation
    169
  - Flywheel Bench Procedures
    170
    
    Flywheel Ring Gear Replacement
    170
  - Connecting Rod and Piston Bench Procedures
    171
    
    Connecting Rod - Piston Disassembly
    171
    
    Piston Inspection and Cleaning
    173
    
    Piston Ring Inspection and Replacement
    174
    
    Connecting Rod - Piston Assembly
    175
  - Cylinder Head Overhaul
    177
    
    Tools and Equipment
    177
    
    Inlet and Exhaust Valve Removal
    180
    
    Cylinder Head Cleaning and Inspection
    181
    
    Valve Guide Replacement
    182
    
    Valve Spring Inspection
    183
    
    Injector Sleeve Replacement
    184
    
    Expansion Plug Replacement
    191
    
    Valve Inspection
    192
    
    Valve Installation
    192
  - Rocker Arm Shaft Bench Procedures
    194
    
    Description
    194
    
    Inspection
    195
    
    Rocker Arm Shaft Assembly
    195
    
    Rocker Arm Shaft Disassembly
    195
  - Camshaft Bench Procedures
    196
    
    Camshaft Inspection
    196
  - Cooling System Components Bench Procedures
    197
    
    Special Tool
    197
    
    Oil Cooler Reconditioning
    198
    
    EGR Cooler Cleaning
    199
    
    EGR Cooler Pressure Test
    201
  - Engine Reassembly
    203
    
    Special Tools
    203
    
    General Instructions
    206
    
    Crankshaft Installation
    207
    
    Main Bearing Cap Installation
    208
    
    Piston and Connecting Rod Assembly Installation
    210
    
    Block Stiffener Plate Installation
    214
    
    Oil Pump and Valve Housing Installation
    215
    
    Front Engine Support Installation
    216
    
    Crankshaft Front Cover Installation
    217
    
    Crankshaft Front Seal Installation
    218
    
    Timing Gear Mounting Plate Installation
    219
    
    Cylinder Head Installation
    220
    
    Camshaft Installation
    223
    
    Unit Injector Installation
    225
    
    Valve Yoke (Bridge) Installation
    228
    
    Rocker Arm Shaft and Engine Brake Installation
    229
    
    Timing Gear Train Installation
    232
    
    Flywheel Housing Installation
    235
    
    Oil Pan Installation
    236
    
    Oil Filler Pipe and Dipstick Pipe Installation
    238
    
    Power Take-Off Installation
    238
    
    Timing Gear Cover Installation
    238
    
    Crankshaft Rear Seal Installation
    240
    
    Flywheel and Pilot Bearing Installation
    240
    
    EGR Crossover (Cooler Outlet) Pipe Installation
    242
    
    Fan Bracket Installation
    242
    
    Coolant Pump Installation
    243
    
    Oil Cooler and Cooling Duct Cover Installation
    244
    
    Thermostat and Cover Installation
    244
    
    Coolant Pipe Installation
    248
    
    Exhaust Manifold Installation
    249
    
    Oil Filter Housing Installation
    249
    
    EGR Valve Installation
    250
    
    EGR Cooler Inlet Pipe Installation
    251
    
    EGR Cooler Installation
    251
    
    Turbocharger Installation
    252
    
    Starter Installation
    253
    
    Air Compressor Installation
    254
    
    Tandem Pump (Fuel and Power Steering) Installation
    255
    
    Inlet Manifold Installation
    256
    
    EECU and Cooler Installation
    257
    
    EGR Mixer Installation
    257
    
    EGR Venturi Housing Installation
    257
    
    Intermediate and Mixer Inlet Piping Installation
    257
    
    Fuel Lines and Fuel Filter Housing Installation
    259
    
    Crankcase Ventilation Separator
    260
    
    Alternator and Refrigerant Compressor Installation
    261
    
    Crankshaft Vibration Damper and Fan Pulley Installation
    262
    
    Wiring Harness Installation
    262
    
    Cylinder Head (Valve) Cover Installation
    263
    
    Filters and Miscellaneous Components Installation
    264
    
    Removing Engine from Engine Stand
    264
    
    Engine Installation
    266
    
    General Instructions
    266
    
    Installation
    266
    
    Special Tools
    266
Repair Instructions, Part 2

270
- In-Chassis Part/Component Procedures
  271
- Oil Pump Replacement (in Chassis)
  271
  - Oil Pump Removal
    272
  - Oil Pump Installation
    272
- Crankcase Ventilation (CCV) Separator Replacement
  274
  - CCV Separator Removal
    274
  - CCV Separator Installation
    274
- Turbocharger Smart Remote Actuator (Sra) Replacement
  274
  - Preliminary Steps
    274
  - Turbocharger SRA Removal
    275
  - Turbocharger SRA Inspection and Installation
    276
  - Final Assembly
    279
- Unit Injector Cleaning
  279
  - Preliminary Steps
    279
  - Cleaning and Inspection
    280
  - Final Steps
    280
- Injector Copper Sleeve Replacement
  281
  - Tools and Equipment
    281
  - Preliminary Steps
    283
  - Copper Sleeve Removal
    283
  - Copper Sleeve Installation
    287
  - Final Steps
    290
- Valve Stem Height Measurement Procedure
  290
- Valve Stem Seal Replacement
  293
  - Special Tools
    293
  - Preliminary Steps
    294
  - Seal Removal
    294
  - Seal Installation
    294
  - Final Steps
    295
- Repair Instructions, Part 3
  
  296
  - Mp7 Engine Setup and Adjustment
    297
    
    Special Tools
    297
    
    Valve and Unit Injector Adjustment
    298
    
    Checking and Adjusting Timing Gear Backlash
    302
  - Engine Final Preparation and Operational Check
    305
    
    Filter Element Installation
    305
    
    Engine Lubrication System
    306
    
    Fuel System
    306
    
    Engine Operational Check
    308
  - Rebuilt Engine Run-In Procedures
    308
    
    General
    308
    
    Run-In Check
    308
- Specifications
  
  310
  - Mp7 Engine Mechanical Specifications
    311
    
    Material and Dimensional Data
    311
    
    Engine Component Torque Specifications (Standard Fasteners)
    316
    
    Engine Component Torque Specifications (Critical Fasteners)
    317
  - Engine Gaskets, Lubricants and Sealants
    340
    
    Gasket and Seal Reuse
    340
    
    Lubricants and Sealants
    341
- Special Tools & Equipment
  
  342
  - Mp7 Engine Service Tools
    343
    
    Special Tools for the MP7 Engine
    343
- Index
  
  358

Mack MP7 Operator's Handbook Manual (173 pages)

Brand: Mack | Category: Engine | Size: 3.87 MB

Table of Contents
3
Operator's Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU
5
Foreword
5
Warning Label Information
6
General Information
7
Information for the Owner
7
Federal Emission Requirements
9
Label Information
18
Safety Information
24
Proper Maintenance Procedure
24
Injury Prevention
27
Engine Damage Prevention
35
Electric System Damage Prevention
37
Reporting Safety Defects
39
General Engine Information
40
Engine Overview, MP7 and MP8 Left Side View
40
Engine Overview, MP7 and MP8 Right Side View
41
Engine Overview, MP10 Left Side View
42
Engine Overview, MP10 Right Side View
43
Electrical System
44
Batteries
44
Battery Warmer
46
Battery Condition
46
Charging
47
Load Test
49
Electrical Connection Protection
49
Precautions When Installing Electrical Equipment
51
Engine Storage
54
Maintenance and Service
55
Maintenance Hazards
55
Engine Components, Service Schedules
55
Cooling System
58
Fuel System
67
Engine Oil
80
Driveshaft Lubrication
88
Engine Air Filter
90
Exhaust After-Treatment System
93
Drive Belt Replacement Intervals
103
Automatic Belt Tensioner Maintenance
111
Turbocharger and Charge Air Cooler
115
Preventive Maintenance Air Suspensions
118
Steering and Brakes Maintenance
119
Tires, Wheels and Hub Maintenance
123
Chassis Maintenance
138
Cab Maintenance
140
Lubrication
146
Oil Capacity Tables and Viscosity Charts
152
Service Check List
157
Preventive Maintenance
157
Service Charts
161
Scheduled Services
161
Tire Record
165
Fuel and Oil Record
166
Engine Data
167
Literature
168
Service Assistance and Manuals
168
Customer Service
169

Mack MP7 Body Builder Instructions (44 pages)

BODY BUILDER INSTRUCTIONS CHU, CXU, GU, TD, MRU, LR

Brand: Mack | Category: Engine | Size: 3.58 MB

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Engine Trucks Alarm Clock Trimmer Automobile Accessories

More Mack Manuals

Mack MP7 Manuals

Mack MP7 Service Manual (364 pages)

Table of Contents

Introduction

Visual Identification

Description and Operation

Component Locator

Troubleshooting

Maintenance

Repair Instructions, Part 1

Repair Instructions, Part 2

Repair Instructions, Part 3

Specifications

Special Tools & Equipment

Index

Mack MP7 Operator's Handbook Manual (173 pages)

Table of Contents

Mack MP7 Body Builder Instructions (44 pages)

Table of Contents

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