5-101.

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200 SETUP AND ADJUSTMENTS

Continuation of Adjustments 3. Continue adjusting yokes, valves and slave
cylinder lash for the remaining cylinders, in
1. Using engine barring socket J 38587-A, firing order, placing each piston 30 degrees
manually rotate engine in normal rotation past TDC by rotating the crankshaft and
direction 120 degrees until pointer in aligning marks on the flywheel with pointer
flywheel housing aligns with the “5” mark on marked VALVE and appropriate mark on
the flywheel. The No. 5 piston will be on the vibration damper, if equipped.
compression stroke. If engine is equipped
with a pointer on the timing gear cover and
marks on the vibration damper, rotate the [221 GP] INJECTION PUMP
engine until the pointer marked VALVE FIXED-TIMING PROCEDURES
aligns with the “5” mark on the vibration
damper. Refer to Figure 7-11.

Whenever the injection pump is removed from a

MACK E7 engine, it is necessary to set injection
pump-to-engine timing using the fixed-timing
method. This method uses a portable fixed-timing
light which electronically determines port closure
to verify precise injection pump-to-engine timing.

Description
The fixed-timing method is a simple, accurate
procedure which uses a timing light to set
injection-to-engine timing. Using the fixed-timing
method ensures optimum fuel economy and
engine durability, and maintains engine exhaust
within established EPA limits.

Figure 7-11 — Engine Crankshaft Rotation 70

77
J3

2. Adjust the yoke, valves and slave piston lash

R
WE
PO OR
NS
SE
N

as previously outlined for the No. 1 cylinder.

IO
SIT B
PO
RE
A OO
-M
NT 200402a
KE

Figure 7-12 — Fixed Timing Method

E7 engine firing order is 1 - 5 - 3 - 6 - 2 - 4.

Make sure key is off.

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200 SETUP AND ADJUSTMENTS

앫 On all P7100 non V-MAC mechanically
controlled fuel-injection systems, injection
timing is referenced to the No. 1 cylinder.
The engine must be timed during the
compression stroke of cylinder No. 1.
앫 On all P7100 V-MAC electronically
controlled fuel-injection systems, injection
timing is referenced to the No. 6 cylinder.
The engine must be timed during the
compression stroke of cylinder No. 6.
앫 On all P8500 V-MAC electronically
controlled fuel-injection systems, injection
timing is referenced to the No. 1 cylinder.
The engine must be timed during the
compression stroke of cylinder No. 1.

The injection pump driven gear capscrews on

factory-assembled E7 engines come in three
different head sizes (15 mm, 16 mm or 17 mm).
All four capscrews on a given engine will be the
same and the torque is the same for all three
head sizes: 40 lb-ft (54 N•m).
200493a

Figure 7-13 — V-MAC Hub Rotation Tool J 38740

On mechanically governed engines, different
head sizes pose no problem. On V-MAC engines,
however, different capscrew head sizes can
affect the use of V-MAC hub rotation tool
J 38740, used to rotate the injection pump when When removing capscrews and washers, be
setting injection pump-to-engine timing. J 38740 extremely careful not to drop a washer into the
actually consists of two tools: engine. Removing the washer is difficult and may
require some engine disassembly.
앫 An adapter with two posts that fit into tapped
holes in drive hub.
앫 An adapter with two tubes, one on each Following are procedures for:
end, fit over the heads of two of the timing 앫 Setting Static Fuel Injection Pump Timing
adjustment capscrews. (This adapter will not
fit over the heads of some of the timing 앫 Fuel Injection Pump Driven Gear Installation
adjustment capscrews. If this problem 앫 Checking Pump-to-Engine Timing
occurs, simply remove two of the adjustment
capscrews and washers, and use the tool 앫 Fuel Injection Pump Access Cover
with posts in the openings.) Installation
앫 Fuel Injection Pump Pre-Lubrication
앫 Timing Event Marker (TEM) Installation

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200 SETUP AND ADJUSTMENTS

Accurately setting the injection pump timing is the Thoroughly clean all residue from the fixed timing
best way to ensure optimum fuel economy, port threads (timing access window) before
engine durability, and maintain engine exhaust installing tool sensor. This will prevent the
within established EPA limits. possibility of a false reading.

2. Clean all residue from the TEM sensor or

Special Tools Required plug threads.
앫 Fixed Timing Position Sensor (Light)
J 37077
앫 Alignment Fixture J 37078
앫 Pump Drive Gear Alignment Dowels
J 37085
앫 Hub Rotation Tool J 38740

Setting Static Fuel Injection Pump

Timing
To set the static fuel injection pump timing, prior
to pump removal, proceed as follows:
1. Remove the TEM sensor (on mechanically Figure 7-15 — Cleaning TEM Sensor Threads
governed engines, remove plug) from the
fixed timing port.

Figure 7-14 — Removing TEM Sensor

Page 7-13
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200 SETUP AND ADJUSTMENTS

3. Clean the J 37077 tool sensor probe points
with compressed air before using. This helps
prevent metallic contamination between the
sensor probe points.

J 37077

200405a

Figure 7-17 — Installing J 37077 Tool

5. Slowly turn the knurled surface clockwise to

lock the tool into place. Check to make sure
tool is seated by applying pressure to the
end of the tool and checking for any
movement. If movement is detected, remove
and reinstall the tool.

200406a

Figure 7-18 — Turning Knurled Surface Clockwise

6. Connect the fixed timing tool ground to the

200492a engine and press power switch on.
Figure 7-16 — Cleaning Sensor Probe Points

4. Install fixed timing position sensor tool

J 37077. Make sure that tool is correctly
aligned with the locating groove in the fixed
timing port.

J3
70
77
PO
PO W
ER
SIT
IO
N
A SE
NS
KE OR
NT
-M B
OO
RE
200407a

Figure 7-19 — Grounding and Turning Tool On

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200 SETUP AND ADJUSTMENTS

7. To continue the procedures for setting the Fuel Injection Pump Driven Gear
timing, refer to the following applications for
an engine with front timing indicator or with
Installation
rear timing indicator. To install the fuel injection pump gear:
ENGINE WITH FRONT TIMING INDICATOR 1. Verify crankshaft is set to correct BTDC
position for pump timing.
E7 mechanically governed engines with
automatic transmissions use the Center Web 2. Connect timing-light tool J 37077 (refer to
Vibration Damper with timing marks. The beginning of the section, Setting Static Fuel
vibration damper timing indicator and engine front Injection Pump Timing). Using hub rotation
turnover bracket are used in this application. tool J 38740, rotate the timing gear hub
clockwise until both lights A and B are lit.
1. Rotate the engine crankshaft counterclock-
wise (as viewed from the front of the engine)
to a minimum of 45 degrees before Top
Dead Center (TDC).
2. Rotate the engine crankshaft clockwise until
lamps A and B are both lit. Fuel injection J 37077

pump-to-engine timing is now set and the J 38740

injection pump can be removed from the POWER

engine. POSITION SENSOR

A B

ENGINE WITH REAR TIMING INDICATOR KENT-MOORE

E7 mechanically governed engines with manual

transmissions and all V-MAC engines with 200452a
manual and automatic transmissions use the
flatback vibration damper with no timing marks. Figure 7-20 — Rotating Timing Gear Hub Clockwise
They are also equipped with flywheel and
flywheel housings that incorporate engine timing
and turnover features. With rear timing, the front
timing indicator and engine front turnover bracket 앫 Use the proper hub rotation tool J 38740
are not utilized. which allows rotation of the hub only.
1. Remove all six 8-mm capscrews to access 앫 Do not use the inner shaft nut (25 mm) to
the flywheel housing timing window. rotate the timing gear hub.
2. Remove the plastic plug in the cast- 앫 If the inner shaft nut is used to rotate the hub,
machined opening in the forward face of the the nut may loosen, resulting in subsequent
housing. failure.
3. Insert engine barring socket tool J 38587
into the opening.
4. Install a 1/2-inch drive ratchet into tool
J 38587 to rotate the flywheel.
5. Rotate the flywheel counterclockwise to a
minimum of 45 degrees before TDC.
6. Rotate the flywheel clockwise in normal
direction (as viewed from the front of the
engine), until lamps A and B are both lit.
Fuel injection pump-to-engine timing is now
set and the injection pump can be removed
from the engine. Remove tool J 38587 from
the flywheel housing.

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200 SETUP AND ADJUSTMENTS

3. Install two pump drive gear alignment 5. Install two driven gear capscrews in the
dowels, J 37085, to ease alignment of drive open holes. Install capscrews snugly to
gear to timing gear hub. remove clearance but allow relative motion
between hub and gear.

J 37085

200453a 200455a

Figure 7-21 — Installing Drive Alignment Dowels Figure 7-23 — Installing Driven Gear Capscrews

4. Install the fuel injection pump driven gear on 6. Remove the alignment dowels and install
the timing gear hub so the screw holes in the remaining capscrews in the same manner.
hub are centered in the gear slots/alignment
dowels. 7. Using hub rotation tool J 38740, rotate the
timing gear hub counterclockwise until
screws bottom in the ends of the gear slots
in the fuel injection pump driven gear. When
this happens, both lamps will go out.

Three different head sizes have been used for

the injection pump timing adjustment capscrews.
Refer to Description at the beginning of this
procedure for additional information.

200454a

Figure 7-22 — Installing Driven Gear

Page 7-16
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200 SETUP AND ADJUSTMENTS

J 38740

7
707
J3

R
WE
PO
OR
NS
SE
ION
SIT
PO B
A RE
OO
-M
NT
KE

200458a

Figure 7-24 — Rotating Timing Gear Hub

Counterclockwise

8. Rotate timing gear hub clockwise until both

A and B lamps are lit. There is only a very
small band of rotation for which both lamps
are lit.

200460a

J 37077
Figure 7-26 — Torquing Driven Gear Capscrews
POWER

POSITION SENSOR

A B
KENT-MOORE

Lamp A or B may go out during torquing

procedure. This is acceptable. Do not attempt to
keep lamps lit. Doing so may cause improper
pump-to-engine timing.
200459a

Figure 7-25 — Rotating Timing Gear Hub Clockwise

9. Torque all fuel injection pump driven gear

capscrews to 40 lb-ft (54 N폷m) using torque
wrench J 24407 or equivalent.

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200 SETUP AND ADJUSTMENTS

Checking Pump-to-Engine Timing Fuel Injection Pump Access Cover
Installation
To install the fuel injection pump access cover:
Using hub bolt to rotate engine backward may 1. Lubricate the access cover O-ring with
change bolt torque. Check torque of hub bolt after Lubrizol OS-50044 or equivalent.
completing timing procedure.

1. Rotate engine crankshaft counterclockwise

to a minimum of 45 degrees before TDC.
Both A and B lamps will go out.
2. Rotate engine crankshaft clockwise until
both A and B lamps are lit. If timing pointer
does not cover a value within ± 0.5 (1/2)
degree of desired timing, the engine is not
timed correctly. Before continuing, check
and verify piston is at TDC. Refer to
Locating Piston Top Dead Center (TDC) in
SETUP AND ADJUSTMENTS.
200461a

Figure 7-27 — Lubricating Access Cover O-Ring

If timing is not within specification, reset and 2. Install clamp and access cover capscrews.
recheck timing.
3. Torque access cover capscrews to 30 lb-ft
(41 N폷m) using torque wrench J 24407 or
3. After achieving correct timing, remove timing equivalent.
tools.
a. Turn tester power off.
b. Disconnect tester ground.
c. Remove fixed timing probe.
4. Install fixed timing port plug or TEM sensor.
5. Check torque of hub bolt. The correct torque
is 360 lb-ft (488 N•m).

200463a

Figure 7-28 — Installing and Torquing Access Cover

Capscrews

4. Run wire through both the drilled access

cover capscrews and through the center of
the lead seal and loop it. Then bring it
through again.

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200 SETUP AND ADJUSTMENTS

200465a

Figure 7-29 — Installing Access Cover Seal Figure 7-31 — P7100 Injection Pump/Mechanical
Governor Pre-Lubrication
5. Using Midget sealing tool 814 or equivalent,
compress the lead seal. To pre-lubricate the P7100 V-MAC fuel injection
6. Reconnect fuel injection pump oil supply pump and governor, remove the timing event
line. marker located on the governor and add
3.5 ounces (104 ml) of clean engine oil. Reinstall
the timing event marker. To pre-lubricate the
Fuel Injection Pump Pre-Lubrication V-MAC injection pump, remove the plug in the
side of the pump housing and add 11 ounces of
To pre-lubricate the P8500/RE30 fuel injection clean engine oil. Reinstall the plug.
pump and governor, add 12 ounces (0.4 liter) of
clean engine oil through the Timing Event Marker
(TEM) port located in the RE30 governor
housing. Oil will run through the governor into the
pump.

TEM PORT Figure 7-32 — P7100 V-MAC Injection Pump/Governor

Pre-Lubrication

200466a

Figure 7-30 — P8500/RE30 Injection Pump

Pre-Lubrication
Pre-lubrication is required anytime a new or used
To pre-lubricate the P7100 fuel injection pump fuel injection pump is removed and then installed
with mechanical governor, remove the timing on the engine.
sensor (fixing plate) plug in the governor housing.
Add 12 ounces (355 ml) of clean engine oil. This
will fill both the governor and fuel injection pump.
Reinstall the timing sensor (fixing plate) plug.

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200 SETUP AND ADJUSTMENTS

Timing Event Marker (TEM)
Installation
To install the TEM:
1. Thoroughly clean all oil residue from the
TEM and timing access window.
2. Completely back off the TEM jam nut
(toward the sensor pigtail).
3. Apply a 1/8- to 1/4-inch bead of Silastic
(MACK part No. 342SX32 or equivalent)
around the sensor threads at the jam nut.

Figure 7-35 — Torquing TEM Sensor Jam Nut

APPLY 7. Wipe the excess Silastic with a dry cloth.

1/8–1/4 INCH
BEAD OF 8. Reconnect all brackets, connections and
SILASTIC fuel lines.

2
1

205205a

Figure 7-33 — Silastic Application

4. Install the TEM sensor into the timing access

window and hand tighten until seated in the
timing window.

3
5 4
9 8 6
7

200363a

Figure 7-36 — Pump Line Connections

1. Return from secondary 5. Return to secondary filter

filter 6. Return from primary filter
Figure 7-34 — Installing TEM Sensor 2. Cylinder head overflow 7. Lubrication supply line
line 8. Capscrew
5. Tighten the jam nut, running it over the 3. Return to tank line 9. Capscrew
Silastic. 4. Capscrew

6. Torque the jam nut to 22 lb-ft (30 N폷m) using

9. Check all connections and clamps for
torque wrench J 24406 or equivalent.
tightness. Check for leaks.

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200 SETUP AND ADJUSTMENTS

[212 NP] LOCATING PISTON 6. Rotate engine in direction opposite to
normal rotation until a reading of 0.060 inch
TOP DEAD CENTER (TDC) (1.524 mm) is obtained on the dial indicator.
7. Rotate engine in normal rotation direction
E7 Series Engines with Front until dial indicator reads exactly 0.035 inch
Timing Indicators (0.889 mm).

During timing inspection, if timing is found to be 8. Place a mark on the masking tape on the
incorrect, check piston TDC and retime engine. vibration damper to align with pump timing
The following instructions are provided to aid in indicator pointer.
locating piston TDC in the event the engine front 9. Rotate engine in normal rotation direction
timing pointer is bent or misaligned. past zero on dial indicator until a reading of
0.060 inch (1.524 mm) is obtained.

On engines with front timing indicators, vibration

damper is marked to show TDC location relative
to No. 1 piston on compression stroke. After
locating piston TDC, front timing indicator may be
adjusted slightly until it aligns with the TC or “0”
mark stamped on vibration damper.

Special Tool Required

앫 Top Dead Center Indicator Tool J 29539-A

Locating Piston TDC

If chassis is equipped with an engine stop control,

pull control out to prevent accidental starting.

Refer to Figure 7-37.

1. Rotate engine in normal rotation direction
until No. 1 piston is approximately at TDC on
Figure 7-37 — Locating Piston TDC
compression stroke.
2. Remove injection nozzle holder assembly
from the No. 1 cylinder (front cylinder on E6
and E7 engines).
3. Install TDC indicator tool J 29539-A in
nozzle holder opening.
4. Rotate engine in normal rotation direction
until the highest reading is obtained on the
dial indicator. At this point, zero dial
indicator.
5. Center a 5-inch (127 mm) length of masking
tape below the pump timing pointer and on
the vibration damper.

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200 SETUP AND ADJUSTMENTS

10. Rotate engine in direction opposite to
normal rotation until a reading of exactly
0.035 inch (0.889 mm) is indicated on dial
indicator.
11. Place a mark on the masking tape on the
vibration damper to align with pump timing
pointer.
12. Measure distance between the two marks
just made on the masking tape and place a
third mark exactly at the midpoint between
the first two marks.
13. Rotate engine in direction opposite to
normal rotation until engine timing pointer
aligns with the middle mark just made on
vibration damper. Remove masking tape.
14. If necessary, without rotating the engine,
realign pump timing pointer until it aligns
with the TC or “0” mark stamped on the
vibration damper.

Page 7-22