navistar o & m manual

OPERATION AND MAINTENANCE MANUAL

7.2 MECHANICAL

1-1

8

7

6

5

4

3

2

17

16

15

14

13

12

11

10

9

IntroductIon

Presentation

Introduction................................................................................................................................................1

How.to.Use.this. 1

Important.Safety.Remarks........................................................................................................................ 2 - 3

Generafl.Instructfions............................................................................................................................... 3

Cleaning.General.Instructions...................................................................................................................4

Engine.Serial.Number.Identification.and.Location....................................................................................5

Cylinder.Numeration..................................................................................................................................6

7

Group ( 001 - 000 )

Page - 001

Engine Identification.................................................................................................................................

Engine Exploded View..............................................................................................................................

Engine Technical Data..............................................................................................................................

Engine Description....................................................................................................................................

8

9 - 10

11 - 22

Manual .........................................................................................................................

This.manual.contains.complete.information.and.specification.to.assembly.and.disassembly.MAXXFORCE.7.2 .engines.and.all.components.manufactured.by.MaHIndra navIStar enGIneS Pvt ltd.I I .

Read.and.follow.all.safety.instructions..Consult.the.item.ATTENSION. in.the.Safety.General.Instructions,. in.the.next.section.

Some.of.the.Operation.and.Maintenance.procedures.require.special.tools.

Make.sure.that.the.correct.tools.are.used.according.indicated.in.the.procedures.

The.assembly.and.disassembly.specifications.and. information.presented. in.this.manual.are.the.ones.which. is.effective.in.the.moment.of.its.print..MaHIndra navIStar enGIneS Pvt ltd.I I .reserves.the.right.of.making.any.change,.at.any.moment..MaHIndra navIStar enGIneS Pvt ltd.I .reserves.the.right.of.doing.changes.in.the.product.at.any.moment.without.this.to.incur.in.any.further.obligation..In.case.of.any.difference.in.the.engine.or.information.of.this.manual,.contact.an.MNEPL. Authorized. Distributor. or. the. factory.

The.components.used.in.MNEPL. engines. production. are. produced. with. last. generation. technology. components. .with.high.level.quality.standards..When.parts.changes.are.necessary,.it.is.recommended.to.use.only.MIM.genuine.spare.parts..

Introduction

How to use this Manual

To.create.this.Manual.it.has.been.taken.as.base.a.generic.MAXXFORCE. 7.2 .engine,.which.operations.and.maintenance.procedures.are.the.same.for.all.models.of.this.series..The.illustrations.therefore,.could.differ.from.application.to.application.

In.this.Manual,.all.references.to.the.components.of.the.engine.are.divided.in.19.specific.sections..For.your.conve-nience,.the.organization.of.the.Manual.is.consistent.with.MNEPL. Service. Bulletins.

Manual contentThe.Manual.contains.an.index.that.can.be.used.as.a.quick.reference.to.access.each.section.

SectIonS contentEach.section.contains.the.following.information:

Page.of.index.in.the.beginning.of.each.section.to.help.for.the.fast.location.of.the.desired.information.

General.information.about.the.operation.of.the.component.and.the.explanation.of.their.main.changes.

Component.disassembly,.cleaning,.inspection.and.dimension.instructions.

Information on Metric System

All.dimensions.are.expressed.in.the.International.Metric.System.(I.S.).

•

•

•

Page - 1

1-3

8

7

6

5

4

3

2

17

16

15

14

13

12

11

10

9

IntroductIon

! attention:. Incorrect.procedures.and.lack.of.care.can.cause.burns,.cuts,.mutilation,.asphyxia.or.otherin-juries.and.even.death.

Carefully.read.all.safety.procedures.and.remarks.before.performing.any.repair. in.the.engine..The.following.list.presents.the.general.cautions.that.must.be.followed.to.guarantee.your.personal.safety..Special.safety.measures.can.be.presented.with.the.procedures,.if.necessary.

Make.sure.that.the.work.area.around.the.engine.is.dry,.well.lightened,.ventilated,.organized,.without.tools.and.loosened.parts,.ignition.sources.and.dangerous.substances..Check.for.dangerous.conditions.can.happen.and.avoid.them.

Always.use.individual.protection.equipments.(safety.eyeglasses,.gloves,.shoes,.etc.).while.you.are.working.

Remember.that.parts.in.movement.can.cause.cuts,.mutilation.and.strangling.

Do.not.use.loosen.or.ripped.clothes..Remove.jewellery.and.watches.before.working.

Disconnect.the.battery.(negative.cable.first).and.discharge.the.capacitors.before.beginning.the.repairs.

In.case.the.repair.is.being.made.in.the.vehicle,.disconnect.the.starter.motor.to.avoid.an.accidental.start.of.the.engine..In.case.of.industrial.engines,.place.a.“Do.Not.Operate”.warning.in.the.operator.compartment.or.on.the.controls.

To.manually.rotate.the.engine,.use.ONLY.the.recommended.procedures..Never.try.to.rotate.the.crankshaft.with.the.fan..This.practice.can.cause.serious.personal.injuries.or.damages.to.the.fan.blades,.causing.the.premature.failure.of.the.component.

If.the.engine.was.in.operation.and.the.cooling.fluid.is.hot,.leave.the.engine.to.cold.down.before.slowly.open.the.cover.of.the.reservoir.to.relief.the.pressure.of.the.cooling.system.

Do.not.work.with.materials.that.are.lifted.by.jacks.or.cranes.

Always.use.correct.blocks,.stands.or.brackets.to.position.the.engine.before.performing.any.repair.

Relief.the.pressure.of.the.pneumatic.(brakes),.lubrication.and.cooling.systems.before.removing.or.disconnect.any.piping,.connections.or.other.elements..Pay.attention.to.the.pressure.existence.before.to.disconnect.any.item.of.a.pressurized.system..Do.not.check.pressure.leakages.with.the.hand..Oil.or.fuel.at.high.pressure.can.cause.injuries.

To.avoid.injuries,.use.a.crane,.or.ask.for.help.to.lift.components.which.weight.more.than.20.kg..Make.sure.that.all.lift.equipments.as.chains,.hooks.or.belts.are.in.good.conditions.and.have.the.correct.load.capacity..Make.sure.that.hooks.are.correctly.positioned..Always.use.an.extension.when.necessary..The.lift.hooks.must.not.receive.side.loads.

Never.leave.the.engine.operating.in.a.closed.and.non.ventilated.area..The.engine.exhaust.gases.are.harmful.to.health.

The .MNEPL.coolant.has.alkaline.substances..Avoid.the.contact.with.the.eyes..Avoid.the.prolonged.or.repetitive.contact.with.the.skin..Do.not.ingest..In.case.of.contact.with.the.skin,.wash.immediately.with.water.and.soap..In.case.of.contact.with.the.eyes,.abundantly.wash.with.water.for,.at.least.15.minutes..CALL.MEDICAL.HELP.IMMEDIATELY..KEEP.AWAY.FROM.THE.REACH.OF.THE.CHILDREN.AND.ANIMALS.

•

•

•

•

•

•

•

•

•

•

•

•

•

•

Important Safety remarks

Page - 2

1-4 Cleaning.solutions.and.solvents.are. inflammable.materials.that.must.be.handled.with.a. lot.of.care..Follow.the.manufacturer.instructions.to.use.these.products..KEEP.AWAY.FROM.THE.REACH.OF.CHILDREN.AND.ANIMALS..

To.avoid.burns,.pay.attention.to.hot.spots.on.engines.that.have.just.been.stopped.and.to.hot.piping.and.com-partments..

always.use.tools.in.good.conditions..Make.sure.that.you.know.how.to.handle.the.tools.before.beginning.any.repair..Use.ONLY.genuine.MNEPL. spare. parts..

Some.international.public.health.institutions.prove.that.used.lubricant.oil.can.be.cancerous.and.contaminates.the.human. reproducer. system..Avoid. inhaling.vapours,. ingesting.or. keeping.prolonged.contact.with. these.substances..

People.with.pacemaker.must.avoid.standing.close.to.the.engine.electronic.injection.system..

•

•

•

•

•

General Instructions

This.engine.has.been.manufactured.with. the.most.advanced. technology;.nevertheless,. it.was.designed. to.be.repaired.using.regular.techniques.complemented.by.quality.standards..

Use.good.quality.fuel,.free.of.water.and.impurities..

Use.only.recommended.lubricant.oil..

In.case.of.any.irregularity.seek.for.a.dealer.or.authorized.service.of.the.vehicle./.equipment.manufacturer.or.MNEPL.. Avoid. that. outsiders. make. any. service. in. the. engine,. because. this. cancels. the. warranty..

To.use.a.parallel.battery.to.start.the...engfine,.the.amperages.of.both.batteries.must.be.the.same.to.avoid.ten-sion.peaks.The.standard.procedure.is.always.first.to.connect.the.cable.on.the.negative.pole.and.later.on.the.positive.pole..Take.care.to.do.not.invert.the.poles..

•

•

•

•

Page - 3

1-5

8

7

6

5

4

3

2

17

16

15

14

13

12

11

10

9

IntroductIon

cleaning General Instructions

cleanInG WItH acIdS and SolventS Several.solvents.and.acid.substances.can.be.used.to.clean.the.parts.of.the.engine..

MaHIndra navIStar enGIneS Pvt ltd. does not recommend any specific substance. always follow the instructions of the manufacturer of the product.

Remove.all.gaskets,.sealing.rings,.and.with.a.brush.of.steel.or.rasper,.the.sludge.deposits,.carbon,.etc.,.before.placing.the.parts.in.the.cleaning.tank..Be.careful.to.do.not.damage.the.surfaces.of.the.sealing.elements.seats..

Flush.all.parts.with.hot.water.after.cleaning..Completely.dry.them.with.compressed.air..Remove.water.from.screw.holes.and.from.lubrication.inner.grooves..

In.case.the.parts.are.not.to.be.used.soon.after.the.cleaning,.dip.them.in.an.appropriate.anti-oxidation.compound.That.compound.must.be.removed.of.the.parts.before.installation.in.the.engine..

The.following.parts.cannot.be.cleaned.with.vapour:.

1.. Electric.and.electronics.components;.

2.. Electric.harness;.

3.. Fuel.injectors;.

4.. High.pressure.pump;.

5.. Belts,.pipes.and.hoses;.

6.. Bearings..

Page - 4

1-6engine Serial number Identification and location

The.engine.identification.and.serial.number.can.be.found.in.the.following.places:.

1.. Identification.plate.on.the.water.pipe..

2.. Engraving.on.the.right.side.of.the.engine.block,.close.to.the.cylinder.head.of.the.cylinder.#3..

6. 12 t c eElectronic.

Aftercooler.

Turbocharged

Series

Cylinders.numbers.

Page - 5

1-7

8

7

6

5

4

3

2

17

16

15

14

13

12

11

10

9

IntroductIon

cylinders numeration

The.cylinders.order.starts.from.the.flywheel,.according.to.the.illustration.below..

During.the.assembly,.check.the.numbers.on.the.block.(A).and.on.the.bearings.(B),.that.must.be.the.same.number,.corresponding.to.the.correct.block.

The.bearing.number.must.start.from.flywheel.to.front.side.

First .cylinder

Page - 6

FIRST CYLINDER

1-8

enGIne SerIal nuMberThe.engine.serial.number.is.stamped.in.the.right.and.rear.side.of.the.engine.block.

.

In

.

the

.

upper

.

side,

.

close

.

to

.

the

.cylinder.head.gasket.

enGIne acceSSorIeSThe.following.engine.accessories.have.manufacturer’s.labels.or.identification.plates:

Turbocharger

Fuel Injection Pump (Stanadyne Rotory). .

Labels.or.identification.plates.include.information.and.specifications.helpful.to.vehicle.operators.and.technicians.

••

engine Identification

6.12 TCA Engine Data Plate:

Page - 7

Page - 8

Engine Exploded View

Engine series No 6.12 TCA 6.12 TCA 6.12 TCA 6.12 TCE

ENGINE TECHNICAL SPECIFICATION

Engine Model S12-III S12-II S12-I SE12-I

Prime rating KVA 125 140 160 180

No. of cylinder No 6 6 6 6

Type of construction Inline / V type

Displacement Ltrs

Bore mm

Stroke mm

Inline

7.12

105

137Stroke mm

kW 114.8 128.1 146.5 163.0

hp 156 174 199 221.2

kW 125.6 139.9 160.0 178.0

hp 170.6 190.1 217.5 242

Tolerance on rated output power % ±5 ±5 ±5 ±5

Rated speed rpm 1500 1500 1500 1500

Rated output

Standby output

137

Rated speed rpm 1500 1500 1500 1500

Method of Starting of engine

Aspiration NA/TC/TCA

Compression Ratio 16.8:1 16.8:1 16.8:1 16.8:1

Brake Mean Effective Pressure (bmep)

1)Rated 12.9 14.4 16.4 18.3

2)Maximum 14.1 15.7 18 20

Firing Order

Turbocharged Aftercooler

1-5-3-6-2-4

Bar

24V ELEC

Firing Order

Method of Jacket cooling

Heat Removal

Dimensions of radiator (L X H X W ) mm

Qty of coolant(Engine + Radiator) Ltr 25 25 25 25

Air Flow at Radiator Outlet CFM 10000 11800 11800 13200

By Water

831x390.5x1135

1-5-3-6-2-4

Radiator

●COOLING SYSTEM

Air Flow at Radiator Outlet CFM 10000 11800 11800 13200

Fan Power KW 6 7 7 8

Tripping Temperature Deg C

Fuel oil

Fuel Filter type

Filtration capacity Micron

Spin-on type with paper element

5

●FUEL SYSTEM OF ENGINE

High speed Diesel(HSD IS 1460:2005)

)

105

Filtration capacity Micron

Filter Change period hrs

Specific fuel consumption at

100%load 202 198 197 193

75%load 200 197 197 195

50%load 214 212 207 202

Specific fuel consumption at

100%load 148.7 145.7 145.0 142.0

5

500

g/kW-h

100%load 148.7 145.7 145.0 142.0

75%load 147.2 145.0 145.0 143.5

50%load 157.5 156.0 152.4 148.7

Tolerance on SFC % +5 +5 +5 +5

Fuel consumption at Ltrs/h

100%load 27.45 30.01 34.15 37.18

75%load 20.38 22.39 25.61 28.18

g/hp-h

75%load 20.38 22.39 25.61 28.18

50%load 14.54 16.06 17.94 19.46


ENGINE TECHNICAL SPECIFICATION


Engine Model S12-III S12-II S12-I SE12-I

Prime rating KVA 125 140 160 180

1)FUEL INJECTION PUMP

Make Bosch Make

Type HPCR

2)GOVERNER DATA

STANADYNE MAKE

Rotary

2)GOVERNER DATA

TypeECU Controlled

(Isochronous)

Response time

Recovery time

Lube Oil Consumption at 100% Load Lit/hr 0.014 0.015 0.017 0.02

●LUBE OIL SYSTEM

As per IS10002

MECHANICAL

(3- 5%)

Lube Oil Consumption at 100% Load Lit/hr 0.014 0.015 0.017 0.02

Recommended lube oil

Lub oil filter type

Filtration capacity Microns

Lube oil change period hours

Maximum lube oil temperatorure Deg C

Lube oil pressure kg/cm2

15W40 API CI4

Full flow: Spin on cartridge type with Paper

element15

500

Min:-10 & Max:125

Must be greater than 1.2 at idling condition & Lube oil pressure kg/cm2

Lube oil system capacity lit

●EXHAUST SYSTEM

Exhaust silencer type

Exhaust noise level (with Silencer) @ 3M dB

Max. Permissible back pressure in Exhaust mm of Hg

Exhaust gas flow kg/hr 558 603 664 800

Must be greater than 1.2 at idling condition &

3.5 at rated speed19.8

Residential Type

Complies with CPCB norms

75

Exhaust gas flow kg/hr 558 603 664 800

Exhaust gas temperature (Max ) Deg C 650

●HEAT REJECTION DETAILS

Heat Rejection to coolant kW 59.73 62.22 70.98 78

Heat Rejection to CAC kW 14.74 19.33 22.49 32.9

Heat Rejection to exhaust kW 82.39 101.19 110.58 127.9

Heat Rejection from engine surface kW 12.1 12.89 14.38 16.07

●AIR INTAKE SYSTEM

600

●AIR INTAKE SYSTEM

Intake filter type

Air intake restriction - with clean element mm of H2O

Air intake restriction - with dirty element mm of H20

Filtration capacity Microns

Maximum Intake manifold temperature Deg C

Combustion air inlet flow rate kg/hr 535 580 637 750

20

55

Dry type Air cleaner

230

600

Combustion air inlet flow rate kg/hr 535 580 637 750

●ENGINE NOISE LEVEL

At 1Mtr

LengthXWidthXHeight (With Radiator) mm

Dry engine weight-with flywheel & flywheel

housingkg 610

Weight to power ratio Kg/Kw 5.21 4.67 4.09 3.74

598.6

●DIMENSIONS & WEIGHT DETAILS

1727X932X1274.4

< 75 dBA for genset with canopy

Weight to power ratio Kg/Kw 5.21 4.67 4.09 3.74

2-2

Page - 9

Fuel System

Description 6 cylinders

Maximum fuel inlet restriction (for gears pump)

0.6 to 1.2 bar

Fuel pressure range in the fuel filter outlet (at crank speed)

9.7 to 12.8 bar

Range of fuel pressure in fuel filter fuel inlet (at operation speed)

10.5 to 13 bar

Maximum pressure load reduction in the fuel filter

≤0.8 bar

lubrication System

Description

Oil pressure Nominal speed Idling speed

••

5.3 bar (hot engine) 3.5 bar (hot engine)

Oil temperatureNominal Maximum

••

90 - 110 °C 120 °C

Oil capacity

cooling System

Description

Volume of water in the engine, without radiator 9 l

Water temperature Nominal Maximum

••

80 - 90 °C 100 °C

thermostat

Thermostat

Opening beginning

Total opening

Maximum opening course

79 ± 2°C 90°C 10.0 mm

l

MaxxForce 7.2

MaxxForce 7.2

0304CAV00010N

19.8

2-4

engine Description

FeatureSMAXXFORCE 7.2 is in-line six cylinder engines with 7.2 Litre displacement.

The firing order of the cylinders is 1–5–3–6–2–4

The cylinder head has four valves per cylinder with cross flow for improved air flow. The head gasket is mated in metal-rubber and is individual for each cylinder head. The fuel Injector is centrally located between the four valves and directs fuel over the piston bowl for improved performance and reduced emissions. The overhead valve train includes mechanical roller lifters, push rods, rocker arms, and dual valves that open using a valve bridge.

To improve the components durability and engine performance this engine uses the hot and cold side concept for components distribution.

Cold side (left engine side)

Hot side (right engine side)

Turbocharger system

A one piece oil pan withstands high-pressure loads during diesel operation.

Manufactured in stamped steel, the oil pan has a compact size and lightweight.

Seven main bearings support the crankshaft for MAXXFORCE 7.2 engines respectively. One insert bushing support the camshaft for each engine, the other support is assembeled in the engine block. The rear oil seal carrier is part of the flywheel housing. The open oil pan breather assembly uses a road draft tube to vent oil pan pressure and an oil separator that returns oil to the oil pan.

Manufactured with forged steel and new shape to improve its strength, the pistons are mated with fractured cap joint connecting rods. Replaceable rolled radius wet cylinder liners are used with the pistons.

The new model of viscous damper for the MAXXFORCE 7.2 engine offers fns to assist in the refrigeration.

A lube oil pump, mounted onto the front of the engine block, is driven directly by the crankshaft. All engines use an enlarged oil cooler and cartritge type spin on filter.

An electric feed pump / mechanical feed pump draws fuel from the fuel tank through a fuel filter assembly that includes a strainer, filter element, drain valves, and water in fuel (WIF) sensor. After filtering, fuel goes to Stanadyne rotary pump and then high pressure fuel goes to the injectors..

The new water pump was designed with seven vanes to increase the water flow.

Page - 10

Group - 01

Exhaust manifold

•

•

•

•

Fuel Supply System

Intake Air Manifold

1

8

7

6

5

4

3

2-5

17

16

15

14

13

12

11

10

9

technIcal Data

acceSSorIeS FeatureS

The alternator is used to charge the battery and to power a Genset system when the engine is running, driven by the pulley system and the belt accessories. It’s located in the cold side in the front of the block on the upper position.

The starter motor is an electric motor that initiates rotational motion in an internal combustion engine before it can power itself. On the MAXXFORCE engines it’s located in the cold side, next to the Flywheel.

The high pressure pump from 3rd generation supplies the injectors with fuel in high pressure. The maximum pressure rate is 1800 bar. It’s located on the cold side next to the powertrain

The Wastegate Turbocharger Borg Warner K Series is an air compressor used for forced-induction of an internal combustion engine. The purpose of a turbocharger is to increase the air mass entering the engine to create more

Page - 11

Turbocharger is an air compressor used for forced- induction of an internal combustion engineThe purpose of a turbocharger is to increase the air mass entering the engine to create more power. In the MAXXFORCE engine it's located on the hot side , next to the waterpipe.

2-6

toP VIeW

1.

2.

Coolant temperature sensor (ECT)

Valve cover

engine component locations

Page - 12

2

1

1

8

7

6

5

4

3

2-7

17

16

15

14

13

12

11

10

9

technIcal Data

Front VIeW

1. Water bypass tube assembly thermostat outlet

3. Pulley

4.

5.

Vibration damper

Front cover

Page - 14

1

2

3

45

2. Alternator

leFt VIeW (colD SIDe)

Mechanical components

1.

2.

3.

Manifold, Intake

4.

Oil cooler assembly

5.

Oil filter

Fuel filter

High pressure pipes

Page - 15

1

2

34

5

2-10

rIGht VIeW (hot SIDe)

1.

2.

3.

4.

5.

Oil dipstick

Turbo inlet pipe

Turbo outlet pipe

Exhaust manifold

Turbo exhaust curve

Page - 17

1

234

5

6. Flywheel housing

7. Cylinder block

6

7

1

8

7

6

5

4

3

2-11

17

16

15

14

13

12

11

10

9

technIcal Data

rear VIeW

1.

2.

3.

Flywheel

Lube Oil sump

Flywheel Housing

Page - 18

1

2

3

4. Water Outlet tube

4

6-9

NOTEs

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________PDF processed with CutePDF evaluation edition www.CutePDF.com

1

8

7

6

5

4

3-1

2

17

16

15

14

13

12

11

10

9

OPERATION ANd MAINTENANcE

Operation and Maintenance

Engine Operation .....................................................................................................................................

Cooling Fluid and Coolant ........................................................................................................................

Maintenance Table ....................................................................................................................................

Conservation for Inactive Engines for Long Periods .................................................................................

Starting Engine Preparation .....................................................................................................................

Oil Element .............................................................................................................................................

Page - 001

Water Pump Checking ............................................................................................................................

3-2

Engine Operation

Start / Stop

Before operating the MAXXFORCE 7.2 engine check:

Water level.

Fuel level.

Lubricant level.

Soon after to start the engine, heat it up at medium speed, without load.Watch lubricant oil pressure and water temperature.

It is recommended to start the engine without accelerating, keeping the engine at idling speed for 30 seconds in order to pre-lubricate the turbocharger.

Before stopping the engine, run about 30 seconds at idling speed so that the turbo decrease its speed.

cold Start

The difficulty of start at very low temperatures can happen due to the collapse of the filter because paraffin formation or lack of ignition of the fuel.

The following actions can be observed:

Use winter fuel, which does not form paraffinic flakes at low temperatures, or;

Case the winter fuel is not available, it is necessary that the filter has a heater on the cylinder head to allow fuel flow before the start.

Turbocharger cares

Almost all failures in turbochargers are caused by lubrication deficiency (delay in lubrication, restriction or lack of oil, intake of impurities in the oil, etc.) and objects or impurities entrance through intake.

To maximize the turbo lifetime follow these cautions:

Do not accelerate the engine immediately after the start.

Wait 30 seconds with the engine at idling speed before stop it.

Pre-lubricate the turbocharger after oil change or other service that evolves oil drain. Crank the engine a few times before start the engine. Run the engine and allow it to run at idling speed for a period of time to establish a complete circulation and oil pressure before apply high speeds and load.

In low temperatures or when the engine is being reactivated after a long period without operation, start the engine and let it running at idling speed before operating at high speeds.

Avoid operating the engine at idling speed for long periods of time.

·

·

·

·

·

·

·

·

·

·

·

·

·

·

·

·

Page - 1

1

8

7

6

5

4

3-3

2

17

16

15

14

13

12

11

10

9


Running-in

All MIM engines are assembled and tested in the factory, making sure its immediate operation.

However, it needs to be correctly ran-in, regarding that its performance and durability depends on the cares taken during first operation phase.

As general rule, it is considered as running-in, a period of first 2,000 km for vehicular engines or the first 50 service hours for stationary, industrial and agriculture engines. The vehicle or equipment under moderate operation has decisive importance to its durability, service safety and economy.

During this period it is very important to follow these recommendations:

Carefully check if engine oil level is correct;

Carefully check if water level of the engine cooling system is correct;

Average load factor in 24hours should not exeed 75% load of the Rated capacityand in every 12hours 10%

Over load permitted for one hour.

Avoid leaving the engine running at idling speed for a long period of time;

Strictly follow the maintenance instructions.

Following these recommendations the useful life of the engine will be prolonged.

FuEL SPEcIFIcATIONS - HSd IS 1460:2005

··

·

··

Page - 2

FUEL SYSTEM

· Drain water and sediments from water seperator and fuael tank every day.· Fill the fuel to the fuel tank if necessary.· Change fuel filter periodically as for maintenance plan (Refer Maintenance Table)

FuEL INjEcTION SySTEM

Page - 2

System Schematic :

Page - 3

FuEL INjEcTION SySTEM

Page - 2

Workshop Manual

6-9

NOTEs

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________


3-4

If necessary, Topup up to the ' H' mark, without exceeding it.

Do not operate the engine with the level below the ' L' mark.

Use only recommended lubricant oil ( 15W40 API CI4 ).

Do not mix different oil brands.

Oil change

Install the plug with a new washer and tighten according to the specification.

Fill with recommended lubricant oil up to ' H' mark of the dipstick.

·

···

·

·

·

·

! Attention:

The lubricant oil is very important for a good conservation of the inner engine components. Lubricanting oil contaminated with sand, soil, dust, water or fuel causes problems to the engine.

Check the appearance of the engine lubricant oil. A dark coloration and low viscosity means presence of fuel in the lubricanting oil.The presence of foaming or a milky coloration indicates presence of water in the oil.

Lubricant Oil Specifications

It must be used multiviscous type lubricant oil that accomplish, at least, to the SAE 15W40 API CI-4 (or upper) specifications and to the recommended viscosities.

! Attention:

check Lubricant oil condition

MNEPL recomended oilDo not mix different oil brand / grade. Use only

Page -3

Always use MNEPL recommended genuine engine oil

·

The oil must be hot for easy drain.

Change the Lubricating oil as per Maintenance Plan.·

Remove the carter plug and washer drain the oil.

LuBRIcANTINg OIL

Oil Level check

Stop the engine and wait 30 minutes so that the oil can

flow back to the carter.

Before pulling oil dipstick, clean the surroundings.

·

·

Use the same oil Brand and Grade.

3-10

2. Using the wrench indicated, unscrew the filter

REMOvAL

1. Remove the drain plug (R ½”) and discard the washer. Drain engine oil and dispose of used engine oil according to applicable laws.

Oil Element

Page - 8

Oil Filter change

Clean the sealing area of the flter with a clean cloth.

Lubricate the flter gasket and tighten it.

Run the engine and check the oil leakages.

Stop the engine and, after 30 minutes, check oil level Topup if Necessary.

·

·

·

·

Remove the old filter.·

Prime the new filter with clean and fresh oil and fix.(Use always GENIUNE spares). ·

1

8

7

6

5

4

3-11

2

17

16

15

14

13

12

11

10

9

INSTALLATION

1. Clean area around oil filter head, clean gasket

2.

Lubricate oil filter gasket with fresh engine oil.

3. Fill the oil filter with fresh engine oil.

Tighten the filter untill the gasket contacts the filterhead surface.

4.

surface of filter head.

Use oil filter wrench to tighten the filter

Operate the engine and check for leakages

an additional 3/4 of a turn.

5.

6.

Page - 9

12-2

Lubrication system

OIL LubRIcATION cIRcuIT

Page - 1

1

8

7

6

5

4

3-5

2

17

16

15

14

13

12

11

10

9


! Attention: · Do not open the expansion reservoir cap while the engine is hot.

· Check the level when the engine is cold.

· Check the level of the cooling system daily. If the level is not correct, add clean water and MWM coolant according to the proportion recommended on the bottle.

· Carefully open the first stage of the cap relieving the vapour pressure.

· Check for leaks through cooling piping.

· Check the nominal pressure of the cap in case of change.

Water Pump check

cooling Fluid and coolant

Note: Image is shown with gear housing removedIf water is coming from this hole, it means there is a leakage coming from the water pump.

Page -4

Check the inspection hole located onthe left side of the engine block (seenby the flywheel side). If there are signsof water or oil leakage, probably thereis leakage through the water pump orthrough the sealing rings. Check andchange, if necessary.

6-9

NOTEs

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________


14-2

Cooling System

COOLINg CIRCuIT

Page - 1

6-9

NOTEs

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________


1

8

7

6

5

4

3-7

2

17

16

15

14

13

12

11

10

9


Remarks:1)

This table is only for guidance. The Maintenance Table of the Genset prevails over this table. 2)

3)

If the engine stays inactive for a long time, it must perform an idling speed test fortnightly, until to reach the operation temperature.

4)

Independent of the intervals indicated for engine lubricant oil changes, it must be changed at each 6 months.

Electronic parts (phase, speed, air pressure, temperature, oil pressure and water temperature sensors) are maintenance-free and checked by recommended diagnose scanner for errors stored in failure memory.

Maintenance Table

Note: Mentioned parts are under evaluation and maintenance fequency can get changed after evaluation.

Page - 5

6-9

NOTEs

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________


3-8

conservation for Inactive Engines for Long Period

MNEPL engines are produced protected for, at the most, 6 inactivity months under shut shelter. When the engine is to stay inactive for a long period, it is necessary to follow these cares:

Clean the outer parts of the engine.

Operate the engine until to reach the operating temperature.

Drain cooling system and lubricant oil.

Drain fuel system (reservoir, low pressure system).

Operate the engine for 15 minutes at 2/3 of the nominal speed, without load, using a mixture of fuel with 15% of the protective oil SAE 20 W 20.

Remove valves cover from cylinder heads and spray protective oil on the springs and rocker arms. Reinstall covers.

Apply protective oil on machined surfaces.

Remove belt.

Seal all the holes of the engine, to avoid dust and water penetration.

Remarks:

Renew the engine conservation procedure after each 8 months of inactivity.

In case of new brand engines, do not consider items 1, 2 and 3.

ENgINE PREPARATION TO RETuRN FOR SERvIcE

Before operating an engine which stayed inactive for a long period, follow these procedures:

Clean the outer parts of the engine.

Change engine lubricnting oil flter.

Install belt and adjust tension.

Remove valve covers and lubricate rocker arms with engine oil. Reinstall covers.

Drain the fuel mixture from the reservoir and fill with new fuel.

Change fuel filter.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

·

·

1.

2.

3.

4.

5.

6.

7.

8.

9.

Page - 6

Fill up the oil sump with protective oil SAE 20 W 20

Drain fluid from cooling system and oil from oil sump. The fuel mixture can stay in the system

Fill the radiator with clean water and coolant according to the recommended proportion.

Fill the cooling system with clean water and coolant in the recomended proportion

Fill the oil pan with new recomended grade of 15W40 engine oil in recomended quantity.

Edited by Foxit Reader Copyright(C) by Foxit Corporation,2005-2009 For Evaluation Only.

1

8

7

6

5

4

3-9

2

17

16

15

14

13

12

11

10

9


cLEAN ENgINE

! Warning: To avoid serious personal injury, possible death, or damage to the engine or Genset, read all safety instructions in the “Safety Information” section of this manual.

1. Cap all turbocharger and manifold openings to prevent water and degreased agents from entering any engine components internally.

2.

Use an appropriate detergent mixed in the correct ratio of water and applies to engine using a warm water and moderate pressure washer or similar cleaning equipment.

NOTE: Do not use high pressure or excessive hot water temperature as it may damage the engine components.

NOTE: Do not use solvent, thinner or any product that derivates from petrol as these products may damage the wiring harness and other plastics made components.

dRAIN ENgINE FLuIdS

draining the Oil

1. Place an oil drain pan beneath the oil drain plug to collect the oil.

2. Remove oil pan drain plug (R ½”) and washer. Drain engine oil and dispose of used engine oil according to applicable laws.

3. Discard washer, inspect drain plug and replace if necessary. Place a new washer onto drain plug and install to oil pan. Apply the torque of 55 to

75 N.m.

6 cylinders Engine

ENgINE STARTINg Preparation

!

!

Page - 7

1

8

7

6

5

4

3

2

17-1

16

15

14

13

12

11

10

9

FAILuREs DIAgNOsIs

Diagnosis Failures

Introduction..............................................................................................................................................1

Trouble Shooting Chart............................................................................................................................2

17-2

Introduction

! Attention :. ·. Study.in.full.detail.the.problem.before.trying.any.action..

. ·. First.check.the.simplest.and.obvious..

. ·. Find.the.main.cause.and.correct.the.problem..

Next.they.are.presented.some.typical.problems.which.the.engine.may.present,.their.probable.causes.and.possible.corrections.for.these.problems.

Page - 1

CO

MP

LA

INT

S

Ha

rd S

tart

ing

or

Fa

ilure

to S

tart

En

gin

e M

issi

ng

Exc

ess

ive

Bla

ck S

mo

ke a

t Id

le

Exc

ess

ive

Wh

ite S

mo

ke a

t id

le

Exc

ess

ive

Blu

e S

mo

ke

Co

ola

nt T

em

pe

ratu

re T

oo

Hig

h

Lo

ss o

f Co

ola

nt

En

gin

e O

utp

ut P

ow

er

Lo

w

Ca

nn

ot R

ea

ch r

ate

d R

PM

En

gin

e O

il S

pe

win

g o

ut f

rom

Bre

ath

er

Tu

be

Exc

ess

ive

oil

Co

nsu

mp

tion

Exc

ess

ive

Fu

el C

on

sum

ptio

n

En

gin

e S

urg

es

( S

pe

ed

ch

an

ge

)

Lo

w o

il P

ress

ure

Hig

h O

il P

ress

ure

Lu

bric

atin

g O

il C

on

tam

ina

ted

with

Fu

el

Lu

bric

atin

g O

il C

on

tam

ina

ted

with

Co

ola

nt

Fu

el/

Oil

Le

aki

ng

fro

m E

xha

ust

Ma

nifo

ld

En

gin

e S

tart

s b

ut d

oe

sno

t ke

ep

ru

nn

ing

Lubricating System

CoolingSystem

Operation and Maintenance

Practice

Mechanical Adjustments

or Repair

Trouble Shooting MAXXFORCE 7.2 Mechanical

Cause

Air System

Fuel System

Fuel Return Line Restricted

Fuel Lift Pump Defective

High Pressure/ Fuel Leakage

Fuel Filter Choked

FIP Timing Incorrect

FIP Rack Sticky

Loose Cylinder Cap Screw

Worn or Scored Liners or Pistons

Air Compressor Pumping Oil

Broken or Worn Piston Rings

Engine Camshaft Out of Time

Engine Compression Low

Rocker Adjusting Screw Cup not seated properly on Push rod ball

Engine Idle Speed Too low

Cylinder Head Gasket Leak Blown Off

Cracked Cylinder Head

Valve Leakage / Valve Lash Bad

Dirty Filters/ Breather

Long Idle Periods

Engine Overloaded

Oil Needs Changing

External coolant Leakage

Low Coolant Capacity / Dirty radiator

Radiator Pressure Cap incorrect

Driving Technique

Insuffecient Coolant

Defective Water Pump

Faulty Thermostat

Damage Hose

Oil Cooler Leakage

Oil Cooler Pluged

Turbocharger Drain Line Obstruction

Oil Level Too High

Oil Suction Line Restricted

Leakage From Valve Stem Oil Seal

Faulty Oil Pressure Regulator

Crankcase Low or Out of Oil

Defective oil Pump

External / Internal Leakage

Dirty oil Filter

Faulty Cylinder Oil Control

Shutoff Lever partialy engaged

Water in Fuel

Oil Pressure Transducer / Gauge Defective

Incorrect Grade oil

Fuel Shutoff Not Actuating

FIP Caliberation Defective

FIP Internal Plunger Seal Leakage

Fuel temperature High

Injector Defective

Injector Installed with More Than One Sealing Washer

Broken fuel Pump Drive Shaft

Throttle Linkage Worn or Incorrectly Adjusted

Restricted Air Intake

High Exhaust Back Pressure

Air Leakage Between Yurbocharger and Intake Manifold

Leaking Radiator

Defective Turbocharger

Charge Air Cooler Malfunctioning

Air Filter Choked

Low/ Out of Fuel

Air in Fuel System

Restricted Fuel Lines

Page - 2

6-9

NOTEs

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________


ENGINEERING TECHNICAL DOCUMENTMN/ETD 30

REV 02

TORQUE CHART ( 6.12 TCA MECHANICAL GENSET ENGINE)TORQUE CHART ( 6.12 TCA MECHANICAL GENSET ENGINE)

Engine Block

Qty. Description Size Application Torque (Nm)

2 Bolt M14 Bearing Cap to Block1st 2nd Torq. Range

50 - 5 155 ̊± 5° 170 to 282

Qty. Description Size Application Torque(Nm) Required Sealing

1 Plug 3/8” Water Drain Plug to Block 10 + 5 Loctite 567

1 Hollow Bolt M8x1 Oil Ejector to Block 10 ± 1.5 **

1 Plug 1/2” Water Drain Plug to Block 15 + 5 Loctite 567

Connecting Rod


2 BoltMJ

12x58

Connecting Rod to

Crankshaft

1st 2nd Torq. Range

40 ± 5 80 ̊± 2° 130 to 16040 ± 5 80 ̊± 2° 130 to 160

Camshaft


4 Bolt M8x25 Gear to Camshaft1st 2nd Torq. Range

15 ± 1 30 ̊± 2° 35 to 6515 ± 1 30 ̊± 2° 35 to 65

2 Bolt M8x16 Camshaft Lock to Block 25 ± 4

Oil Pump

Qty. Description Size Application Torque(Nm)

2 Bolt M8x20 Oil Pump to Block 20 ± 5

Water Pump


2 Bolt M8x20 Water Pump to Block 20 ± 5

This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore, it must not be copied,

wholly or partly, or retransmitted without previous authorization. All rights reserved.

PRINTED COPIES ARE NOT CONTROLLED SHEET

1/10

2 Bolt M8x20 Water Pump to Block 20 ± 5

APPendIx A

Group - 17

Page - 1


REV 02

Gear HousingGear Housing


10 Bolt M8x20 Gear Housing to Block 25 ± 5

3 Bolt M8x50 Gear Housing to Block 25 ± 5

2 Hollow Bolt M8x1 Lubrication pipe to Gear Housing 7.5 ± 2.5

1 Hollow Bolt M8x1 Lubrication pipe to Block 7.5 ± 2.5

3 Bolt M10x70 Intermediate Bearing with Gear to Block 60 ± 53 Bolt M10x70 Intermediate Bearing with Gear to Block 60 ± 5

1 Plug M10x1 Gear Housing (Rear Half) 10 ± 5

1 Plug M14x1.5 Plug-Allen Tapered 20 ± 3

Valve Lubrication Pipes


6 Hollow Bolt M10x1 Valve Lubrication pipe to Cylinder Head 10 + 56 Hollow Bolt M10x1 Valve Lubrication pipe to Cylinder Head 10 + 5

1 Hollow Bolt M12x1.5 Valve drive Lubrication Pipe to Oil cooler 10 + 5

Front Cover


16 Bolt M8x16 Front Cover to Gear Housing 25 ± 316 Bolt M8x16 Front Cover to Gear Housing 25 ± 3

9 Bolt M8x55 Front Cover to Gear Housing to Block 25 ± 3

1 Inspection Cover S65 X 4 Inspection cover to front cover 20 ± 3

Alternator Bracket

Qty. Description Size Application Torque(Nm)Qty. Description Size Application Torque(Nm)

3 Bolt M10x35Alternator Bracket to

Gear Housing40 ± 6

1 Bolt M10x20 Pulley to Alternator Bracket 40 ± 6

Water Outlet Pipe


12 Bolt M8x55 Water Outlet Pipe to Cylinder Head 25 ± 4

2 Bolt M8x30 Connection water outlet 25 ± 3

2 Bolt M8x30 Connection by pass 25 ± 3




2/10

Page - 2


REV 02


1 Hollow Bolt M12 Water outlet tube to degassing tank 20 ± 3

1 Nipple M22 Nipple Bypass connection for AC application 40 ± 5

1 Plug M22X1.5 Plug, Connection Bypass for Non-AC application 25 + 5

2

Turbocharging


4 Stud M10x25 Turbocharger to Exhaust Manifold 6 ± 2

4 Stover Stud M10 Turbocharger Stud to Exhaust Manifold 70 ± 10

Turbocharger Inlet Lubrication Pipe to 1 Hollow Bolt M14x1.5

Turbocharger Inlet Lubrication Pipe to

Turbocharger25 ± 5

1 Hollow Bolt M14x1.5 Turbocharger Inlet Lubrication Pipe to Block 25 ± 5

2 Bolt M8x20Turbocharger Lubrication Return Pipe to

Turbocharger 20 ± 3

2 Bolt M8x16 Turbocharger Elbow Bracket 25 + 5

1 V band Clamp -- V band clamp elbow-turbo to Turbocharger 10 + 21 V band Clamp -- V band clamp elbow-turbo to Turbocharger 10 + 2

Cylinder Head

Qty. Description Size Application

Pre-

Torque

(Nm)

Torque

(Nm)Torque

1 (°)

Torque

2 (°)

Torque

3 (°)

Torque

Range

Cylinder Head to 120 To20 Bolt M14x152

Cylinder Head to

Block40+5 60+ 10 60± 3 60± 3 90± 3

120 To

260

2 Bolt M14Cylinder Head to Fan

Bracket40+5 60+ 10 60± 3 60± 3 90± 3

120 To

260

2Engine lifting

hookM12

Cylinder Head

mounting bolt- 80 ± 10 - - - -


2Socket head

cap screwM5x10 Lubrication pipe to Cylinder head 5 ± 1

1 Nut M22 High pressure connector nut 50 + 5

1 Nut M8x10 Nut – Valve clearance adjustment 20 + 5




3/10

Page - 3


REV 02

High Pressure PumpHigh Pressure Pump


3 Stud M8 X 30High Pressure Pump adaptor

to Gear Housing8 ± 1

3 Nut M8 High Pressure Pump to Gear Housing 38 ± 3

1 Nut M14x1.5 Gear to High Pressure Pump 180 ± 5 21 Nut M14x1.5 Gear to High Pressure Pump 180 ± 5

1 Hollow Screw M12 High Pressure Pump –Tube ,Fuel Return 22.5 ± 2.5

1 Connector M8 Connector for Boost pressure 10 + 5

1 Box Nut M10x1 Tube, Injection Pump to Intake manifold 12.5 ± 2.5

Low Pressure Pipe

2

Low Pressure Pipe


6 Connection M8x1 Pipe, Fuel Return to Cylinder Head 8 ± 1

High Pressure PipeHigh Pressure Pipe


6 Nut M12Nut high pressure tube to

fuel injection pump15 + 5

6 Nut M14Nut high pressure tube to

Connector high pressure tube25 + 5

Fuel Filter


2 Bolt M10x30 Fuel Filter to Block 35 ± 4

2 Connection M14x1.5 Fuel inlet to Filter Head 20 + 62 Connection M14x1.5 Fuel inlet to Filter Head 20 + 6

1 Hollow Bolt M12x1.5 Pipe, Fuel Filter outlet to VE Pump 20 + 6

1 Hollow Bolt M14x1.5Pipe, Fuel Filter inlet for mechanical

feed Pump20 + 6

1 Hollow Bolt M14x1.5 Pipe, Fuel Filter inlet NRV 20 + 6




4/10

Page - 4


REV 02

Assy, Fuel Injector and Valve CoverAssy, Fuel Injector and Valve Cover


1 Screw M6 Special Step Bolt Fuel injection Clamp 4± 1

2 Bolt M6 x 60 Valve Cover 8.5 ± 1

Qty.Descri

ption Size Application

Torque

(Nm)

Relieve

to (Nm)

Torque

(Nm)

Torque

1 (°)

Torque

2 (°)

Torque

3 (°)

Torque

Range

1 Screw M6Screw- Fastening

Bridge Fuel Injector1+0.5 0 4 ± 1 90 90 30 7+6

Intake Manifold


12 Bolt M8x35Intake Manifold to

Cylinder Head24 ± 2

Intake Manifold to12 Bolt M8x80

Intake Manifold to


1 Hollow Bolt M12X1.5 Tube-Intake Manifold to FIP 20 + 6

Exhaust Manifold


12 Stud M10x45Exhaust Manifold to

Cylinder Head6 ± 2

12 Stover Nut M10Exhaust Manifold to stud


Exhaust ElbowExhaust Elbow


4 Stud M10 Exhaust Elbow to Turbocharger 6 ± 2

4 Stover Nut M10Exhaust Elbow to

Turbocharger60 ± 10




5/10

Page - 5


REV 02

Crankshaft Pulley


4 Cylindrical Bolt M16x65Crankshaft Pulley to

Crankshaft

1st 2nd

100 ± 10 275 ± 15

9 Bolt M8 Damper to Crankshaft Pulley 35 ± 59 Bolt M8 Damper to Crankshaft Pulley 35 ± 5

Oil Suction Pipe


2 Bolt M8x20 Oil Suction Pipe to Block 25 ± 4

Water Inlet Manifold


3 Bolt M8x20 Water Inlet connection 20 ± 3

Engine Breather


1 Bolt M8x20 Breather to Block 25 ± 5

1 Bolt M8x16Engine breather tube to

Breather housing10 + 2

Oil PanOil Pan


34 Bolt M8x16 Oil Pan to Block 25 + 5




6/10

Page - 6


REV 02

FlywheelFlywheel


8 Cylindrical Bolt M16x35 Flywheel to Crankshaft1st 2nd

100 ± 10 275 ± 15

Flywheel HousingFlywheel Housing


13 Bolt M12x30 Flywheel Housing to Block 100 ± 5

Lubricating Oil Flilter Head and Oil CoolerLubricating Oil Flilter Head and Oil Cooler


10 Screw M8x 40 oil cooler to block 25 ± 3

1 Hollow Bolt M14X1.5 Adapter 25 + 5

Standard Torque Table for Normal Steel Bolts

(According to DIN 2230)

Nominal SizeBolt Class ( Nm)

8.8 10.9 12.9

M5 6 ± 1 9 ± 1 10 ± 1.5M5 6 ± 1 9 ± 1 10 ± 1.5

M6 10 ± 1.5 15 ± 2 18 ± 3

M8 25 ± 4 37 ± 6 43 ± 7

M10 50 ± 8 73 ± 11 84 ± 13

M12 86 ± 13 124 ± 19 145 ± 22

M14 135 ± 20 198 ± 30 231± 35

M16 207 ± 31 304 ± 46 325 ± 49

M18 298 ± 45 424 ± 64 497 ± 75M18 298 ± 45 424 ± 64 497 ± 75

M20 418 ± 63 595 ± 89 696 ± 104

M22 569 ± 85 810 ± 122 948 ± 142

NOTE : This table is only applied when the Torque isn’t referred in the Service Manual. For all other conditions

use the special torques provided by the related procedures .




7/10


Page - 7


REV 02

GENSET ENGINE ADD-ON COMPONENTSIntake CurveIntake Curve


3Screw, Hex. Flanged

headM8x35 Intake curve to intake manifold 20 ± 3

1 Stud M8x25 Intake curve to intake manifold 6 ± 2

1 Nut, Hex. M8x8 Intake curve to intake manifold 20 ± 3

2 Plug, Allen Tapered M22 X 1.5 X 5.8 For Plugging Heater Holes 30 ± 5

2

2

22 Plug, Allen Tapered M22 X 1.5 X 5.8 For Plugging Heater Holes 30 ± 5

Air Cleaner Assembly


1Clamp SAE J1 508

Type SLTB

SAE No.-

142

Clamping Hose ,Air cleaner-

Turbocharger to Air Cleaner

Assembly

7.3 ± 1.3

Air Cleaner Assembly to

2

Fan Assembly

4 Screw, Hex. M8x20Air Cleaner Assembly to

Air cleaner Mounting Bracket25 ± 4

1Clamp SAE J1 508

Type SLTB

SAE No.-

110

Clamping Hose ,Air cleaner-

Turbocharger to Turbocharger 7.3 ± 1.3

2Screw, Serrated Hex.

flanged headM12x30

Air cleaner Mounting Bracket to

Cylinder Block70 ± 10


6 Screw, Hex. Flanged head M8x20 Fan Hub to Fan(30 inch) 25 ± 4


Flanged headM10X70 Fan pulley to Fan Hub and Fan 50 ± 8

2 Bolt, Hex. Flanged head M8X35Fan Bracket to Spacer mounted

on cylinder Head bolts25 ± 4

1 Bolt, Hex. Flanged head M10x50 Fan Bracket to Timing case 50 ± 81 Bolt, Hex. Flanged head M10x50 Fan Bracket to Timing case 50 ± 8

4 Bolt, Hex. Flanged head M10x35Housing Fan Bearing to Fan

Bracket50 ± 8

1 Screw, Hex. Flanged head M10X20Tensioner Pulley to Lever belt

Tensioner 40 + 6

2 Screw, Hex. Flanged head M8X25Lever belt tensioner to Fan

Bracket25 ± 4

2 Screw, Hex. Flanged head M8X80 Fan Bracket to Timing case 25 ± 4

2

2 Screw, Hex. Flanged head M8X80 Fan Bracket to Timing case 25 ± 4

2 Hexagonal Spacer M12X1.5 Spacer mounted on cylinder Head 50 ± 8

1 Bolt, Hex. Flanged head M10x50 Bolt to Fan shaft 50 ± 8

Water Flow Tube Assembly


1Temparature sensor

cum SwitchM14 X 1.5 X 11 Sensor fitted in water flow tube Max. 20 2




8/10

1cum Switch

M14 X 1.5 X 11 Sensor fitted in water flow tube Max. 20 2

Page - 8


REV 02

Fuel Filter Assembly

Turbocharger Bracket Assembly


1Screw, Hex. Flanged M8 x 30 X Elbow, turbocharger Mounting bracket

25 + 5


1 Banjo bolt M12X1.5X8.8 Fuel Pump end to NRV pipe 23 ± 3 2


Head

M8 x 30 X

1.25 X 10.9

Elbow, turbocharger Mounting bracket

to turbocharger25 + 5


Head

M8 x 25 X

1.25 X 8.8

Turbocharger Mounting bracket to

Elbow, turbocharger25 + 5

Gear Case Assembly


Air compressor closing plate to Gear 3 Screw, Hex. Flanged M10X30X8.8

Air compressor closing plate to Gear

Case45± 5

Intake Manifold Assembly


1 Plug, Allen Tapered M12 X 1.5 X 5.8 For Pluging Intake manifold Hole 10± 2

2

2

Feed Pump Assembly


3 Allen bolt M6X16X8.8 Feed Pump mounting to Gear case 10 ± 1.5

2 Screw, Hex. Flanged M8 X 25X 1.25 X 8.8 Feed Pump mounting to Gear case 25 ± 4

1 Plug, Allen Tapered M12 X 1.5 X 5.8 For Pluging Intake manifold Hole 10± 2

2

2

2 Banjo bolt M14X1.5X8.8 Feed Pump Inlet/Outlet 23± 3

1 Adapter M14X1.5X8.8 Feed Pump adapter to Timing case 30 ± 4

Starter Motor Assembly


3 Screw, Hex. Flanged M10 X 20 X 8.8 Starter Motor (24V) Mounting 45± 5

2

2

2

3 Screw, Hex. Flanged M10 X 20 X 8.8 Starter Motor (24V) Mounting 45± 5

Cylinder Block


1 Plug, Allen Tapered M14 X 1.5 X 5.8Plugging Compressor inlet Hole in

Cylinder block10+5

2




9/10

Cylinder block

Page - 9


REV 02

Radiator & Intercooler


2 Clamp SAE J1 508 Type SLTB SAE No.-

76

Hose clamp for intake curve to

intercooler7.3 ± 1.3


76

Hose clamp for Elbow Turbocharger to

Tube, turbocharger-intercooler7.3 ± 1.3


76

Hose Clamp for Tube, turbocharger-

intercooler to Intercooler inlet7.3 ± 1.3

SAE No.- Hose Clamp for Engine Water Outlet 2 Clamp SAE J1 508 Type SLTB

SAE No.-

42

Hose Clamp for Engine Water Outlet

pipe 7.3 ± 1.3


42

Hose clamp for Engine Water outlet pipe

to Hose, Radiator side7.3 ± 1.3


34

Hose clamp for Engine Water outlet pipe

to hose at Radiator inlet7.3 ± 1.3


42Hose clamp on Engine Water inlet pipe 7.3 ± 1.3

Engine Mounting Foot

Qty. Engine Size Application Torque(Nm)

42


42

Hose clamp on small end of reducer hose

at radiator outlet7.3 ± 1.3


48

Hose Clamp on reducer hose at radiator

outlet7.3 ± 1.3



Flanged headM12x30 Engine Mounting Foot to Cylinder Block 70 ± 10

Lubricating Oil Filter Head and Oil cooler


1Oil Pressure sensor

cum switchM12x12

Oil Pressure sensor cum switch mounted

at Oil Filter HeadMax. 50 2

Alternator 24 V Assembly


2 Screw, Hex. Flanged head M8 x 20Pull rod, Alternator Bracket to Main

Alternator Bracket20 ± 3

1 Screw, Hex. Flanged head M12 x 35Pull rod, Alternator Bracket to

Alternator (Charging)70 ± 10

Main Alternator Bracket to

Release Date Milind Khanolkar Sachin Mahajan Amol Relkar Cesar Almeida

NOTE : This table is only applied when the Torque isn’t referred in the Service Manual. For all other conditions


1 Screw, Hex. Flanged head M10 x 110Main Alternator Bracket to

Alternator (Charging)40 ± 6




10/10

24 Dec. 2010 Prepared Verified ApprovedChecked

Page - 10

A-9

B

APPendIx A

Page - 11

6-9

NOTEs

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________


navistar o & m manual

Documents