navistar o & m manual
DESCRIPTION
manual for NAVISTAR ENGIENSTRANSCRIPT
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 series No 6.12 TCA 6.12 TCA 6.12 TCA 6.12 TCE
ENGINE TECHNICAL SPECIFICATION
Engine series No 6.12 TCA 6.12 TCA 6.12 TCA 6.12 TCE
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
OPERATION ANd MAINTENANcE
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
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________PDF processed with CutePDF evaluation edition www.CutePDF.com
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
OPERATION ANd MAINTENANcE
! 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
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________PDF processed with CutePDF evaluation edition www.CutePDF.com
14-2
Cooling System
COOLINg CIRCuIT
Page - 1
6-9
NOTEs
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________PDF processed with CutePDF evaluation edition www.CutePDF.com
1
8
7
6
5
4
3-7
2
17
16
15
14
13
12
11
10
9
OPERATION ANd MAINTENANcE
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
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________PDF processed with CutePDF evaluation edition www.CutePDF.com
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.
1
8
7
6
5
4
3-9
2
17
16
15
14
13
12
11
10
9
OPERATION ANd MAINTENANcE
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
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________PDF processed with CutePDF evaluation edition www.CutePDF.com
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
Qty. Description Size Application Torque (Nm)
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
Qty. Description Size Application Torque (Nm)
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
Qty. Description Size Application Torque(Nm)
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
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
Gear HousingGear Housing
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
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
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
2/10
Page - 2
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
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 - - - -
Qty. Description Size Application Torque(Nm)
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
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
3/10
Page - 3
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
High Pressure PumpHigh Pressure Pump
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
6 Connection M8x1 Pipe, Fuel Return to Cylinder Head 8 ± 1
High Pressure PipeHigh Pressure Pipe
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
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
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
4/10
Page - 4
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
Assy, Fuel Injector and Valve CoverAssy, Fuel Injector and Valve Cover
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
12 Bolt M8x35Intake Manifold to
Cylinder Head24 ± 2
Intake Manifold to12 Bolt M8x80
Intake Manifold to
Cylinder Head24 ± 2
1 Hollow Bolt M12X1.5 Tube-Intake Manifold to FIP 20 + 6
Exhaust Manifold
Qty. Description Size Application Torque(Nm)Qty. Description Size Application Torque(Nm)
12 Stud M10x45Exhaust Manifold to
Cylinder Head6 ± 2
12 Stover Nut M10Exhaust Manifold to stud
Cylinder Head70 ± 10
Exhaust ElbowExhaust Elbow
Qty. Description Size Application Torque(Nm)
4 Stud M10 Exhaust Elbow to Turbocharger 6 ± 2
4 Stover Nut M10Exhaust Elbow to
Turbocharger60 ± 10
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
5/10
Page - 5
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
Crankshaft Pulley
Qty. Description Size Application Torque (Nm)
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
Qty. Description Size Application Torque(Nm)
2 Bolt M8x20 Oil Suction Pipe to Block 25 ± 4
Water Inlet Manifold
Qty. Description Size Application Torque(Nm)Qty. Description Size Application Torque(Nm)
3 Bolt M8x20 Water Inlet connection 20 ± 3
Engine Breather
Qty. Description Size Application Torque(Nm)
1 Bolt M8x20 Breather to Block 25 ± 5
1 Bolt M8x16Engine breather tube to
Breather housing10 + 2
Oil PanOil Pan
Qty. Description Size Application Torque(Nm)
34 Bolt M8x16 Oil Pan to Block 25 + 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
6/10
Page - 6
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
FlywheelFlywheel
Qty. Description Size Application Torque (Nm)
8 Cylindrical Bolt M16x35 Flywheel to Crankshaft1st 2nd
100 ± 10 275 ± 15
Flywheel HousingFlywheel Housing
Qty. Description Size Application Torque(Nm)
13 Bolt M12x30 Flywheel Housing to Block 100 ± 5
Lubricating Oil Flilter Head and Oil CoolerLubricating Oil Flilter Head and Oil Cooler
Qty. Description Size Application Torque(Nm)
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 .
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
7/10
use the special torques provided by the related procedures .
Page - 7
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
GENSET ENGINE ADD-ON COMPONENTSIntake CurveIntake Curve
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
6 Screw, Hex. Flanged head M8x20 Fan Hub to Fan(30 inch) 25 ± 4
6Screw, Serrated Hex.
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
Qty. Description Size Application Torque(Nm)
1Temparature sensor
cum SwitchM14 X 1.5 X 11 Sensor fitted in water flow tube Max. 20 2
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
8/10
1cum Switch
M14 X 1.5 X 11 Sensor fitted in water flow tube Max. 20 2
Page - 8
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
Fuel Filter Assembly
Turbocharger Bracket Assembly
Qty. Description Size Application Torque(Nm)
1Screw, Hex. Flanged M8 x 30 X Elbow, turbocharger Mounting bracket
25 + 5
Qty. Description Size Application Torque(Nm)
1 Banjo bolt M12X1.5X8.8 Fuel Pump end to NRV pipe 23 ± 3 2
1Screw, Hex. Flanged
Head
M8 x 30 X
1.25 X 10.9
Elbow, turbocharger Mounting bracket
to turbocharger25 + 5
1Screw, Hex. Flanged
Head
M8 x 25 X
1.25 X 8.8
Turbocharger Mounting bracket to
Elbow, turbocharger25 + 5
Gear Case Assembly
Qty. Description Size Application Torque(Nm)
Air compressor closing plate to Gear 3 Screw, Hex. Flanged M10X30X8.8
Air compressor closing plate to Gear
Case45± 5
Intake Manifold Assembly
Qty. Description Size Application Torque(Nm)
1 Plug, Allen Tapered M12 X 1.5 X 5.8 For Pluging Intake manifold Hole 10± 2
2
2
Feed Pump Assembly
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
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
Qty. Description Size Application Torque(Nm)
1 Plug, Allen Tapered M14 X 1.5 X 5.8Plugging Compressor inlet Hole in
Cylinder block10+5
2
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
9/10
Cylinder block
Page - 9
ENGINEERING TECHNICAL DOCUMENTMN/ETD 30
REV 02
Radiator & Intercooler
Qty. Description Size Application Torque(Nm)
2 Clamp SAE J1 508 Type SLTB SAE No.-
76
Hose clamp for intake curve to
intercooler7.3 ± 1.3
2 Clamp SAE J1 508 Type SLTB SAE No.-
76
Hose clamp for Elbow Turbocharger to
Tube, turbocharger-intercooler7.3 ± 1.3
2 Clamp SAE J1 508 Type SLTB SAE No.-
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
1 Clamp SAE J1 508 Type SLTB SAE No.-
42
Hose clamp for Engine Water outlet pipe
to Hose, Radiator side7.3 ± 1.3
1 Clamp SAE J1 508 Type SLTB SAE No.-
34
Hose clamp for Engine Water outlet pipe
to hose at Radiator inlet7.3 ± 1.3
2 Clamp SAE J1 508 Type SLTB SAE No.-
42Hose clamp on Engine Water inlet pipe 7.3 ± 1.3
Engine Mounting Foot
Qty. Engine Size Application Torque(Nm)
42
1 Clamp SAE J1 508 Type SLTB SAE No.-
42
Hose clamp on small end of reducer hose
at radiator outlet7.3 ± 1.3
1 Clamp SAE J1 508 Type SLTB SAE No.-
48
Hose Clamp on reducer hose at radiator
outlet7.3 ± 1.3
Qty. Engine Size Application Torque(Nm)
8Screw, Serrated Hex.
Flanged headM12x30 Engine Mounting Foot to Cylinder Block 70 ± 10
Lubricating Oil Filter Head and Oil cooler
Qty. Engine Size Application Torque(Nm)
1Oil Pressure sensor
cum switchM12x12
Oil Pressure sensor cum switch mounted
at Oil Filter HeadMax. 50 2
Alternator 24 V Assembly
Qty. Description Size Application Torque(Nm)
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
use the special torques provided by the related procedures .
1 Screw, Hex. Flanged head M10 x 110Main Alternator Bracket to
Alternator (Charging)40 ± 6
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
10/10
24 Dec. 2010 Prepared Verified ApprovedChecked
Page - 10
A-9
B
APPendIx A
Page - 11
6-9
NOTEs
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________PDF processed with CutePDF evaluation edition www.CutePDF.com
6-9
NOTEs
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________PDF processed with CutePDF evaluation edition www.CutePDF.com