OPERATION AND MAINTENANCE MANUAL 7.2 MECHANICAL IntroductIon Presentation Introduction. ..............................................................................................................................................1 . How.to.Use.this. Manual ......................................................................................................................... 1 Important.Safety.Remarks........................................................................................................................ 2 - 3 Generafl.Instructfions............................................................................................................................... 3 Cleaning.General.Instructions................................................................................................................... 4 Engine.Serial.Number.Identification.and.Location....................................................................................5 Cylinder.Numeration. ................................................................................................................................6 . Engine Identification................................................................................................................................. 7 Engine Exploded View.............................................................................................................................. 8 Engine Technical Data.............................................................................................................................. 9 - 10 Engine Description.................................................................................................................................... 11 - 22 Introduction 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. .reserves.the.right.of.making. I I any.change,.at.any.moment..MaHIndra navIStar enGIneS Pvt ltd. .reserves.the.right.of.doing.changes. I 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 . factory. . . . . the 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.. 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.convenience,.the.organization.of.the.Manual.is.consistent.with.MNEPL Service Bulletins. . . Manual content The.Manual.contains.an.index.that.can.be.used.as.a.quick.reference.to.access.each.section. SectIonS content Each.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 IntroductIon Important Safety remarks ! attention:. Incorrect.procedures.and.lack.of.care.can.cause.burns,.cuts,.mutilation,.asphyxia.or.otherinjuries.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. 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.compartments.. 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.tension.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 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 engine 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 e Electronic. Aftercooler. Turbocharged Series Cylinders.numbers. Page - 5 IntroductIon cylinders numeration The.cylinders.order.starts.from.the.flywheel,.according.to.the.illustration.below.. FIRST CYLINDER 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. Page - 6 1-8 engine Identification enGIne SerIal nuMber The.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. . . . . . . . . 6.12 TCA Engine Data Plate: enGIne acceSSorIeS The.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. Page - 7 Engine Exploded View Page - 8 ENGINE TECHNICAL SPECIFICATION Engine series Engine Model Prime rating No. of cylinder Type of construction Displacement Bore Stroke Rated output Standby output Tolerance on rated output power Rated speed Method of Starting of engine Aspiration Compression Ratio Brake Mean Effective Pressure (bmep) 1)Rated 2)Maximum Firing Order ●COOLING SYSTEM Method of Jacket cooling Heat Removal Dimensions of radiator (L X H X W ) Qty of coolant(Engine + Radiator) Air Flow at Radiator Outlet Fan Power Tripping Temperature ●FUEL SYSTEM OF ENGINE Fuel oil Fuel Filter type Filtration capacity Filter Change period Specific fuel consumption at 100%load 75%load 50%load Specific fuel consumption at 100%load 75%load 50%load Tolerance on SFC Fuel consumption at 100%load 75%load 50%load 6.12 TCA 6.12 TCA 6.12 TCA 6.12 TCE S12-III S12-II S12-I SE12-I 125 140 160 180 KVA No 6 6 6 6 Inline Inline / V type 7.12 Ltrs 105 mm mm 137 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 % ±5 ±5 ±5 ±5 rpm 1500 1500 1500 1500 24V ELEC Turbocharged Aftercooler NA/TC/TCA 16.8:1 16.8:1 16.8:1 16.8:1 No Bar 12.9 14.1 14.4 15.7 16.4 18 1-5-3-6-2-4 18.3 20 mm Ltr CFM KW Deg C 25 10000 6 Radiator By Water 831x390.5x1135 25 25 11800 11800 7 7 105 25 13200 8 High speed Diesel(HSD IS 1460:2005) ) Spin-on type with paper element Micron hrs g/kW-h 202 200 214 148.7 147.2 157.5 +5 27.45 20.38 14.54 198 197 212 145.7 145.0 156.0 +5 30.01 22.39 16.06 5 500 197 197 207 145.0 145.0 152.4 +5 34.15 25.61 17.94 193 195 202 142.0 143.5 148.7 +5 37.18 28.18 19.46 g/hp-h % Ltrs/h ENGINE TECHNICAL SPECIFICATION Engine series Engine Model Prime rating 1)FUEL INJECTION PUMP Make Type 2)GOVERNER DATA Type Response time Recovery time ●LUBE OIL SYSTEM Lube Oil Consumption at 100% Load Recommended lube oil Lub oil filter type Filtration capacity Lube oil change period Maximum lube oil temperatorure Lube oil pressure Lube oil system capacity ●EXHAUST SYSTEM Exhaust silencer type Exhaust noise level (with Silencer) @ 3M Max. Permissible back pressure in Exhaust Exhaust gas flow Exhaust gas temperature (Max ) ●HEAT REJECTION DETAILS Heat Rejection to coolant Heat Rejection to CAC Heat Rejection to exhaust Heat Rejection from engine surface ●AIR INTAKE SYSTEM Intake filter type Air intake restriction - with clean element Air intake restriction - with dirty element Filtration capacity Maximum Intake manifold temperature Combustion air inlet flow rate ●ENGINE NOISE LEVEL At 1Mtr ●DIMENSIONS & WEIGHT DETAILS LengthXWidthXHeight (With Radiator) Dry engine weight-with flywheel & flywheel housing Weight to power ratio No KVA 6.12 TCA 6.12 TCA 6.12 TCA S12-III S12-II S12-I 125 140 160 STANADYNE MAKE Rotary MECHANICAL (3- 5%) As per IS10002 Lit/hr 0.015 0.017 0.02 15W40 API CI4 Full flow: Spin on cartridge type with Paper element 15 500 Min:-10 & Max:125 Must be greater than 1.2 at idling condition & 3.5 at rated speed 19.8 Residential Type Complies with CPCB norms 75 603 664 800 600 650 62.22 19.33 101.19 12.89 70.98 22.49 110.58 14.38 78 32.9 127.9 16.07 0.014 6.12 TCE SE12-I 180 Bosch Make HPCR ECU Controlled (Isochronous) Microns hours Deg C kg/cm2 lit dB mm of Hg kg/hr Deg C kW kW kW kW 558 59.73 14.74 82.39 12.1 mm of H2O mm of H20 Microns Deg C kg/hr 535 Dry type Air cleaner 230 600 20 55 580 637 750 < 75 dBA for genset with canopy mm kg Kg/Kw 5.21 1727X932X1274.4 598.6 4.67 4.09 610 3.74 Fuel System 2-2 Description Maximum fuel inlet restriction (for gears pump) Fuel pressure range in the fuel filter outlet (at crank speed) Range of fuel pressure in fuel filter fuel inlet (at operation speed) Maximum pressure load reduction in the fuel filter 6 cylinders 0.6 to 1.2 bar 9.7 to 12.8 bar 10.5 to 13 bar ≤0.8 bar lubrication System Description Oil pressure • Nominal speed • Idling speed Oil temperature • Nominal • Maximum Oil capacity MaxxForce 7.2 5.3 bar (hot engine) 3.5 bar (hot engine) 90 - 110 °C 120 °C 19.8 l cooling System Description Volume of water in the engine, without radiator Water temperature • Nominal • Maximum MaxxForce 7.2 9l 80 - 90 °C 100 °C thermostat Opening beginning 79 ± 2°C Page - 9 Total opening 90°C Maximum opening course 10.0 mm Thermostat 0304CAV00010N engine Description 2-4 FeatureS MAXXFORCE 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) • Fuel Supply System • Intake Air Manifold Hot side (right engine side) • Turbocharger system • Exhaust manifold 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 the high pressure fuel goes to the injectors.. The new water pump was designed with seven vanes to increase the water flow. Page - 10 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. Turbocharger 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 power. In the MAXXFORCE engine it's located on the hot side , next to the waterpipe. Page - 11 engine component locations 2-6 2 1 toP VIeW 1. Coolant temperature sensor (ECT) 2. Valve cover Page - 12 technIcal Data 2 3 1 5 4 Front VIeW 1. Water bypass tube assembly thermostat outlet 2. Alternator 3. Pulley 4. Vibration damper 5. Front cover Page - 14 1 5 4 2 3 leFt VIeW (colD SIDe) Mechanical components 1. Manifold, Intake 2. Oil cooler assembly 3. Oil filter 4. Fuel filter 5. High pressure pipes Page - 15 2 2-10 4 3 6 5 7 1 rIGht VIeW (hot SIDe) 1. Oil dipstick 2. Turbo inlet pipe 3. Turbo outlet pipe 4. Exhaust manifold 5. Turbo exhaust curve 6. Flywheel housing 7. Cylinder block Page - 17 technIcal Data 4 3 1 2 rear VIeW 1. Flywheel 2. Lube Oil sump 3. Flywheel Housing 4. Water Outlet tube Page - 18 NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ OPERATION ANd MAINTENANcE Operation and Maintenance Engine Operation ..................................................................................................................................... Cooling Fluid and Coolant ........................................................................................................................ Water Pump Checking ............................................................................................................................ Maintenance Table.................................................................................................................................... Conservation for Inactive Engines for Long Periods ................................................................................. Starting Engine Preparation ..................................................................................................................... Oil Element ............................................................................................................................................. Engine Operation Start / Stop · 3-2 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 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 SYSTEM FuEL SPEcIFIcATIONS - HSd IS 1460:2005 · · · 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) Page - 2 FuEL INjEcTION SySTEM Page - 3 FuEL INjEcTION SySTEM Page - 2 NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ · LuBRIcANTINg OIL Oil Level check · 3-4 Stop the engine and wait 30 minutes so that the oil can flow back to the carter. · · · · · Before pulling oil dipstick, clean the surroundings. If necessary, Topup up to the ' H' mark, without exceeding it. Use the same oil Brand and Grade. 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 · · · · · Change the Lubricating oil as per Maintenance Plan. The oil must be hot for easy drain. Remove the carter plug and washer drain the oil. 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: Always use MNEPL recommended genuine engine oil check Lubricant oil condition 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: Do not mix different oil brand / grade. Use only MNEPL recomended oil Page -3 Oil Filter change · · · 3-10 Remove the old filter. Clean the sealing area of the flter with a clean cloth. Prime the new filter with clean and fresh oil and fix.(Use always GENIUNE spares). 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. · · · Oil Element 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. 2. Using the wrench indicated, unscrew the filter Page - 8 INSTALLATION 1. Clean area around oil filter head, clean gasket surface of filter head. 2. Lubricate oil filter gasket with fresh engine oil. 4. Tighten the filter untill the gasket contacts the filter head surface. 3. Fill the oil filter with fresh engine oil. 5. Use oil filter wrench to tighten the filter an additional 3/4 of a turn. 6. Operate the engine and check for leakages Page - 9 Lubrication system OIL LubRIcATION cIRcuIT 12-2 Page - 1 OPERATION ANd MAINTENANcE cooling Fluid and coolant ! 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 Check the inspection hole located on the left side of the engine block (seen by the flywheel side). If there are signs of water or oil leakage, probably there is leakage through the water pump or through the sealing rings. Check and change, if necessary. Note: Image is shown with gear housing removed If water is coming from this hole, it means there is a leakage coming from the water pump. Page -4 NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ Cooling System COOLINg CIRCuIT Page - 1 NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ OPERATION ANd MAINTENANcE Maintenance Table Remarks: 1) 2) This table is only for guidance. The Maintenance Table of the Genset prevails over this table. If the engine stays inactive for a long time, it must perform an idling speed test fortnightly, until to reach the operation temperature. 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. 3) 4) Note: Mentioned parts are under evaluation and maintenance fequency can get changed after evaluation. Page - 5 NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ Edited by Foxit Reader Copyright(C) by Foxit Corporation,2005-2009 For Evaluation Only. 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: 1. Clean the outer parts of the engine. 3-8 2. Operate the engine until to reach the operating temperature. 3. Drain cooling system and lubricant oil. 4. Fill the radiator with clean water and coolant according to the recommended proportion. 5. Fill up the oil sump with protective oil SAE 20 W 20 6. Drain fuel system (reservoir, low pressure system). 7. 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. 8. Drain fluid from cooling system and oil from oil sump. The fuel mixture can stay in the system 9. Remove valves cover from cylinder heads and spray protective oil on the springs and rocker arms. Reinstall covers. 10. Apply protective oil on machined surfaces. 11. Remove belt. 12. 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 1. Before operating an engine which stayed inactive for a long period, follow these procedures: 2. Clean the outer parts of the engine. 3. Fill the cooling system with clean water and coolant in the recomended proportion 4. Change engine lubricnting oil flter. 5. Fill the oil pan with new recomended grade of 15W40 engine oil in recomended quantity. 6. Install belt and adjust tension. 7. Remove valve covers and lubricate rocker arms with engine oil. Reinstall covers. 8. Drain the fuel mixture from the reservoir and fill with new fuel. 9. Change fuel filter. Page - 6 OPERATION ANd MAINTENANcE ENgINE STARTINg Preparation cLEAN ENgINE 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. ! 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. 6 cylinders Engine ! ! NOTE : Do not use high pressure or excessive hot water temperature as it may damage the engine components. 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. NOTE : Page - 7 FAILuREs DIAgNOsIs Diagnosis Failures Introduction. ............................................................................................................................................1 . Trouble Shooting Chart............................................................................................................................2 Introduction Next.they.are.presented.some.typical.problems.which.the.engine.may.present,.their.probable.causes.and.possible. corrections.for.these.problems. ! 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.. 17-2 Page - 1 Engine Oil Spewing out from Breather Tube Lubricating Oil Contaminated with Coolant Fuel/ Oil Leaking from Exhaust Manifold Engine Output Power Low Cannot Reach rated RPM Excessive Blue Smoke Trouble Shooting MAXXFORCE 7.2 Mechanical COMPLAINTS Cause Restricted Air Intake High Exhaust Back Pressure Air System Air Leakage Between Yurbocharger and Intake Manifold Defective Turbocharger Charge Air Cooler Malfunctioning Air Filter Choked Low/ Out of Fuel Air in Fuel System Restricted Fuel Lines Injector Defective Injector Installed with More Than One Sealing Washer Broken fuel Pump Drive Shaft Throttle Linkage Worn or Incorrectly Adjusted Shutoff Lever partialy engaged Water in Fuel Fuel System High Pressure/ Fuel Leakage Fuel Filter Choked FIP Timing Incorrect FIP Rack Sticky Fuel Shutoff Not Actuating FIP Caliberation Defective FIP Internal Plunger Seal Leakage Fuel temperature High Fuel Return Line Restricted Fuel Lift Pump Defective Oil Pressure Transducer / Gauge Defective Incorrect Grade oil Defective oil Pump External / Internal Leakage Dirty oil Filter Faulty Cylinder Oil Control Lubricating System Oil Suction Line Restricted Leakage From Valve Stem Oil Seal Faulty Oil Pressure Regulator Crankcase Low or Out of Oil Oil Cooler Leakage Oil Cooler Pluged Turbocharger Drain Line Obstruction Oil Level Too High Insuffecient Coolant Defective Water Pump Faulty Thermostat Cooling System Damage Hose External coolant Leakage Low Coolant Capacity / Dirty radiator Leaking Radiator Radiator Pressure Cap incorrect Driving Technique Operation and Maintenance Practice Dirty Filters/ Breather Long Idle Periods Engine Overloaded Oil Needs Changing Engine Idle Speed Too low Cylinder Head Gasket Leak Blown Off Cracked Cylinder Head Valve Leakage / Valve Lash Bad Mechanical Adjustments or Repair Broken or Worn Piston Rings Engine Camshaft Out of Time Engine Compression Low Rocker Adjusting Screw Cup not seated properly on Push rod ball Loose Cylinder Cap Screw Worn or Scored Liners or Pistons Air Compressor Pumping Oil Page - 2 Engine Starts but doesnot keep running Lubricating Oil Contaminated with Fuel Engine Surges ( Speed change) Hard Starting or Failure to Start Coolant Temperature Too High Excessive White Smoke at idle Excessive Black Smoke at Idle Excessive Fuel Consumption Excessive oil Consumption High Oil Pressure Low oil Pressure Loss of Coolant Engine Missing NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ Group - 17 APPendIx A ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 TORQUE CHART ( 6.12 TCA MECHANICAL GENSET ENGINE) Engine Block Qty. 2 Description Bolt Size M14 Application Bearing Cap to Block 1st 50 - 5 Torque (Nm) 2nd 155 ± 5° Torq. Range 170 to 282 Qty. 1 1 1 Description Plug Hollow Bolt Plug Size 3/8” M8x1 1/2” Application Water Drain Plug to Block Oil Ejector to Block Water Drain Plug to Block Torque(Nm) 10 + 5 10 ± 1.5 15 + 5 Required Sealing Loctite 567 ** Loctite 567 Connecting Rod Qty. 2 Description Bolt Size MJ 12x58 Application Connecting Rod to Crankshaft 1st 40 ± 5 Torque (Nm) 2nd 80 ± 2° Torq. Range 130 to 160 Camshaft Qty. 4 2 Description Bolt Bolt Size M8x25 M8x16 Application Gear to Camshaft Camshaft Lock to Block 1st 15 ± 1 Torque (Nm) 2nd Torq. Range 30 ± 2° 35 to 65 25 ± 4 Oil Pump Qty. 2 Description Bolt Size M8x20 Application Oil Pump to Block Torque(Nm) 20 ± 5 Water Pump Qty. 2 Description Bolt Size M8x20 Application Water Pump to Block Torque(Nm) 20 ± 5 SHEET 1/10 PRINTED COPIES ARE NOT CONTROLLED 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. Page - 1 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Gear Housing Qty. 10 3 2 1 3 1 1 Description Bolt Bolt Hollow Bolt Hollow Bolt Bolt Plug Plug Size M8x20 M8x50 M8x1 M8x1 M10x70 M10x1 M14x1.5 Application Gear Housing to Block Gear Housing to Block Lubrication pipe to Gear Housing Lubrication pipe to Block Intermediate Bearing with Gear to Block Gear Housing (Rear Half) Plug-Allen Tapered Torque(Nm) 25 ± 5 25 ± 5 7.5 ± 2.5 7.5 ± 2.5 60 ± 5 10 ± 5 20 ± 3 Valve Lubrication Pipes Qty. 6 1 Description Hollow Bolt Hollow Bolt Size M10x1 M12x1.5 Application Valve Lubrication pipe to Cylinder Head Valve drive Lubrication Pipe to Oil cooler Torque(Nm) 10 + 5 10 + 5 Front Cover Qty. 16 9 1 Description Bolt Bolt Inspection Cover Size M8x16 M8x55 S65 X 4 Application Front Cover to Gear Housing Front Cover to Gear Housing to Block Inspection cover to front cover Torque(Nm) 25 ± 3 25 ± 3 20 ± 3 Alternator Bracket Qty. 3 1 Description Bolt Bolt Size M10x35 M10x20 Application Alternator Bracket to Gear Housing Pulley to Alternator Bracket Torque(Nm) 40 ± 6 40 ± 6 Water Outlet Pipe Qty. 12 2 2 Description Bolt Bolt Bolt Size M8x55 M8x30 M8x30 Application Water Outlet Pipe to Cylinder Head Connection water outlet Connection by pass Torque(Nm) 25 ± 4 25 ± 3 25 ± 3 PRINTED COPIES ARE NOT CONTROLLED 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. SHEET 2/10 Page - 2 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Qty. 1 1 1 Description Hollow Bolt Nipple Plug Size M12 M22 M22X1.5 Application Water outlet tube to degassing tank Nipple Bypass connection for AC application Plug, Connection Bypass for Non-AC application Torque(Nm) 20 ± 3 40 ± 5 25 + 5 2 Turbocharging Qty. 4 4 1 1 2 2 1 Description Stud Stover Stud Hollow Bolt Hollow Bolt Bolt Bolt V band Clamp Size M10x25 M10 M14x1.5 M14x1.5 M8x20 M8x16 -Application Turbocharger to Exhaust Manifold Turbocharger Stud to Exhaust Manifold Turbocharger Inlet Lubrication Pipe to Turbocharger Turbocharger Inlet Lubrication Pipe to Block Turbocharger Lubrication Return Pipe to Turbocharger Turbocharger Elbow Bracket V band clamp elbow-turbo to Turbocharger Torque(Nm) 6±2 70 ± 10 25 ± 5 25 ± 5 20 ± 3 25 + 5 10 + 2 Cylinder Head Qty. 20 2 2 Description Bolt Bolt Engine lifting hook Size M14x152 M14 M12 Application Cylinder Head to Block Cylinder Head to Fan Bracket Cylinder Head mounting bolt PreTorque (Nm) 40+5 40+5 Torque Torque Torque Torque Torque (Nm) Range 1 (°) 2 (°) 3 (°) 120 To 60+ 10 60± 3 60± 3 90± 3 260 120 To 60+ 10 60± 3 60± 3 90± 3 260 80 ± 10 - Qty. 2 1 1 Description Socket head cap screw Nut Nut Size M5x10 M22 M8x10 Application Lubrication pipe to Cylinder head High pressure connector nut Nut – Valve clearance adjustment Torque(Nm) 5±1 50 + 5 20 + 5 PRINTED COPIES ARE NOT CONTROLLED 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. SHEET 3/10 Page - 3 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 High Pressure Pump Qty. 3 3 1 1 1 1 Description Stud Nut Nut Hollow Screw Connector Box Nut Size M8 X 30 M8 M14x1.5 M12 M8 M10x1 Application High Pressure Pump adaptor to Gear Housing High Pressure Pump to Gear Housing Gear to High Pressure Pump High Pressure Pump –Tube ,Fuel Return Connector for Boost pressure Tube, Injection Pump to Intake manifold Torque(Nm) 8±1 38 ± 3 180 ± 5 22.5 ± 2.5 10 + 5 12.5 ± 2.5 2 Low Pressure Pipe Qty. 6 Description Connection Size M8x1 Application Pipe, Fuel Return to Cylinder Head Torque(Nm) 8±1 High Pressure Pipe Qty. 6 6 Description Nut Nut Size M12 M14 Application Nut high pressure tube to fuel injection pump Nut high pressure tube to Connector high pressure tube Torque(Nm) 15 + 5 25 + 5 Fuel Filter Qty. 2 2 1 1 1 Description Bolt Connection Hollow Bolt Hollow Bolt Hollow Bolt Size M10x30 M14x1.5 M12x1.5 M14x1.5 M14x1.5 Application Fuel Filter to Block Fuel inlet to Filter Head Pipe, Fuel Filter outlet to VE Pump Pipe, Fuel Filter inlet for mechanical feed Pump Pipe, Fuel Filter inlet NRV Torque(Nm) 35 ± 4 20 + 6 20 + 6 20 + 6 20 + 6 PRINTED COPIES ARE NOT CONTROLLED 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. SHEET 4/10 Page - 4 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Assy, Fuel Injector and Valve Cover Qty. 1 2 Description Screw Bolt Size M6 M6 x 60 Application Special Step Bolt Fuel injection Clamp Valve Cover Torque(Nm) 4± 1 8.5 ± 1 Qty. Descri ption Size Application Torque (Nm) Relieve to (Nm) Torque (Nm) Torque 1 (°) Torque Torque Torque 2 (°) 3 (°) Range 1 Screw M6 Screw- Fastening Bridge Fuel Injector 1+0.5 0 4±1 90 90 30 7+6 Intake Manifold Qty. 12 12 1 Description Bolt Bolt Hollow Bolt Size M8x35 M8x80 M12X1.5 Application Intake Manifold to Cylinder Head Intake Manifold to Cylinder Head Tube-Intake Manifold to FIP Torque(Nm) 24 ± 2 24 ± 2 20 + 6 Exhaust Manifold Qty. 12 12 Description Stud Stover Nut Size M10x45 M10 Application Exhaust Manifold to Cylinder Head Exhaust Manifold to stud Cylinder Head Torque(Nm) 6±2 70 ± 10 Exhaust Elbow Qty. 4 4 Description Stud Stover Nut Size M10 M10 Application Exhaust Elbow to Turbocharger Exhaust Elbow to Turbocharger Torque(Nm) 6 ± 2 60 ± 10 PRINTED COPIES ARE NOT CONTROLLED 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. SHEET 5/10 Page - 5 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Crankshaft Pulley Qty. 4 9 Description Cylindrical Bolt Bolt Size M16x65 M8 Application Crankshaft Pulley to Crankshaft Damper to Crankshaft Pulley 1st 100 ± 10 35 ± 5 Torque (Nm) 2nd 275 ± 15 Oil Suction Pipe Qty. 2 Description Bolt Size M8x20 Application Oil Suction Pipe to Block Torque(Nm) 25 ± 4 Water Inlet Manifold Qty. 3 Description Bolt Size M8x20 Application Water Inlet connection Torque(Nm) 20 ± 3 Engine Breather Qty. 1 1 Description Bolt Bolt Size M8x20 M8x16 Application Breather to Block Engine breather tube to Breather housing Torque(Nm) 25 ± 5 10 + 2 Oil Pan Qty. 34 Description Bolt Size M8x16 Application Oil Pan to Block Torque(Nm) 25 + 5 PRINTED COPIES ARE NOT CONTROLLED 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. SHEET 6/10 Page - 6 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Flywheel Qty. 8 Description Cylindrical Bolt Size M16x35 Application Flywheel to Crankshaft 1st 100 ± 10 Torque (Nm) 2nd 275 ± 15 Flywheel Housing Qty. 13 Description Bolt Size M12x30 Application Flywheel Housing to Block Torque(Nm) 100 ± 5 Lubricating Oil Flilter Head and Oil Cooler Qty. 10 1 Description Screw Hollow Bolt Size M8x 40 M14X1.5 Application oil cooler to block Adapter Torque(Nm) 25 ± 3 25 + 5 Standard Torque Table for Normal Steel Bolts (According to DIN 2230) Nominal Size M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 8.8 6±1 10 ± 1.5 25 ± 4 50 ± 8 86 ± 13 135 ± 20 207 ± 31 298 ± 45 418 ± 63 569 ± 85 Bolt Class ( Nm) 10.9 9±1 15 ± 2 37 ± 6 73 ± 11 124 ± 19 198 ± 30 304 ± 46 424 ± 64 595 ± 89 810 ± 122 12.9 10 ± 1.5 18 ± 3 43 ± 7 84 ± 13 145 ± 22 231± 35 325 ± 49 497 ± 75 696 ± 104 948 ± 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 . PRINTED COPIES ARE NOT CONTROLLED 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. SHEET 7/10 Page - 7 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Intake Curve Qty. 3 1 1 2 GENSET ENGINE ADD-ON COMPONENTS Size M8x35 M8x25 M8x8 M22 X 1.5 X 5.8 Application Intake curve to intake manifold Intake curve to intake manifold Intake curve to intake manifold For Plugging Heater Holes Torque(Nm) 20 ± 3 6±2 20 ± 3 30 ± 5 Description Screw, Hex. Flanged head Stud Nut, Hex. Plug, Allen Tapered 2 2 2 Air Cleaner Assembly Qty. 1 4 1 2 Description Clamp SAE J1 508 Type SLTB Screw, Hex. Clamp SAE J1 508 Type SLTB Screw, Serrated Hex. flanged head Size SAE No.142 M8x20 SAE No.110 M12x30 Application Clamping Hose ,Air cleanerTurbocharger to Air Cleaner Assembly Air Cleaner Assembly to Air cleaner Mounting Bracket Clamping Hose ,Air cleanerTurbocharger to Turbocharger Air cleaner Mounting Bracket to Cylinder Block Torque(Nm) 7.3 ± 1.3 25 ± 4 7.3 ± 1.3 70 ± 10 Fan Assembly Qty. 6 6 2 1 4 1 2 2 2 1 Description Screw, Hex. Flanged head Screw, Serrated Hex. Flanged head Bolt, Hex. Flanged head Bolt, Hex. Flanged head Bolt, Hex. Flanged head Screw, Hex. Flanged head Screw, Hex. Flanged head Screw, Hex. Flanged head Hexagonal Spacer Bolt, Hex. Flanged head Size M8x20 M10X70 M8X35 M10x50 M10x35 M10X20 M8X25 M8X80 M12X1.5 M10x50 Application Fan Hub to Fan(30 inch) Fan pulley to Fan Hub and Fan Fan Bracket to Spacer mounted on cylinder Head bolts Fan Bracket to Timing case Housing Fan Bearing to Fan Bracket Tensioner Pulley to Lever belt Tensioner Lever belt tensioner to Fan Bracket Fan Bracket to Timing case Spacer mounted on cylinder Head Bolt to Fan shaft Torque(Nm) 25 ± 4 50 ± 8 25 ± 4 50 ± 8 50 ± 8 40 + 6 25 ± 4 25 ± 4 50 ± 8 50 ± 8 2 Water Flow Tube Assembly Qty. 1 Description Temparature sensor cum Switch Size M14 X 1.5 X 11 Application Sensor fitted in water flow tube Torque(Nm) Max. 20 SHEET 8/10 2 PRINTED COPIES ARE NOT CONTROLLED 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. Page - 8 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Fuel Filter Assembly Qty. 1 Description Banjo bolt Size M12X1.5X8.8 Application Fuel Pump end to NRV pipe Torque(Nm) 23 ± 3 2 Turbocharger Bracket Assembly Qty. 1 1 Description Screw, Hex. Flanged Head Screw, Hex. Flanged Head Size M8 x 30 X 1.25 X 10.9 M8 x 25 X 1.25 X 8.8 Application Elbow, turbocharger Mounting bracket to turbocharger Turbocharger Mounting bracket to Elbow, turbocharger Torque(Nm) 25 + 5 25 + 5 Gear Case Assembly Qty. 3 Description Screw, Hex. Flanged Size M10X30X8.8 Application Air compressor closing plate to Gear Case Torque(Nm) 45± 5 2 Intake Manifold Assembly Qty. 1 Description Plug, Allen Tapered Size M12 X 1.5 X 5.8 Application For Pluging Intake manifold Hole Torque(Nm) 10± 2 2 Feed Pump Assembly Qty. 3 2 2 1 Description Allen bolt Screw, Hex. Flanged Banjo bolt Adapter Size M6X16X8.8 M8 X 25X 1.25 X 8.8 M14X1.5X8.8 M14X1.5X8.8 Application Feed Pump mounting to Gear case Feed Pump mounting to Gear case Feed Pump Inlet/Outlet Feed Pump adapter to Timing case Torque(Nm) 10 ± 1.5 25 ± 4 23± 3 30 ± 4 2 Starter Motor Assembly Qty. 3 Description Screw, Hex. Flanged Size M10 X 20 X 8.8 Application Starter Motor (24V) Mounting Torque(Nm) 45± 5 2 Cylinder Block Qty. 1 Description Plug, Allen Tapered Size M14 X 1.5 X 5.8 Application Plugging Compressor inlet Hole in Cylinder block Torque(Nm) 10+5 2 PRINTED COPIES ARE NOT CONTROLLED 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. SHEET 9/10 Page - 9 ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Radiator & Intercooler Qty. 2 2 2 2 1 1 2 1 1 Description Clamp SAE J1 508 Type SLTB Clamp SAE J1 508 Type SLTB Clamp SAE J1 508 Type SLTB Clamp SAE J1 508 Type SLTB Clamp SAE J1 508 Type SLTB Clamp SAE J1 508 Type SLTB Clamp SAE J1 508 Type SLTB Clamp SAE J1 508 Type SLTB Clamp SAE J1 508 Type SLTB Size SAE No.76 SAE No.76 SAE No.76 SAE No.42 SAE No.42 SAE No.34 SAE No.42 SAE No.42 SAE No.48 Application Hose clamp for intake curve to intercooler Hose clamp for Elbow Turbocharger to Tube, turbocharger-intercooler Hose Clamp for Tube, turbochargerintercooler to Intercooler inlet Hose Clamp for Engine Water Outlet pipe Hose clamp for Engine Water outlet pipe to Hose, Radiator side Hose clamp for Engine Water outlet pipe to hose at Radiator inlet Hose clamp on Engine Water inlet pipe Hose clamp on small end of reducer hose at radiator outlet Hose Clamp on reducer hose at radiator outlet Torque(Nm) 7.3 ± 1.3 7.3 ± 1.3 7.3 ± 1.3 7.3 ± 1.3 7.3 ± 1.3 7.3 ± 1.3 7.3 ± 1.3 7.3 ± 1.3 7.3 ± 1.3 Engine Mounting Foot Qty. 8 Engine Screw, Serrated Hex. Flanged head Size M12x30 Application Engine Mounting Foot to Cylinder Block Torque(Nm) 70 ± 10 Lubricating Oil Filter Head and Oil cooler Qty. 1 Engine Oil Pressure sensor cum switch Size M12x12 Application Oil Pressure sensor cum switch mounted at Oil Filter Head Torque(Nm) Max. 50 2 Alternator 24 V Assembly Qty. 2 1 1 Description Screw, Hex. Flanged head Screw, Hex. Flanged head Screw, Hex. Flanged head Size M8 x 20 M12 x 35 M10 x 110 Application Pull rod, Alternator Bracket to Main Alternator Bracket Pull rod, Alternator Bracket to Alternator (Charging) Main Alternator Bracket to Alternator (Charging) Torque(Nm) 20 ± 3 70 ± 10 40 ± 6 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 . Release Date 24 Dec. 2010 Milind Khanolkar Prepared Sachin Mahajan Checked Amol Relkar Verified Cesar Almeida Approved SHEET 10/10 PRINTED COPIES ARE NOT CONTROLLED 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. Page - 10 APPendIx A Page - 11 NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________