Navistar O & M Manual

OPERATION AND MAINTENANCE MANUAL

7.2 MECHANICAL

IntroductIon

Psi Introduction.  1 How.to.Use.this.Manual ......................................................................................................................... 1 ImportantSaetyRemarks2 - 3 GenerafInstructons 3 Cleaning.General.Instructions.4 Engine.Serial.Number.Identication.and.Location5 Cylinder.Numeration.  6 Engine Identification................................................................................................................................. 7 Engine Exploded View..............................................................................................................................8 Engine Technical Data..............................................................................................................................9 - 10 Engine Description.................................................................................................................................... 11 - 22

IntroductIon

Psi Introduction.  1 How.to.Use.this.Manual ......................................................................................................................... 1 ImportantSaetyRemarks2 - 3 GenerafInstructons 3 Cleaning.General.Instructions.4 Engine.Serial.Number.Identication.and.Location5 Cylinder.Numeration.  6 Engine Identification................................................................................................................................. 7 Engine Exploded View..............................................................................................................................8 Engine Technical Data..............................................................................................................................9 - 10 Engine Description.................................................................................................................................... 11 - 22

Ii This.manual.contains.complete.inormation.and.specication.to. This.manual.contains.complete.in ormation.and.specication.to.assembly.and. assembly.and.disassembly.MA disassembly.MAXXFORCE.72 XXFORCE.72 engines.and.all.components.manuactured.by.MaHIndra engines.and.all.components.manuactured.by. MaHIndra I navIStar I enGIneS Pvt ltd.  ATTENSION.in.the.Saety.General.Instructions,.in.the. Read.and.ollow.all.saety.instructions.Consult.the.item. next.section

Some.o.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.specications.and.inormation.presented.in.this.manual.are.the.ones.which.is. eective.in.the.moment.o.its.print.MaHIndra eective.in.the.moment.o.its.print. MaHIndra I navIStar I enGIneS Pvt ltd. .reserves.the.right.o.making. any.change,.at.any.moment.MaHIndra MaHIndra navIStar I enGIneS Pvt ltd. .reserves.the.right.o.doing.changes. in.the.product.at.any.moment.without.this.to.incur.in.any.urther.obligation in.the.product.at.any.moment.wi thout.this.to.incur.in.any.urther.obligation.In.case.o.any.di .In.case.o.any.dierence.in.the.engine. erence.in.the.engine. or.inormation or.in ormation.o.th .o.this.ma is.manual,. nual,.contac contact.an.M t.an.MNEPL NEPL Auth Authorized orized Distrib Distributor utor or the act actory ory The.compo The.co mponen nents. ts.use used.i d.in.M n.MNEP NEPLengin Lengines es pro produc ductio tion n are prod produce uced d wit with h las lastt gen genera eratio tion n tec techno hnolog logy y com compon ponent ents s with.high.level.quality. with.high.le vel.quality.standards. standards.When.parts.changes.are.necessary When.parts.changes.are.necessary,.it.is. ,.it.is.recommended.to.use. recommended.to.use.only.MIM. only.MIM.genuine. genuine. spare.parts.

Hw  us his M To.create.this.Man o.create.this.Manual.it.has.been.take ual.it.has.been.taken.as.base.a.generic.MAXXF n.as.base.a.generic.MAXXFORCE. ORCE. 72 .engine,.whic .engine,.which.operati h.operations.and. ons.and. maintenance.proced mainte nance.procedures.are.the.same.or.all.models.o.this.series ures.are.the.same.or.all.models.o.this.series.The.illust .The.illustratio rations.thereo ns.thereore,.could.di re,.could.dier.rom. er.rom. application.to.application In.this.Manual,.all.reerences.to.the.components.o.the.engine.are.divided.in.19.specic. In.this.Manual,.all.reerences.to.the.components.o. the.engine.are.divided.in.19.specic.sections sections.For.y .For.your.conveour.convenience,.the. nience ,.the.organiz organization. ation.o.the. o.the.Manu Manual.is. al.is.consis consistent.w tent.with.M ith.MNEPL NEPL Service Bulle Bulletins tins

Manual content The.Manual.contains.an.index.that.can.be.used.as.a.quick.reerence.to.access.each.section

SectIonS content Each.section.contains.the.ollowing.inormation: •

Page.o.index.in.the.beginning.o.each.section.to.help.or.the.ast.location.o.the.desired.inormation

•

General.inormation.about.the.operation.o.the.component.and.the.explanation.o.their.main.changes

•

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

Imi  Mi Sysm All.dimensions.are.expressed.in.the.International.Metric.System.(IS)

Page - 1

IntroductIon

Imp Sy rmks

!

ai:

Incorrect.procedur Incorrect.pr ocedures.an es.and.lac d.lack.o k.o.care .care.can. .can.cause. cause.burns burns,.cut ,.cuts,. s,.muti mutilation lation,.asp ,.asphyxi hyxia.or. a.or.otherin otherin- juries.and.even.death

Careully.read.all. sa Careully.read.all. saety.procedures ety.procedures and.remarks.beore.perorm and.remarks.beore.perorming.any.repair.in. ing.any.repair.in. the.engine the.engine.The.ollowi .The.ollowing.list. ng.list. presents.the.general.cautions.that.must.be.ollowed.to.guarantee.your.personal.saety.Special.saety.measures. can.be.presented.with.the.procedures,.i.necessary •

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

•

Always.use.individual.protection.equipments.(saety.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.beore.working

•

Disconnect.the.battery.(negative.cable.rst).and.discharge.the.capacitors.beore.beginning.the.repairs

•

•

•

In.case.the.repair.is.being.made.in.the.vehicle,.disconnect.the.starter.motor.to.a In.case.the.repair.is.being.made.in.the.v ehicle,.disconnect.the.starter.motor.to.avoid.an.accidental.start.o.the. void.an.accidental.start.o.the. engine.In.case. engine .In.case.o.industrial.engines,.place. o.industrial.engines,.place.a.“Do. a.“Do.Not.Operate”. Not.Operate”.warning.in.the.operator. warning.in.the.operator.compartment.or.on.the. compartment.or.on.the. controls To.manually.rotate.the.engine,.use.ONLY.the.recommended.procedures.Never.try.to.rotate.the.crankshat.with. the.an.This.practice.can.cause.serious.personal.injuries.or.damages.to.the.an.blades,.causing.the.premature. ailure.o.the.component I.the.engine.was.in.operation.and.the.cooling.fuid.is.hot,.leave.the.engine.to.cold.down.beore.slowly.open. the.cover.o.the.reservoir.to.relie.the.pressure.o.the.cooling.system

•

Do.not.work.with.materials.that.are.lited.by.jacks.or.cranes

•

Always.use.correct.blocks,.stands.or.brackets.to.position.the.engine.beore.perorming.any.repair

•

•

•

•

Relie.the.pressure.o.the.pneumatic.(brakes),.lubrication.and.cooling.systems.beore.removing.or. Relie.the.pressure.o.the.pneumatic.(brakes),.lubrication.and.cooling.systems. beore.removing.or.disconnect. disconnect. any.piping,.connections.or.other.elements.Pay.attention.to.the.pressure.existence.beore.to.disconnect.any. item.o.a.pressurized.system.Do.not.check.pressure.leakages.with.the.hand.Oil.or.uel.at.high.pressure.can. cause.injuries To.avoid.injuries,.use.a.crane,.or.ask.or.help.to.lit.components.which.weight.more.than.20.kg.Make.sure.that. all.lit.equipments.as.chains,.hooks.or.belts.are.in.good.conditions.and.have.the.correct.load.capacity.Make. sure.that.hooks.are.correctly.positioned sure.that.hooks.are.correctly .positioned.Always .Always.use. .use.an.extens an.extension.when.necessary ion.when.necessary.The.lit.hooks.must.not. receive.side.loads Never.leave.the.engine.operating.in.a.closed.and.non.ventilated.area.The.engine.exhaust.gases.are.harmul. to.health TheMNEPL . .coolant.has.alkaline.substances.Av .coolant.has.alkaline.substances .Avoid.the.contact.with.the.eyes oid.the.contact.with.the.eyes.Avoid.the.prolonged.or.repetitiv .Avoid.the.prolonged.or.repetitive. e. contact.with.the.skin.Do.not.ingest.In.case.o.contact.with.the.skin,.wash.immediately.with.water.and.soap. In.case.o.contact.with.the.eyes,.abundantly.wash.with.water.or,.at.least.15.minutes.CALL.MEDICAL.HELP. IMMEDIATELY.KEEP.AW .KEEP.AWA AY.FROM.THE.REACH.OF.THE.C Y.FROM.THE.REACH.OF.THE.CHILDREN. HILDREN.AND.ANI AND.ANIMALS MALS

Page - 2

1-4

•

•

•

•

•

Cleaning.solutions and.solvent Cleaning.solutions and.solvents.are. s.are. infam infammabl mable.materials.that. e.materials.that.ms ms.be.handled.with.a.lot.o.care.Follow. .be.handled.with.a.lot.o.care.Follow. the.manuacturer.instructions.to.use.these.products.KEEP.AWAY.FROM.THE.REACH.OF.CHILDREN.AND. ANIMALS. To.avoid.burns,.pay o.avoid.burns,.pay.attention.to.hot.spots.on.engines.that.have.just.been.stopped.and.to.hot.piping.and.com.attention.to.hot.spots.on.engines.that.have.just.been.stopped.and.to.hot.piping.and.compartments. awys.use.tools.in.good.conditions.Make.sure.that.you.know.how.to.handle.the.tools.beore.beginning.any. awys.use.tools.in.good.conditions.Make.sure.that.you.know.how.to.handle.the.tools.beore.beginning.any. repair.Use.ONL repair .Use.ONLY.genuine.MNEPL Y.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.

G Isis This.engine.has.been.manuactured.with.the.most.advanced.technology;.nevertheless,.it.was.designed.to.be. repaired.using.regular.techniques.complemented.by.quality.standards. •

Use.good.quality.uel,.ree.o.water.and.impurities.

•

Use.only.recommended.lubricant.oil.

•

•

In.case.o.any.irregularity.seek.or.a.dealer.or.authorized.service.o.the.vehicle./.equipment.manuacturer.or. MNEP MN EPLA LAvo void id th that at ou outs tsid iders ers ma make ke an any y se servi rvice ce in th the e en engi gine ne,, bec becau ause se th this is ca canc ncel els s th the e wa warr rrant anty y To.use.a. parallel.battery. to.star to.start.the. t.the..engne, .engne,the.amperages.o.both.batteries. the.amperages.o. both.batteries.must.be.the. must.be.the.same.to.avoid.tensame.to.avoid.tension.peaksThe.standard.procedure.is.always.rst.to.connect.the.cable.on.the.negative.pole.and.later.on.the. positive.pole.T positive.pole .Take.care.to.do.not.invert.the.poles. ake.care.to.do.not.invert.the.poles.

Page - 3

IntroductIon

cig G Isis cleanInG WItH acIdS and SolventS Several.solvents.and.acid.substances.can.be.used.to.clean.the.parts.o.the.engine. MaHIndra navIStar enGIneS Pvt ltd. s  mm y spif ss. awys w h isis  h m  h p. Remove.all.gaskets,.sealing.rings,.and.with.a.brush.o.steel.or.rasper,.the.sludge.deposits,.carbon,.etc,.beore. placing.the.parts.in.the.cleaning.tank.Be.careul.to.do.not.damage.the.suraces.o.the.sealing.elements.seats. Flush.all.parts.with.hot.water.ater.cleaning.Completely.dry.them.with.compressed.air.Remove.water.rom.screw. holes.and.rom.lubrication.inner.grooves. In.case.the.parts.are.not.to.be.used.soon.ater.the.cleaning,.dip.them.in.an.appropriate.anti-oxidation.compound That.compound.must.be.removed.o.the.parts.beore.installation.in.the.engine. The.ollowing.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

egi Si nm Iifi  li The.engine.identication.and.serial.number.can.be.ound.in.the.ollowing.places:. 1 Identication.plate.on.the.water.pipe 2. Engraving.on.the.right.side.o.the.engine.block,.close.to.the.cylinder.head.o.the.cylinder.#3.

6. 12 t c e Electronic.

Atercooler.

Turbocharged

Series

Cylinders.numbers.

Page - 5

IntroductIon

cyis nmi The.cylinders.order.starts.rom.the.fywheel,.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.rom.fywheel.to.ront.side

Page - 6

1-8

egi Iifi enGIne SerIal nuMber The.engine.serial.number.is.stamped.in.the.right.and.rear.side.o.the.engine.blockIn the upper side, close to the cylinder.head.gasket

6.12 TCA Engine Data Plate:

enGIne acceSSorIeS The.ollowing.engine.accessories.have.manuacturer’s.labels.or.identication.plates: •

Turbocharger

•

Fuel Injection Pump (Stanadyne Rotory)

Labels.or.identication.plates.include.inormation.and.specications.helpul.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 ro e Rated output Standby output Tolerance on rated output power Rated speed Method of Starting of engine Aspiration

6.12 TCA 6.12 TCA 6.12 TCA S12-III S12-II S12-I 125 140 160 KVA No 6 6 6 Inline / V type Inline Ltrs 7.12 mm 105 mm kW 114.8 128.1 146.5 hp 156 174 199 kW 125.6 139.9 160.0 hp 170.6 190.1 217.5 % ±5 ±5 ±5 rpm 1500 1500 1500 24V ELEC No

Fan Power Tripping Temperature ●FUEL SYSTEM OF ENGINE

Bar

mm Ltr KW Deg C

163.0 221.2 178.0 242 ±5 1500

Turbocharged Aftercooler

NA/TC/TCA

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)

6.12 TCE SE12-I 180 6

16.8:1

16.8:1

12.9 14.1

14.4 15.7

16.8:1

16.4 18 1-5-3-6-2-4

Radiator By Water 831x390.5x1135 25 25

25 6

7

7 105

16.8:1 18.3 20

25 8

High speed Diesel(HSD IS 1460:2005)

Fuel oil

Spin-on type with paper element

Fuel Filter type 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

hrs g/kW-h

g/hp-h

% Ltrs/h

50%load

ENGINE TECHNICAL SPECIFICATION

500 202 200 214

198 197 212

197 197 207

193 195 202

148.7 147.2 157.5 +5

145.7 145.0 156.0 +5

145.0 145.0 152.4 +5

142.0 143.5 148.7 +5

27.45 . 14.54

30.01 . 16.06

34.15 . 17.94

37.18 . 19.46

ENGINE TECHNICAL SPECIFICATION ng ne ser es Engine Model Prime rating 1)FUEL INJECTION PUMP Make Type 2 GOVERNER DATA

o KVA

. S12-III 125

. S12-II 140

. SE12-I 180

S12-I 160

STANADYNE MAKE Rotary

Bosch Make HPCR

MECHANICAL (3- 5%)

ECU Controlled (Isochronous)

Type Response time Recovery time ●LUBE OIL SYSTEM

As per IS10002 .

Recommended lube oil

.

. 15W40 API CI4

.

Full flow: Spin on cartridge type with Paper

Lub oil filter type Filtration capacity Lube oil change period Maximum lube oil temperatorure

.

Microns hours Deg C

15 500 Min:-10 & Max:125 .

Lube oil system capacity ●EXHAUST SYSTEM Exhaust silencer type Exhaust noise level (with Silencer) @ 3M Max. Permissible back pressure in Exhaust Exhaust as 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 ENGINE NOISE LEVEL At 1Mtr ●DIMENSIONS & WEIGHT DETAILS LengthXWidthXHeight (With Radiator) Dry engine weight-with flywheel & flywheel housing Weight to power ratio

lit

dB mm of Hg k hr Deg C kW kW kW kW

mm of H2O mm of H20 Microns Deg C k hr

19.8

558

59.73 14.74 82.39 12.1

535

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

Dry type Air cleaner 230 600 20 55 580 637

78 32.9 127.9 16.07

750

●

< 75 dBA for genset with canopy 1727X932X1274.4

mm

598.6

kg Kg/Kw

5.21

4.67

610 4.09

3.74

F Sysm 2-2

Dsipi

6 cyids

Maximum uel inlet restriction (or gears pump)

0.6 to 1.2 bar

Fuel pressure range in the uel flter outlet (at crank speed)

9.7 to 12.8 bar

Range o uel pressure in uel flter uel inlet (at operation speed)

10.5 to 13 bar

Maximum pressure load reduction in the uel flter

≤0.8 bar

lbii Sysm Dsipi

MaxxForce 7.2

Oil pressure Nominal speed Idling speed

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

• •

Oil temperature Nominal Maximum

90 - 110 °C 120 °C

• •

Oil capacity

19.8 l

cig Sysm Dsipi

MaxxForce 7.2

Volume o water in the engine, without radiator

9 l

Water temperature Nominal Maximum

80 - 90 °C 100 °C

• •

tms

Thermostat 0304CAV00010N

Opening beginning

Total opening

Maximum opening course

79 ± 2°C

90°C

10.0 mm

Page - 9

egi Dsipi 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 our valves per cylinder with cross ow or improved air ow. The head gasket is mated in metal-rubber and is individual or each cylinder head. The uel Injector is centrally located between the our valves and directs uel over the piston bowl or improved perormance and reduced emissions. The overhead valve train includes mechanical roller liters, push rods, rocker arms, and dual valves that open using a valve bridge. To improve the components durability and engine perormance this engine uses the hot and cold side concept or components distribution. Cold side (let 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. Manuactured 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 assemb eled in the engine block. The rear oil seal carrier is part o the ywheel housing. The open oil pan breather assembly uses a road drat tube to vent oil pan pressure and an oil separator that returns oil to the oil pan.

Manuactured with orged steel and new shape to improve its strength, the pistons are mated with ractured cap joint connecting rods. Replaceable rolled radius wet cylinder liners are used with the pistons. The new model o viscous damper or the MAXXFORCE 7.2 engine oers ns to assist in the rerigeration. A lube oil pump, mounted onto the ront o the engine block, is driven directly by the crankshat. All engines use an enlarged oil cooler and cartritge type spin on flter. An electric feed pump / mechanical feed pump draws uel rom the uel tank through a uel flter assembly that includes a strainer, flter element, drain valves, and water in uel (WIF) sensor. Ater fltering, uelgoes 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 ow.

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 ront o the block on the upper position. The starter motor is an electric motor that initiates rotational motion in an inter nal combustion engine beore it can power itsel. 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

egi cmp lis 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

3 4 2

leFt VIeW (colD SIDe) Mi cmps 1. Manifold, Intake 2. Oil cooler assembly 3. Oil filter 4. Fuel flter 5. High pressure pipes

Page - 15

2

3

4

2-10

6

5

7

1

rIGht VIeW (hot SIDe) 1. Oil dipstick 2. Turbo inlet pipe 3. Turbo outlet pipe 4. Exhaust maniold 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 an Maintenane 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

·

Beore operating the MAXXFORCE 7.2 engine check:

·

Water level.

·

Fuel level.

·

Lubricant level.

·

·

·

Soon ater 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 or 30 seconds in order to pre-lubricate the turbocharger. Beore stopping the engine, run about 30 seconds at idling speed so that the turbo decrease its speed.

cold Start The diculty o start at very low temperatures can happen due to the collapse o the lter because paran ormation or lack o ignition o the uel. The ollowing actions can be observed: ·

·

Use winter uel, which does not orm paranic fakes at low temperatures, or; Case the winter uel is not available, it is necessary that the lter has a heater on the cylinder head to allow uel fow beore the start.

Turboharger cares ·

Almost all ailures in turbochargers are caused by lubrication deciency (delay in lubrication, restr iction or lack o oil, intake o impurities in the oil, etc.) and objects or impurities entrance through intake.

·

To maximize the turbo lietime ollow these cautions:

·

Do not accelerate the engine immediately ater the start.

·

Wait 30 seconds with the engine at idling speed beore stop it.

·

·

·

Pre-lubricate the turbocharger ater oil change or other service that evolves oil drain. Crank the engine a ew times beore start the engine. Run the engine and allow it to run at idling speed or a period o time to establish a complete circulation and oil pressure beore apply high speeds and load. In low temperatures or when the engine is being reactivated ater a long period without operation, start the engine and let it running at idling speed beore operating at high speeds. Avoid operating the engine at idling speed or long periods o time.

Page - 1


Rnning-in All MIM engines are assembled and tested in the actory, making sure its immediate operation. However, it needs to be correctly ran-in, regarding that its perormance and durability depends on the cares taken during frst operation phase. As general rule, it is considered as running-in, a per iod o frst 2,000 km or vehicular engines or the frst 50 service hours or stationary, industrial and agriculture engines. The vehicle or equipment under moderate operation has decisive importance to its durability, service saety and economy. During this period it is very important to ollow these recommendations: ·

Careully check i engine oil level is correct;

·

Careully check i water level o the engine cooling system is correct;

·

Average load actor in 24hours should not exeed 75% load o the Rated capacityand in every 12hours 10% Over load permitted or one hour.

·

Avoid leaving the engine running at idling speed or a long period o time;

·

Strictly ollow the maintenance instructions.

Following these recommendations the useul lie o 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 chek ·

Stop the engine and wait 30 minutes so that the oil can flow back to the carter.

3-4 ·

Before pulling oil dipstick, clean the surroundings.

·

I necessar y, 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 dierent 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 specifcation.

·

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

!

Attention: Always use MNEPL recommended genuine engine oil

chek Lubriant oil condition The lubricant oil is very important or a good conservation o the inner engine components. Lubricanting oil contaminated with sand, soil, dust, water or uel causes problems to the engine. Check the appearance o the engine lubricant oil. A dark coloration and low viscosity means presence o uel in the lubricanting oil.The presence o oaming or a milky coloration indicates presence o water in the oil.

Lubriant Oil Speifations It must be used multiviscous type lubricant oil that accomplish, at least, to the SAE 15W40 API CI-4 (or upper) specifcations 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 o used engine oil according to applicable laws.

2. Using the wrench indicated, unscrew the flter

Page - 8

INSTALLATION 1.

2.

3.

Clean area around oil filter head, clean gasket surface of filter head.

4.

Tighten the filter untill the gasket contacts the filter head surface.

Lubricate oil filter gasket with fresh engine oil.

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.

Page - 9

Operate the engine and check for leakages

Lriation sytem OIL LubRIcATION cIRcuIT

12-2

Page - 1


cooling Flui an 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 o the cooling system daily. I the level is not correct, add clean water and MWM coolant according to the proportion recommended on the bottle.

·

Careully open the frst stage o the cap relieving the vapour pressure.

·

Check or leaks through cooling piping.

·

Check the nominal pressure o the cap in case o change.

Water Pump chek 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

I water is coming rom this hole, it means there is a leakage coming rom the water pump.

Page -4

NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9

____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________

Coolin System COOLINg CIRCuIT

Page - 1

NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9

____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________

OPERATION ANd M AINTENANcE

Maintenane Table

Remarks: 1)

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

2)

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

3)

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

4)

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.

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.

conseration for Inatie Enines for Lon Period MNEPL engines are produced protected or, at the most, 6 inactivity months under shut shelter. When the engine is to stay inactive or a long period, it is necessary to ollow these cares: 1. Clean the outer parts o 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 uel system (reservoir, low pressure system). 7. Operate the engine or 15 minutes at 2/3 o the nominal speed, without load, using a mixture o uel with 15% o 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 rom cylinder heads and spray protective oil on the springs and rocker arms. Reinstall covers. 10. Apply protective oil on machined suraces. 11. Remove belt. 12. Seal all the holes o the engine, to avoid dust and water penetration.

Remarks: ·

Renew the engine conservation procedure ater each 8 months o inactivity.

·

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

ENgINE PREPARATION TO RETuRN FOR SERvIcE 1. Beore operating an engine which stayed inactive or a long period, ollow these procedures: 2. Clean the outer parts o the engine. 3. Fill the cooling system with clean water and coolant in the recomended proportion 4. Change engine lubricnting oil lter. 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 uel mixture rom the reservoir and fll with new uel. 9. Change uel flter.

Page - 6


dRAIN ENgINE FLuIdS

ENgINE STARTINg Preparation

drainin the Oil

cLEAN ENgINE

!

Warnin:

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.

Page - 7

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 cyliners Enine

FAILuREs DIAgNOsIs

Dianoi Failre Introduction.1 Trouble Shooting Chart .2

Introdction 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

Trouble Shooting MAXXFORCE 7.2 Mechanical S T N I A L P M O C

t r a t S o t e r u l i a F r o g n i t r a t S d r a H

g n i s s i M e n i g n E

e l d I t a e k o m S k c a l B e v i s s e c x E

e l d i t a e k o m S e t i h W e v i s s e c x E

e k o m S e u l B e v i s s e c x E

h g i H o o T e r u t a r e p m e T t n a l o o C

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 S hutoff 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 P luged 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 C up not seated properly on Push rod ball Loose Cylinder Cap Screw Worn or Scored Liners or Pistons Air Compressor Pumping Oil

Page - 2

t n a l o o C f o s s o L

w o L r e w o P t u p t u O e n i g n E

M P R d e t a r h c a e R t o n n a C

e b u T r e h t a e r B m o r f t u o g n i w e p S l i O e n i g n E

n o i t p m u s n o C l i o e v i s s e c x E

n o i t p m u s n o C l e u F e v i s s e c x E

) e g n a h c d e e p S ( s e g r u S e n i g n E

e r u s s e r P l i o w o L

e r u s s e r P l i O h g i H

l e u F h t i w d e t a n i m a t n o C l i O g n i t a c i r b u L

t n a l o o C h t i w d e t a n i m a t n o C l i O g n i t a c i r b u L

d l o f i n a M t s u a h x E m o r f g n i k a e L l i O / l e u F

g n i n n u r p e e k t o n s e o d t u b s t r a t S e n i g n E

NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9

____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________

APPendIx A

MN/ETD 30 REV 02

ENGINEERING TECHNICAL DOCUMENT

TOR UE CHART 6.12 TCA MECHANICAL GENSET ENGINE Engine Block Qty. 2

Description Bolt

Size

Application

Torque (Nm)

M14

Bearing Cap to Block

1st

2nd

Torq. Range

50 - 5

155 ̊ ± 5°

170 to 282

Qty.

Description

Size

Application

Torque(Nm)

1 1 1

Plug Hollow Bolt Plug

3/8” M8x1 1/2”

Water Drain Plug to Block Oil Ejector to Block Water Drain Plug to Block

10 + 5 10 ± 1.5 15 + 5

Required Sealing Loctite 567 ** Loctite 567

Connecting Rod Qty. 2

Description Bolt

Size

Application

Torque (Nm)

MJ 12x58

Connecting Rod to Crankshaft

Size

Application

1st

2nd

Torq. Range

40 ± 5

80̊ ± 2°

130 to 160

Camshaft Qty.

Description

Torque (Nm) 1st

2nd

Torq. Range

4

Bolt

M8x25

Gear to Camshaft

2

Bolt

M8x16

Camshaft Lock to Block

Qty.

Description

Size

Application

Torque(Nm)

2

Bolt

M8x20

Oil Pump to Block

20 ± 5

̊

° 25 ± 4

Oil Pump

Water Pump Qty.

Description

Size

Application

Torque(Nm)

2

Bolt

M8x20

Water Pum to Block

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.

Page - 1

SHEET

1/10


MN/ETD 30 REV 02

Qty.

Description

Size

Application

Torque(Nm)

10 3 2 1 3 1 1

Bolt Bolt Hollow Bolt Hollow Bolt Bolt Plug Plug

M8x20 M8x50 M8x1 M8x1 M10x70 M10x1 M14x1.5

Gear Housing to Block Gear Housing to Block Lubrication pipe to Gear Housing Lubrication pipe to Block Intermediate Bearin with Gear to Block Gear Housing (Rear Half) Plug-Allen Tapered

25 ± 5 25 ± 5 7.5 ± 2.5 7.5 ± 2.5 60 ± 5 10 ± 5 20 ± 3

Valve Lubrication Pipes Qty.

Description

Size

Application

Torque(Nm)

6 1

Hollow Bolt Hollow Bolt

M10x1 M12x1.5

Valve Lubrication pipe to Cylinder Head Valve drive Lubrication Pipe to Oil cooler

10 + 5 10 + 5

Front Cover Qty.

Description

Size

Application

Torque(Nm)

16

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 Qt .

Descri tion

Size

A

lication

Tor ue Nm

3

Bolt

M10x35

Alternator Bracket to Gear Housing

40 ± 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



Page - 2

SHEET

2/10

MN/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 4

Stud Stover Stud

M10x25 M10

Turbocharger to Exhaust Manifold Turbocharger Stud to Exhaust Manifold

6±2 70 ± 10

1

Hollow Bolt

M14x1.5

1

Hollow Bolt

M14x1.5

Turbocharger Inlet Lubrication Pipe to Block

25 ± 5

2

Bolt

M8x20

Turbocharger Lubrication Return Pipe to Turbocharger

20 ± 3

2

Bolt

M8x16

Turbocharger Elbow Bracket

25 + 5

25 ± 5

Turbocharger

--

-

Cylinder Head Qty.

Description

Size

20

Bolt

M14x152

2

Bolt

M14

2

Engine lifting hook

M12

Qty.

Description

1

Socket head cap screw Nut

1

Nut

2

Application

PreTorque (Nm)

Torque (Nm)

40+5

Cylinder Head to Block Cylinder Head to Fan Bracket Cylinder Head mounting bolt

Torque 1 (°)

Torque 2 (°)

Torque 3 (°)

60+ 10

60± 3

60± 3

90± 3

40+5

60+ 10

60± 3

60± 3

90± 3

-

80 ± 10

-

-

-

Torque Range 120 To 260 120 To 260 -

Size

Application

Torque(Nm)

M5x10

Lubrication pipe to Cylinder head

5±1

M22

High pressure connector nut

50 + 5

M8x10

Nut – Valve clearance adjustment



Page - 3

20 + 5

SHEET

3/10

MN/ETD 30 REV 02


g

ressure ump

Qty.

Description

Size

Application

Torque(Nm)

3

Stud

M8 X 30

High Pressure Pump adaptor to Gear Housing

8±1

3

Nut

M8

High Pressure Pump to Gear Housing

38 ± 3

. 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

Size

Application

M8x1

Pipe, Fuel Return to Cylinder Head

Low Pressure Pipe Qty.

Description

6

g Qty.

Connection

ressure

Torque(Nm) 8±1

pe

Description

Size

Application

Torque(Nm)

6

Nut

M12

Nut high pressure tube to fuel injection pump

15 + 5

6

Nut

M14

Nut high pressure tube to Connector high pressure tube

25 + 5

Qty.

Description

Size

Application

Torque(Nm)

2

Bolt

M10x30

Fuel Filter to Block

35 ± 4

Fuel Filter

onnec on

x .

ue n e o

er ea

+

1

Hollow Bolt

M12x1.5

Pipe, Fuel Filter outlet to VE Pump

20 + 6

1

Hollow Bolt

M14x1.5

Pipe, Fuel Filter inlet for mechanical feed Pump

20 + 6

1

Hollow Bolt

M14x1.5

Pipe, Fuel Filter inlet NRV

20 + 6



Page - 4

SHEET

4/10


MN/ETD 30 REV 02

Assy, Fue Injector an Va ve 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

1

Screw

M6

Application

Screw- Fastening Bridge Fuel Injector

Torque (Nm)

Relieve to (Nm)

1+0.5

0

Torque (Nm)

Torque 1 (°)

4±1

90

Torque Torque Torque 2 (°) 3 (°) Range

90

30

7+6

Intake Manifold Qty.

Description

Size

Application

Torque(Nm)

12

Bolt

M8x35

Intake Manifold to Cylinder Head

24 ± 2

12

Bolt

M8x80

Intake Manifold to Cylinder Head

24 ± 2

Hollow Bolt

M12X1.5

Tube-Intake Manifold to FIP

20 + 6

1

Exhaust Manifold . 12

Stud

M10x45

12

Stover Nut

M10

Exhaust Manifold to Cylinder Head Exhaust Manifold to stud Cylinder Head

6±2 70 ± 10

Qty.

Description

Size

Application

Torque(Nm)

4

Stud

M10

Exhaust Elbow to Turbocharger

6 ± 2

4

Stover Nut

M10

Exhaust Elbow to Turbocharger

60 ± 10



Page - 5

SHEET

5/10


MN/ETD 30 REV 02

Crankshaft Pulley Qty.

Description

Size

Application

4

Cylindrical Bolt

M16x65

Crankshaft Pulley to Crankshaft

Torque (Nm) 1st

2nd

100 ± 10

275 ± 15

Oil Suction Pipe Qty.

Description

Size

Application

Torque(Nm)

2

Bolt

M8x20

Oil Suction Pipe to Block

25 ± 4

Water Inlet Manifold Qt .

Descri tion

Size

A

lication

Tor ue 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

M8x16

Engine breather tube to Breather housing

10 + 2

Qty.

Description

Size

Application

Torque(Nm)

34

Bolt

M8x16

Oil Pan to Block

25 + 5

Oil Pan



Page - 6

SHEET

6/10


MN/ETD 30 REV 02

Flywheel Qty. 8

Description Cylindrical Bolt

yw ee

Size

Application

M16x35

Torque (Nm)

Flywheel to Crankshaft

1

st

2nd

100 ± 10

275 ± 15

ous ng

Qty.

Description

Size

Application

Torque(Nm)

13

Bolt

M12x30

Flywheel Housing to Block

100 ± 5

Lu ricating Oi F i ter Hea an Oi Coo er Qty.

Description

10

Screw

1

Hollow Bolt

Size M8x 40 M14X1.5

Application

Torque(Nm)

oil cooler to block

25 ± 3

Adapter

25 + 5

Standard Torque Table for Normal Steel Bolts (According to DIN 2230) Nominal Size

M6 M8 M10 M12 M14 M16 M18 M20 M22

Bolt Class ( Nm) 8.8

10.9

10 ± 1.5 25 ± 4 50 ± 8 86 ± 13 135 ± 20 207 ± 31 298 ± 45 418 ± 63 569 ± 85

15 ± 2 37 ± 6 73 ± 11 124 ± 19 198 ± 30 304 ± 46 424 ± 64 595 ± 89 810 ± 122

12.9 . 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


Page - 7

SHEET

7/10

MN/ETD 30 REV 02


GENSET ENGINE ADD-ON COMPONENTS Qty.

Description

Size

Application

Torque(Nm)

M8x35

Intake curve to intake manifold

20 ± 3

M8x25


6±2

1

Screw, Hex. Flanged head Stud

1

Nut, Hex.

M8x8


20 ± 3

2

Plug, Allen Tapered

M22 X 1.5 X 5.8

For Plugging Heater Holes

30 ± 5

3

2 2 2

Air Cleaner Assembly Qty.

Description

Size

1

Clamp SAE J1 508 Type SLTB

SAE No.142

4

Screw, Hex.

M8x20

Clamp SAE J1 508 Type SLTB Screw, Serrated Hex. flanged head

SAE No.110

1 2

Application

Torque(Nm)

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

M12x30

7.3 ± 1.3 25 ± 4 7.3 ± 1.3 70 ± 10

Fan Assembly Qty.

Description

Size

Application

Torque(Nm)

6

Screw, Hex. Flanged head Screw, Serrated Hex. Flanged head

M8x20

Fan Hub to Fan(30 inch)

25 ± 4

M10X70

Fan pulley to Fan Hub and Fan

50 ± 8

M8X35

Fan Bracket to Spacer mounted on cylinder Head bolts

25 ± 4

6 2

Bolt, Hex. Flanged head ,

. Housing Fan Bearing to Fan Bracket Tensioner Pulley to Lever belt Tensioner Lever belt tensioner to Fan Bracket

4

Bolt, Hex. Flanged head

M10x35

50 ± 8

1

Screw, Hex. Flanged head

M10X20

2


M8X25

2

Screw, Hex. Flan ed head

M8X80

Fan Bracket to Timin 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

2

40 + 6 25 ± 4

Water Flow Tube Assembly Qty.

Description Temparature sensor cum Switch

Size

Application

Torque(Nm)

.

2

.



Page - 8

SHEET

8/10

MN/ETD 30 REV 02


Fuel Filter Assembly Qty.

Description

Size

Application

Torque(Nm)

1

Banjo bolt

M12X1.5X8.8

Fuel Pump end to NRV pipe

23 ± 3

2

Turbocharger Bracket Assembly Qty. 1 1

Description

Size

. Head Screw, Hex. Flanged Head

Application

,

Torque(Nm)

, 1.25 X 10.9 M8 x 25 X 1.25 X 8.8

25 + 5

to turbocharger Turbocharger Mounting bracket to Elbow, turbocharger

25 + 5

Gear Case Assembly Qty.

Description

Size

Application

Torque(Nm)

3

Screw, Hex. Flanged

M10X30X8.8

Air compressor closing plate to Gear Case

45± 5

2

Intake Manifold Assembly Qty.

Description ug,

Size

en apere

.

Application .

or

ug ng n a e man o

Torque(Nm) oe

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

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

2

Starter Motor Assembly Qty.

Description

Size

Application

Torque(Nm)

3

Screw, Hex. F ange

M10 X 20 X 8.8

Starter Motor 24V Mount ng

45± 5

Cylinder Block Qty.

Description

Size

Application

Torque(Nm)

1

Plug, Allen Tapered

M14 X 1.5 X 5.8

Plugging Compressor inlet Hole in C linder block

10+5



Page - 9

SHEET

9/10

2

MN/ETD 30 REV 02


Radiator & Intercooler Qty.

Description

2


2


2


2


1


1


2


1


1


Size

Application

SAE No.76 SAE No.76 SAE No.76 SAE No.42 SAE No.42 SAE No.34 SAE No.-

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

SAE No.42 SAE No.48

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

Hose clamp on Engine Water inlet pipe

7.3 ± 1.3 7.3 ± 1.3 7.3 ± 1.3

Engine Mounting Foot Qt .

En ine

Size

A

8

Screw, Serrated Hex. Flanged head

M12x30

lication

Tor ue Nm

Engine Mounting Foot to Cylinder Block

70 ± 10

Lubricating Oil Filter Head and Oil cooler Qty.

Engine

Size

Application

Torque(Nm)

1

Oil Pressure sensor cum switch

M12x12

Oil Pressure sensor cum switch mounted at Oil Filter Head

Max. 50

Alternator 24 V Assembly Qty.

Description

Size

Application

2


M8 x 20

1


M12 x 35

1


M10 x 110

Torque(Nm)

Pull rod, Alternator Bracket to Main Alternator Bracket Pull rod, Alternator Bracket to Alternator (Charging) Main Alternator Bracket to Alternator (Charging)

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

Amol Relkar

Checked

Verified

Cesar Almeida Approved



Page - 10

SHEET

10/10

2

APPendIx A

Page - 11

NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9

____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________

Navistar O & M Manual

Recommend Documents