IntroductIon
Psi Introduction. 1 How.to.Use.this.Manual ......................................................................................................................... 1 ImportantSaetyRemarks2 - 3 GenerafInstructons 3 Cleaning.General.Instructions.4 Engine.Serial.Number.Identication.and.Location5 Cylinder.Numeration. 6 Engine Identification................................................................................................................................. 7 Engine Exploded View..............................................................................................................................8 Engine Technical Data..............................................................................................................................9 - 10 Engine Description.................................................................................................................................... 11 - 22
IntroductIon
Psi Introduction. 1 How.to.Use.this.Manual ......................................................................................................................... 1 ImportantSaetyRemarks2 - 3 GenerafInstructons 3 Cleaning.General.Instructions.4 Engine.Serial.Number.Identication.and.Location5 Cylinder.Numeration. 6 Engine Identification................................................................................................................................. 7 Engine Exploded View..............................................................................................................................8 Engine Technical Data..............................................................................................................................9 - 10 Engine Description.................................................................................................................................... 11 - 22
Ii This.manual.contains.complete.inormation.and.specication.to. This.manual.contains.complete.in ormation.and.specication.to.assembly.and. assembly.and.disassembly.MA disassembly.MAXXFORCE.72 XXFORCE.72 engines.and.all.components.manuactured.by.MaHIndra engines.and.all.components.manuactured.by. MaHIndra I navIStar I enGIneS Pvt ltd. ATTENSION.in.the.Saety.General.Instructions,.in.the. Read.and.ollow.all.saety.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.specications.and.inormation.presented.in.this.manual.are.the.ones.which.is. eective.in.the.moment.o.its.print.MaHIndra eective.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.dierence.in.the.engine. erence.in.the.engine. or.inormation 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.
Hw 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. 72 .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.thereo ns.thereore,.could.di re,.could.dier.rom. er.rom. application.to.application In.this.Manual,.all.reerences.to.the.components.o.the.engine.are.divided.in.19.specic. In.this.Manual,.all.reerences.to.the.components.o. the.engine.are.divided.in.19.specic.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.reerence.to.access.each.section
SectIonS content Each.section.contains.the.ollowing.inormation: •
Page.o.index.in.the.beginning.o.each.section.to.help.or.the.ast.location.o.the.desired.inormation
•
General.inormation.about.the.operation.o.the.component.and.the.explanation.o.their.main.changes
•
Component.disassembly,.cleaning,.inspection.and.dimension.instructions
Imi Mi Sysm All.dimensions.are.expressed.in.the.International.Metric.System.(IS)
IntroductIon
Imp Sy rmks
!
ai:
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
Careully.read.all. sa Careully.read.all. saety.procedures ety.procedures and.remarks.beore.perorm and.remarks.beore.perorming.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.saety.Special.saety.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.(saety.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.beore.working
•
Disconnect.the.battery.(negative.cable.rst).and.discharge.the.capacitors.beore.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.crankshat.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.beore.slowly.open. the.cover.o.the.reservoir.to.relie.the.pressure.o.the.cooling.system
•
Do.not.work.with.materials.that.are.lited.by.jacks.or.cranes
•
Always.use.correct.blocks,.stands.or.brackets.to.position.the.engine.beore.perorming.any.repair
•
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•
•
Relie.the.pressure.o.the.pneumatic.(brakes),.lubrication.and.cooling.systems.beore.removing.or. Relie.the.pressure.o.the.pneumatic.(brakes),.lubrication.and.cooling.systems. beore.removing.or.disconnect. disconnect. any.piping,.connections.or.other.elements.Pay.attention.to.the.pressure.existence.beore.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.lit.components.which.weight.more.than.20.kg.Make.sure.that. all.lit.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.lit.hooks.must.not. receive.side.loads Never.leave.the.engine.operating.in.a.closed.and.non.ventilated.area.The.engine.exhaust.gases.are.harmul. 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
1-4
•
•
•
•
•
Cleaning.solutions and.solvent Cleaning.solutions and.solvents.are. s.are. infam infammabl mable.materials.that. e.materials.that.ms ms.be.handled.with.a.lot.o.care.Follow. .be.handled.with.a.lot.o.care.Follow. the.manuacturer.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. awys.use.tools.in.good.conditions.Make.sure.that.you.know.how.to.handle.the.tools.beore.beginning.any. awys.use.tools.in.good.conditions.Make.sure.that.you.know.how.to.handle.the.tools.beore.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 Isis This.engine.has.been.manuactured.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.manuacturer.or. MNEP MN EPLA LAvo 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..engne, .engne,the.amperages.o.both.batteries. the.amperages.o. both.batteries.must.be.the. must.be.the.same.to.avoid.tensame.to.avoid.tension.peaksThe.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.
IntroductIon
cig G Isis 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 spif ss. awys w h isis h m h p. Remove.all.gaskets,.sealing.rings,.and.with.a.brush.o.steel.or.rasper,.the.sludge.deposits,.carbon,.etc,.beore. placing.the.parts.in.the.cleaning.tank.Be.careul.to.do.not.damage.the.suraces.o.the.sealing.elements.seats. Flush.all.parts.with.hot.water.ater.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.ater.the.cleaning,.dip.them.in.an.appropriate.anti-oxidation.compound That.compound.must.be.removed.o.the.parts.beore.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
egi Si nm Iifi li The.engine.identication.and.serial.number.can.be.ound.in.the.ollowing.places:. 1 Identication.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.
Atercooler.
Turbocharged
Series
Cylinders.numbers.
IntroductIon
cyis nmi 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
1-8
egi Iifi enGIne SerIal nuMber The.engine.serial.number.is.stamped.in.the.right.and.rear.side.o.the.engine.blockIn the upper side, close to the cylinder.head.gasket
6.12 TCA Engine Data Plate:
enGIne acceSSorIeS The.ollowing.engine.accessories.have.manuacturer’s.labels.or.identication.plates: •
Turbocharger
•
Fuel Injection Pump (Stanadyne Rotory)
Labels.or.identication.plates.include.inormation.and.specications.helpul.to.vehicle.operators.and.technicians
Engine Exploded View
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 50%load
hrs g/kW-h
g/hp-h
% Ltrs/h
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 Sysm 2-2
Dsipi
6 cyids
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
lbii Sysm Dsipi
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
cig Sysm Dsipi
MaxxForce 7.2
Volume o water in the engine, without radiator
9 l
Water temperature Nominal Maximum
80 - 90 °C 100 °C
• •
tms
Thermostat 0304CAV00010N
Opening beginning
Total opening
Maximum opening course
79 ± 2°C
90°C
10.0 mm
egi Dsipi 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 perormance and reduced emissions. The overhead valve train includes mechanical roller liters, push rods, rocker arms, and dual valves that open using a valve bridge. To improve the components durability and engine perormance this engine uses the hot and cold side concept or components distribution. Cold side (let 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. Manuactured 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 drat tube to vent oil pan pressure and an oil separator that returns oil to the oil pan.
Manuactured 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 oers ns to assist in the rerigeration. A lube oil pump, mounted onto the ront o the engine block, is driven directly by the crankshat. 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. Ater 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.
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 beore 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.
egi cmp lis 2-6
2
1
toP VIeW 1. Coolant temperature sensor (ECT) 2. Valve cover
technIcal Data
2
3
1
5
Front VIeW 1. Water bypass tube assembly thermostat outlet 2.
Alternator
3. Pulley 4. Vibration damper 5. Front cover
4
1
5
3 4 2
leFt VIeW (colD SIDe) Mi cmps 1. Manifold, Intake 2. Oil cooler assembly 3. Oil filter 4. Fuel flter 5. High pressure pipes
2
3
4
2-10
6
5
7
rIGht VIeW (hot SIDe) 1. Oil dipstick 2. Turbo inlet pipe 3. Turbo outlet pipe 4. Exhaust maniold 5. Turbo exhaust curve 6. Flywheel housing 7. Cylinder block
1
technIcal Data
4
3
1
2
rear VIeW 1. Flywheel 2. Lube Oil sump 3. Flywheel Housing 4. Water Outlet tube
NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9
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OPERATION ANd MAINTENANcE
Operation an Maintenane 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
·
Beore operating the MAXXFORCE 7.2 engine check:
·
Water level.
·
Fuel level.
·
Lubricant level.
·
·
·
Soon ater 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. Beore stopping the engine, run about 30 seconds at idling speed so that the turbo decrease its speed.
cold Start The diculty o start at very low temperatures can happen due to the collapse o the lter because paran ormation or lack o ignition o the uel. The ollowing actions can be observed: ·
·
Use winter uel, which does not orm paranic 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 beore the start.
Turboharger cares ·
Almost all ailures in turbochargers are caused by lubrication deciency (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 lietime ollow these cautions:
·
Do not accelerate the engine immediately ater the start.
·
Wait 30 seconds with the engine at idling speed beore stop it.
·
·
·
Pre-lubricate the turbocharger ater oil change or other service that evolves oil drain. Crank the engine a ew times beore 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 beore apply high speeds and load. In low temperatures or when the engine is being reactivated ater a long period without operation, start the engine and let it running at idling speed beore operating at high speeds. Avoid operating the engine at idling speed or long periods o time.
OPERATION ANd MAINTENANcE
Rnning-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 perormance 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 saety and economy. During this period it is very important to ollow these recommendations: ·
Careully check i engine oil level is correct;
·
Careully 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 useul lie 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)
·
FuEL INjEcTION SySTEM
FuEL INjEcTION SySTEM
NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9
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·
LuBRIcANTINg OIL Oil Level chek ·
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 dierent 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
chek Lubriant 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.
Lubriant Oil Speifations 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
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
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.
Operate the engine and check for leakages
Lriation sytem OIL LubRIcATION cIRcuIT
12-2
OPERATION ANd MAINTENANcE
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.
·
Careully 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 chek 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.
NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9
____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________
Coolin System COOLINg CIRCuIT
NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9
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OPERATION ANd M AINTENANcE
Maintenane 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.
NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9
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Edited by Foxit Reader Copyright(C) by Foxit Corporation,2005-2009 For Evaluation Only.
conseration for Inatie Enines 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 suraces. 11. Remove belt. 12. Seal all the holes o the engine, to avoid dust and water penetration.
Remarks: ·
Renew the engine conservation procedure ater 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. Beore 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.
OPERATION ANd MAINTENANcE
ENgINE STARTINg Preparation
drainin the Oil
cLEAN ENgINE
!
Warnin:
dRAIN ENgINE FLuIdS
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.
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 cyliners Enine
FAILuREs DIAgNOsIs
Dianoi Failre Introduction.1 Trouble Shooting Chart .2
Introdction Next.they.are.presented.some.typical.problems.which.the.engine.may.present,.their.probable.causes.and.possible. corrections.for.these.problems
!
17-2
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
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
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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) st
1
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
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Page - 1
SHEET
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ENGINEERING TECHNICAL DOCUMENT
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
PRINTED COPIES ARE NOT CONTROLLED
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Page - 2
SHEET
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MN/ETD 30 REV 02
ENGINEERING TECHNICAL DOCUMENT
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
PRINTED COPIES ARE NOT CONTROLLED
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Page - 3
20 + 5
SHEET
3/10
MN/ETD 30 REV 02
ENGINEERING TECHNICAL DOCUMENT
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
PRINTED COPIES ARE NOT CONTROLLED
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Page - 4
SHEET
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ENGINEERING TECHNICAL DOCUMENT
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
PRINTED COPIES ARE NOT CONTROLLED
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Page - 5
SHEET
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ENGINEERING TECHNICAL DOCUMENT
MN/ETD 30 REV 02
Crankshaft Pulley Qty. 4
Description Cylindrical Bolt
Size
Application
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
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 - 6
SHEET
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ENGINEERING TECHNICAL DOCUMENT
MN/ETD 30 REV 02
Flywheel Qty.
Description
Size
Application
8
Cylindrical Bolt
M16x35
Flywheel to Crankshaft
yw ee
Torque (Nm) 1st
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
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 - 7
SHEET
7/10
MN/ETD 30 REV 02
ENGINEERING TECHNICAL DOCUMENT
GENSET ENGINE ADD-ON COMPONENTS Qty.
Description
Size
Application
Torque(Nm)
M8x35
Intake curve to intake manifold
20 ± 3
M8x25
Intake curve to intake manifold
6±2
1
Screw, Hex. Flanged head Stud
1
Nut, Hex.
M8x8
Intake curve to intake manifold
20 ± 3
2
Plug, Allen Tapered
M22 X 1.5 X 5.8
For Plugging Heater Holes
30 ± 5
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
Screw, Hex. Flanged head
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
.
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.
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MN/ETD 30 REV 02
ENGINEERING TECHNICAL DOCUMENT
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
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.
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2
MN/ETD 30 REV 02
ENGINEERING TECHNICAL DOCUMENT
Radiator & Intercooler Qty.
Description
2
Clamp SAE J1 508 Type SLTB
2
Clamp SAE J1 508 Type SLTB
2
Clamp SAE J1 508 Type SLTB
2
Clamp SAE J1 508 Type SLTB
1
Clamp SAE J1 508 Type SLTB
1
Clamp SAE J1 508 Type SLTB
2
Clamp SAE J1 508 Type SLTB
1
Clamp SAE J1 508 Type SLTB
1
Clamp SAE J1 508 Type SLTB
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
Screw, Hex. Flanged head
M8 x 20
1
Screw, Hex. Flanged head
M12 x 35
1
Screw, Hex. Flanged head
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
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.
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APPendIx A
NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9
____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________
