OPERATION AND MAINTENANCE MANUAL7.2 MECHANICAL IntroductIon Presentation Introduction................................................................................................................................................1 How.to.Use.this. Manual ......................................................................................................................... 1 Important.Safety.Remarks........................................................................................................................ 2 - 3 Generafl.Instructfions............................................................................................................................... 3 Cleaning.General.Instructions................................................................................................................... 4 Engine.Serial.Number.Identification.and.Location....................................................................................5 Cylinder.Numeration..................................................................................................................................6 Engine Identification................................................................................................................................. 7 Engine Exploded View.............................................................................................................................. 8 Engine Technical Data.............................................................................................................................. 9 - 10 Engine Description.................................................................................................................................... 11 - 22 Introduction This.manual.contains.complete.information.and.specification.to.assembly.and.disassembly.MAXXFORCE.7.2 engines.and.all.components.manufactured.by.MaHIndra I navIStar I enGIneS Pvt ltd. . . Read.and.follow.all.safety.instructions..Consult.the.item.ATTENSION.in.the.Safety.General.Instructions,.in.the. next.section. Some.of.the.Operation.and.Maintenance.procedures.require.special.tools. Make.sure.that.the.correct.tools.are.used.according.indicated.in.the.procedures. The.assembly.and.disassembly.specifications.and.information.presented.in.this.manual.are.the.ones.which.is. effective.in.the.moment.of.its.print..MaHIndra I navIStar I enGIneS Pvt ltd. .reserves.the.right.of.making. any.change,.at.any.moment..MaHIndra navIStar I enGIneS Pvt ltd. .reserves.the.right.of.doing.changes. in.the.product.at.any.moment.without.this.to.incur.in.any.further.obligation..In.case.of.any.difference.in.the.engine. or.information.of.this.manual,.contact.an.MNEPL . Authorized . Distributor . . or .the factory. The.components.used.in.MNEPL . engines . production . are . produced . with . last . generation . technology . components . . with.high.level.quality.standards..When.parts.changes.are.necessary,.it.is.recommended.to.use.only.MIM.genuine. spare.parts.. How to use this Manual To.create.this.Manual.it.has.been.taken.as.base.a.generic.MAXXFORCE. 7.2 .engine,.which.operations.and. maintenance.procedures.are.the.same.for.all.models.of.this.series..The.illustrations.therefore,.could.differ.from. application.to.application. In.this.Manual,.all.references.to.the.components.of.the.engine.are.divided.in.19.specific.sections..For.your.convenience,.the.organization.of.the.Manual.is.consistent.with.MNEPL . Service . Bulletins. Manual content The.Manual.contains.an.index.that.can.be.used.as.a.quick.reference.to.access.each.section. SectIonS content Each.section.contains.the.following.information: • Page.of.index.in.the.beginning.of.each.section.to.help.for.the.fast.location.of.the.desired.information. • General.information.about.the.operation.of.the.component.and.the.explanation.of.their.main.changes. • Component.disassembly,.cleaning,.inspection.and.dimension.instructions. Information on Metric System All.dimensions.are.expressed.in.the.International.Metric.System.(I.S.). Page - 1 IntroductIon Important Safety remarks ! attention:. Incorrect.procedures.and.lack.of.care.can.cause.burns,.cuts,.mutilation,.asphyxia.or.otherinjuries.and.even.death. Carefully.read.all.safety.procedures.and.remarks.before.performing.any.repair.in.the.engine..The.following.list. presents.the.general.cautions.that.must.be.followed.to.guarantee.your.personal.safety..Special.safety.measures. can.be.presented.with.the.procedures,.if.necessary. • Make.sure.that.the.work.area.around.the.engine.is.dry,.well.lightened,.ventilated,.organized,.without.tools.and. loosened.parts,.ignition.sources.and.dangerous.substances..Check.for.dangerous.conditions.can.happen.and. avoid.them. • Always.use.individual.protection.equipments.(safety.eyeglasses,.gloves,.shoes,.etc.).while.you.are.working. • Remember.that.parts.in.movement.can.cause.cuts,.mutilation.and.strangling. • Do.not.use.loosen.or.ripped.clothes..Remove.jewellery.and.watches.before.working. • Disconnect.the.battery.(negative.cable.first).and.discharge.the.capacitors.before.beginning.the.repairs. • In.case.the.repair.is.being.made.in.the.vehicle,.disconnect.the.starter.motor.to.avoid.an.accidental.start.of.the. engine..In.case.of.industrial.engines,.place.a.“Do.Not.Operate”.warning.in.the.operator.compartment.or.on.the. controls. • To.manually.rotate.the.engine,.use.ONLY.the.recommended.procedures..Never.try.to.rotate.the.crankshaft.with. the.fan..This.practice.can.cause.serious.personal.injuries.or.damages.to.the.fan.blades,.causing.the.premature. failure.of.the.component. • If.the.engine.was.in.operation.and.the.cooling.fluid.is.hot,.leave.the.engine.to.cold.down.before.slowly.open. the.cover.of.the.reservoir.to.relief.the.pressure.of.the.cooling.system. • Do.not.work.with.materials.that.are.lifted.by.jacks.or.cranes. • Always.use.correct.blocks,.stands.or.brackets.to.position.the.engine.before.performing.any.repair. • Relief.the.pressure.of.the.pneumatic.(brakes),.lubrication.and.cooling.systems.before.removing.or.disconnect. any.piping,.connections.or.other.elements..Pay.attention.to.the.pressure.existence.before.to.disconnect.any. item.of.a.pressurized.system..Do.not.check.pressure.leakages.with.the.hand..Oil.or.fuel.at.high.pressure.can. cause.injuries. • To.avoid.injuries,.use.a.crane,.or.ask.for.help.to.lift.components.which.weight.more.than.20.kg..Make.sure.that. all.lift.equipments.as.chains,.hooks.or.belts.are.in.good.conditions.and.have.the.correct.load.capacity..Make. sure.that.hooks.are.correctly.positioned..Always.use.an.extension.when.necessary..The.lift.hooks.must.not. receive.side.loads. • Never.leave.the.engine.operating.in.a.closed.and.non.ventilated.area..The.engine.exhaust.gases.are.harmful. to.health. • The MNEPL . .coolant.has.alkaline.substances..Avoid.the.contact.with.the.eyes..Avoid.the.prolonged.or.repetitive. contact.with.the.skin..Do.not.ingest..In.case.of.contact.with.the.skin,.wash.immediately.with.water.and.soap.. In.case.of.contact.with.the.eyes,.abundantly.wash.with.water.for,.at.least.15.minutes..CALL.MEDICAL.HELP. IMMEDIATELY..KEEP.AWAY.FROM.THE.REACH.OF.THE.CHILDREN.AND.ANIMALS. Page - 2 1-4 • Cleaning.solutions.and.solvents.are.inflammable.materials.that. must.be.handled.with.a.lot.of.care..Follow. the.manufacturer.instructions.to.use.these.products..KEEP.AWAY.FROM.THE.REACH.OF.CHILDREN.AND. ANIMALS.. • To.avoid.burns,.pay.attention.to.hot.spots.on.engines.that.have.just.been.stopped.and.to.hot.piping.and.compartments.. • always.use.tools.in.good.conditions..Make.sure.that.you.know.how.to.handle.the.tools.before.beginning.any. repair..Use.ONLY.genuine.MNEPL . spare . parts. . • Some.international.public.health.institutions.prove.that.used.lubricant.oil.can.be.cancerous.and.contaminates. the. human. reproducer. system.. Avoid. inhaling. vapours,. ingesting. or. keeping. prolonged. contact. with. these. substances.. • People.with.pacemaker.must.avoid.standing.close.to.the.engine.electronic.injection.system.. General Instructions This. engine. has. been. manufactured. with. the. most. advanced. technology;. nevertheless,. it. was. designed. to. be. repaired.using.regular.techniques.complemented.by.quality.standards.. • Use.good.quality.fuel,.free.of.water.and.impurities.. • Use.only.recommended.lubricant.oil.. • In.case.of.any.irregularity.seek.for.a.dealer.or.authorized.service.of.the.vehicle./.equipment.manufacturer.or. MNEPL. . Avoid . that . outsiders . make . any . service . in . the . engine, . because . this . cancels . the . warranty. . • To.use.a.parallel.battery.to.start.the. ..engfine, .the.amperages.of.both.batteries.must.be.the.same.to.avoid.tension.peaks.The.standard.procedure.is.always.first.to.connect.the.cable.on.the.negative.pole.and.later.on.the. positive.pole..Take.care.to.do.not.invert.the.poles.. Page - 3 parts..careful.with. 4.surfaces. does not recommend any specific substance.parts.of.cleaning.Remove. Flush.and.lubrication....elements..can.cleaning.and.steel.following.vapour:. holes.Completely.be. always follow the instructions of the manufacturer of the product.compound.before.engine.removed.do.parts.the.case.inner. The.sealing. 1. High. MaHIndra navIStar enGIneS Pvt ltd.a..injectors.in.deposits.be.rasper. In.gaskets..and....cleaning..Be.hoses.the.substances. Bearings...installation.the...in.from.grooves.are.after.carbon.harness. 2..the. 5.with.and.them.them.in.of.or.tank..cleaned.air.after..rings.pressure.and.the.acid.sludge.all.the.before.parts.with..pipes.to.anti-oxidation....the.pump.components..screw.compressed.not.an. Remove..the.must. Belts. Electric.used.damage..electronics.the.to.sealing. That.brush.cannot.4 .not. 6.all.be.the.IntroductIon cleaning General Instructions cleanInG WItH acIdS and SolventS Several.water.be..used.seats.dry.engine.clean..etc.water. Electric.from. 3. Fuel.dip.the.parts.to.solvents.hot.. placing.of.with.appropriate. Page .soon.parts.of.compound. engine.of.pipe. 2.the..number.found.close.on.right.on.head.places:.the..side.the.cylinder.#3.the.engine Serial number Identification and location The. 6. 1.water.be..5 .can.identification..cylinder.following.block.plate.in.and. Identification. Turbocharged Series Cylinders. 12 t c e Electronic. Page .serial.of.engine.numbers. Aftercooler.the. Engraving.to.the.. the.must.and.the.IntroductIon cylinders numeration The.number.correct..on.6 ..block.to..the.check.(A)... FIRST CYLINDER During.on.bearings. The.number.starts.the.(B).from.the.the.flywheel.must.the.below.start.same.side.to.numbers.front.flywheel.bearing.cylinders. corresponding.illustration.the.from.that.block.to.according.assembly. Page .order.be. of. Pump (Stanadyne Rotory) Labels.engine.gasket.operators.engine.1-8 engine Identification enGIne SerIal nuMber The.include.right.plates.information.labels.or.and.manufacturer’s. .number.side. . .to.serial.or.7 .identification.the.engine. 6.plates: • Turbocharger • Fuel.head.the. close to the cylinder. .helpful.12 TCA Engine Data Plate: enGIne acceSSorIeS The.rear. .identification.and.Injection. . Page .block.in. .specifications. .and.is.following.technicians. In the upper side.have.accessories.stamped.vehicle. 8 .Engine Exploded View Page . 0 hp 170.06 34.12 TCE S12-III S12-II S12-I SE12-I 125 140 160 180 KVA No 6 6 6 6 Inline Inline / V type 7.3 20 25 13200 8 High speed Diesel(HSD IS 1460:2005) ) paper element Spin-on type with Micron hrs g/kW-h g/hp-h % Ltrs/h 5 500 202 200 214 198 197 212 197 197 207 193 195 202 148.2 157.4 15.2 kW 125.9 160.94 37.12 TCA 6.4 +5 142.18 19.0 +5 145.15 25.1 25 10000 6 14.46 .0 152.12 TCA 6.8:1 No Bar mm Ltr CFM KW Deg C 12.8 128.8:1 16.0 hp 156 174 199 221.61 17.5x1135 25 25 11800 11800 7 7 105 18.ENGINE TECHNICAL SPECIFICATION Engine series Engine Model Prime rating No.7 +5 27.0 156.12 Ltrs 105 mm mm 137 kW 114. of cylinder Type of construction Displacement Bore Stroke Rated output Standby output Tolerance on rated output power Rated speed Method of Starting of engine Aspiration Compression Ratio Brake Mean Effective Pressure (bmep) 1)Rated 2)Maximum Firing Order ●COOLING SYSTEM Method of Jacket cooling Heat Removal Dimensions of radiator (L X H X W ) Qty of coolant(Engine + Radiator) Air Flow at Radiator Outlet Fan Power Tripping Temperature ●FUEL SYSTEM OF ENGINE Fuel oil Fuel Filter type Filtration capacity Filter Change period Specific fuel consumption at 100%load 75%load 50%load Specific fuel consumption at 100%load 75%load 50%load Tolerance on SFC Fuel consumption at 100%load 75%load 50%load 6.12 TCA 6.1 146.0 143.8:1 16.45 20.5 148.6 139.7 16.5 242 % ±5 ±5 ±5 ±5 rpm 1500 1500 1500 1500 24V ELEC Turbocharged Aftercooler NA/TC/TCA 16.54 30.5 163.0 145.4 18 1-5-3-6-2-4 Radiator By Water 831x390.6 190.9 14.0 178.01 22.38 14.1 217.39 16.7 147.7 145.8:1 16.5 +5 145.18 28. 02 15W40 API CI4 Full flow: Spin on cartridge type with Paper element 15 500 Min:-10 & Max:125 Must be greater than 1.19 12.8 speed 558 59.5%) ECU Controlled (Isochronous) Type Response time Recovery time ●LUBE OIL SYSTEM Lube Oil Consumption at 100% Load Recommended lube oil Lub oil filter type Filtration capacity Lube oil change period Maximum lube oil temperatorure Lube oil pressure Lube oil system capacity ●EXHAUST SYSTEM Exhaust silencer type Exhaust noise level (with Silencer) @ 3M Max.09 3.74 .74 82.49 110.12 TCA 6.with clean element Air intake restriction .89 70. Permissible back pressure in Exhaust Exhaust gas flow Exhaust gas temperature (Max ) ●HEAT REJECTION DETAILS Heat Rejection to coolant Heat Rejection to CAC Heat Rejection to exhaust Heat Rejection from engine surface ●AIR INTAKE SYSTEM Intake filter type Air intake restriction .015 0.38 Dry type Air cleaner 230 600 20 55 580 637 78 32.9 127.5 at rated 19.1 535 Residential Type Complies with CPCB norms 75 603 664 800 600 650 62.07 750 < 75 dBA for genset with canopy 1727X932X1274.with dirty element Filtration capacity Maximum Intake manifold temperature Combustion air inlet flow rate ●ENGINE NOISE LEVEL At 1Mtr ●DIMENSIONS & WEIGHT DETAILS LengthXWidthXHeight (With Radiator) Dry engine weight-with flywheel & flywheel housing Weight to power ratio As per IS10002 Lit/hr Microns hours Deg C kg/cm2 lit dB mm of Hg kg/hr Deg C kW kW kW kW mm of H2O mm of H20 Microns Deg C kg/hr 0.12 TCA 6.58 14.ENGINE TECHNICAL SPECIFICATION Engine series Engine Model Prime rating 1)FUEL INJECTION PUMP Make Type 2)GOVERNER DATA No KVA 6.98 22.2 at idling condition & 3.017 0.39 12.4 mm 598.014 0.33 101.12 TCE SE12-I 180 STANADYNE MAKE Rotary Bosch Make HPCR MECHANICAL (3.22 19.12 TCA S12-III S12-II S12-I 125 140 160 6.67 610 4.6 kg Kg/Kw 5.73 14.21 4.9 16. 0 mm Page .7 to 12.8 bar lubrication System Description MaxxForce 7.Fuel System 2-2 Description 6 cylinders Maximum fuel inlet restriction (for gears pump) 0.5 to 13 bar Maximum pressure load reduction in the fuel filter ≤0.5 bar (hot engine) Oil temperature • Nominal • Maximum 90 .3 bar (hot engine) 3.2 bar Fuel pressure range in the fuel filter outlet (at crank speed) 9.6 to 1.90 °C 100 °C thermostat Thermostat 0304CAV00010N Opening beginning Total opening Maximum opening course 79 ± 2°C 90°C 10.2 Description Volume of water in the engine.2 Oil pressure • Nominal speed • Idling speed 5. without radiator 9l Water temperature • Nominal • Maximum 80 .110 °C 120 °C Oil capacity 19.8 l cooling System MaxxForce 7.9 .8 bar Range of fuel pressure in fuel filter fuel inlet (at operation speed) 10. 2 engine offers fns to assist in the refrigeration.2 is in-line six cylinder engines with 7. The new water pump was designed with seven vanes to increase the water flow.10 .2 Litre displacement. the oil pan has a compact size and lightweight.engine Description 2-4 FeatureS MAXXFORCE 7. The head gasket is mated in metal-rubber and is individual for each cylinder head. mounted onto the front of the engine block. Seven main bearings support the crankshaft for MAXXFORCE 7. rocker arms. Manufactured with forged steel and new shape to improve its strength. fuel goes to Stanadyne rotary pump and the high pressure fuel goes to the injectors. the pistons are mated with fractured cap joint connecting rods. Cold side (left engine side) • Fuel Supply System • Intake Air Manifold Hot side (right engine side) • Turbocharger system • Exhaust manifold A one piece oil pan withstands high-pressure loads during diesel operation. and water in fuel (WIF) sensor.. Replaceable rolled radius wet cylinder liners are used with the pistons. The rear oil seal carrier is part of the flywheel housing. push rods. All engines use an enlarged oil cooler and cartritge type spin on filter. and dual valves that open using a valve bridge. One insert bushing support the camshaft for each engine. The open oil pan breather assembly uses a road draft tube to vent oil pan pressure and an oil separator that returns oil to the oil pan. Manufactured in stamped steel. The fuel Injector is centrally located between the four valves and directs fuel over the piston bowl for improved performance and reduced emissions. The overhead valve train includes mechanical roller lifters.2 engines respectively. drain valves. To improve the components durability and engine performance this engine uses the hot and cold side concept for components distribution. After filtering. The firing order of the cylinders is 1–5–3–6–2–4 The cylinder head has four valves per cylinder with cross flow for improved air flow. The new model of viscous damper for the MAXXFORCE 7. filter element. is driven directly by the crankshaft. Page . An electric feed pump / mechanical feed pump draws fuel from the fuel tank through a fuel filter assembly that includes a strainer. the other support is assembeled in the engine block. A lube oil pump. In the MAXXFORCE engine it's located on the hot side . Page .induction of an internal combustion engine The purpose of a turbocharger is to increase the air mass entering the engine to create more power.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.11 . Turbocharger is an air compressor used for forced. next to the Flywheel. On the MAXXFORCE engines it’s located in the cold side. next to the waterpipe. The starter motor is an electric motor that initiates rotational motion in an internal combustion engine before it can power itself. It’s located in the cold side in the front of the block on the upper position. Coolant temperature sensor (ECT) 2.engine component locations 2-6 2 1 toP VIeW 1. Valve cover Page .12 . Vibration damper 5. Front cover Page . Alternator 3.14 . Pulley 4. Water bypass tube assembly thermostat outlet 2.technIcal Data 2 3 1 5 4 Front VIeW 1. Manifold. High pressure pipes Page . Oil filter 4.15 . Fuel filter 5. Intake 2.1 5 3 4 2 leFt VIeW (colD SIDe) Mechanical components 1. Oil cooler assembly 3. Oil dipstick 2. Exhaust manifold 5.2 3 4 2-10 6 5 7 1 rIGht VIeW (hot SIDe) 1. Turbo exhaust curve 6. Cylinder block Page . Turbo outlet pipe 4.17 . Turbo inlet pipe 3. Flywheel housing 7. Lube Oil sump 3.technIcal Data 4 3 1 2 rear VIeW 1. Flywheel Housing 4.18 . Water Outlet tube Page . Flywheel 2. 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Cooling Fluid and Coolant .............................................................................................. Oil Element .............................................................OPERATION ANd MAINTENANcE Operation and Maintenance Engine Operation ............... Maintenance Table.............................................................................. Starting Engine Preparation ........................................................................................................................................................................................ Water Pump Checking ....................... Conservation for Inactive Engines for Long Periods ............................................................................................................................................... keeping the engine at idling speed for 30 seconds in order to pre-lubricate the turbocharger. restriction or lack of oil. · Fuel level.1 . · Before stopping the engine. · It is recommended to start the engine without accelerating. or.Watch lubricant oil pressure and water temperature. run about 30 seconds at idling speed so that the turbo decrease its speed. which does not form paraffinic flakes at low temperatures. · Pre-lubricate the turbocharger after oil change or other service that evolves oil drain. Turbocharger cares · Almost all failures in turbochargers are caused by lubrication deficiency (delay in lubrication. etc. · Lubricant level. intake of impurities in the oil. · In low temperatures or when the engine is being reactivated after a long period without operation. it is necessary that the filter has a heater on the cylinder head to allow fuel flow before the start.2 engine check: · Water level.) and objects or impurities entrance through intake. Page .Engine Operation Start / Stop 3-2 · Before operating the MAXXFORCE 7. Crank the engine a few times before start the engine. cold Start The difficulty of start at very low temperatures can happen due to the collapse of the filter because paraffin formation or lack of ignition of the fuel. · Case the winter fuel is not available. · To maximize the turbo lifetime follow these cautions: · Do not accelerate the engine immediately after the start. · Soon after to start the engine. without load. · Avoid operating the engine at idling speed for long periods of time. heat it up at medium speed. Run the engine and allow it to run at idling speed for a period of time to establish a complete circulation and oil pressure before apply high speeds and load. start the engine and let it running at idling speed before operating at high speeds. The following actions can be observed: · Use winter fuel. · Wait 30 seconds with the engine at idling speed before stop it. service safety and economy. regarding that its performance and durability depends on the cares taken during first operation phase. · Average load factor in 24hours should not exeed 75% load of the Rated capacityand in every 12hours 10% Over load permitted for one hour. it is considered as running-in. FUEL SYSTEM FuEL SPEcIFIcATIONS . As general rule. · Carefully check if water level of the engine cooling system is correct. a period of first 2.2 . industrial and agriculture engines.000 km for vehicular engines or the first 50 service hours for stationary. However. Following these recommendations the useful life of the engine will be prolonged. · Strictly follow the maintenance instructions. making sure its immediate operation. Change fuel filter periodically as for maintenance plan (Refer Maintenance Table) Page . Fill the fuel to the fuel tank if necessary. The vehicle or equipment under moderate operation has decisive importance to its durability.HSd IS 1460:2005 · · · Drain water and sediments from water seperator and fuael tank every day. · Avoid leaving the engine running at idling speed for a long period of time. it needs to be correctly ran-in.OPERATION ANd MAINTENANcE Running-in All MIM engines are assembled and tested in the factory. During this period it is very important to follow these recommendations: · Carefully check if engine oil level is correct. 3 .FuEL INjEcTION SySTEM Page . 2 .FuEL INjEcTION SySTEM Page . 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Lubricant Oil Specifications It must be used multiviscous type lubricant oil that accomplish. · Before pulling oil dipstick. · Fill with recommended lubricant oil up to ' H' mark of the dipstick. · The oil must be hot for easy drain. A dark coloration and low viscosity means presence of fuel in the lubricanting oil. · Install the plug with a new washer and tighten according to the specification. clean the surroundings. at least. Check the appearance of the engine lubricant oil. dust. water or fuel causes problems to the engine. ! Attention: Always use MNEPL recommended genuine engine oil check Lubricant oil condition The lubricant oil is very important for a good conservation of the inner engine components. Lubricanting oil contaminated with sand.The presence of foaming or a milky coloration indicates presence of water in the oil. · Remove the carter plug and washer drain the oil. Use only MNEPL recomended oil Page -3 . to the SAE 15W40 API CI-4 (or upper) specifications and to the recommended viscosities. Use the same oil Brand and Grade.· LuBRIcANTINg OIL Oil Level check · 3-4 Stop the engine and wait 30 minutes so that the oil can flow back to the carter. · Use only recommended lubricant oil ( 15W40 API CI4 ). without exceeding it. · If necessary. ! Attention: Do not mix different oil brand / grade. · Do not operate the engine with the level below the ' L' mark. Topup up to the ' H' mark. Oil change · Change the Lubricating oil as per Maintenance Plan. · Do not mix different oil brands. soil. Using the wrench indicated. Remove the drain plug (R ½”) and discard the washer. · Stop the engine and.Oil Filter change 3-10 · Remove the old filter. · Run the engine and check the oil leakages. unscrew the filter Page . · Prime the new filter with clean and fresh oil and fix. Oil Element REMOvAL 1. Drain engine oil and dispose of used engine oil according to applicable laws. · Clean the sealing area of the flter with a clean cloth. after 30 minutes. 2. · Lubricate the flter gasket and tighten it. check oil level Topup if Necessary.(Use always GENIUNE spares).8 . Operate the engine and check for leakages Page . Clean area around oil filter head. 5. 6. Use oil filter wrench to tighten the filter an additional 3/4 of a turn. Tighten the filter untill the gasket contacts the filter head surface. 3. clean gasket surface of filter head. Fill the oil filter with fresh engine oil. Lubricate oil filter gasket with fresh engine oil. 4.INSTALLATION 1. 2.9 . Lubrication system OIL LubRIcATION cIRcuIT 12-2 Page .1 . · Check the level when the engine is cold. · Check for leaks through cooling piping. probably there is leakage through the water pump or through the sealing rings. Check and change.OPERATION ANd MAINTENANcE cooling Fluid and coolant ! Attention: · Do not open the expansion reservoir cap while the engine is hot. · Carefully open the first stage of the cap relieving the vapour pressure. add clean water and MWM coolant according to the proportion recommended on the bottle. Water Pump check Check the inspection hole located on the left side of the engine block (seen by the flywheel side). If there are signs of water or oil leakage. · Check the nominal pressure of the cap in case of change. · Check the level of the cooling system daily. Page -4 . it means there is a leakage coming from the water pump. Note: Image is shown with gear housing removed If water is coming from this hole. if necessary. If the level is not correct. NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ . 1 .Cooling System COOLINg CIRCuIT Page . 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The Maintenance Table of the Genset prevails over this table. Note: Mentioned parts are under evaluation and maintenance fequency can get changed after evaluation. 4) Electronic parts (phase. speed. Page .OPERATION ANd MAINTENANcE Maintenance Table Remarks: 1) This table is only for guidance. it must perform an idling speed test fortnightly.5 . 2) If the engine stays inactive for a long time. temperature. NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ . Install belt and adjust tension. Reinstall covers. it is necessary to follow these cares: 1. Seal all the holes of the engine. Drain fuel system (reservoir. Remove valve covers and lubricate rocker arms with engine oil. Before operating an engine which stayed inactive for a long period.Edited by Foxit Reader Copyright(C) by Foxit Corporation. without load. Operate the engine for 15 minutes at 2/3 of the nominal speed. The fuel mixture can stay in the system 9. Apply protective oil on machined surfaces. 10. conservation for Inactive Engines for Long Period MNEPL engines are produced protected for. Fill the cooling system with clean water and coolant in the recomended proportion 4. Page . 9. using a mixture of fuel with 15% of the protective oil SAE 20 W 20.2005-2009 For Evaluation Only. to avoid dust and water penetration. 3-8 2. Drain cooling system and lubricant oil. follow these procedures: 2. Drain the fuel mixture from the reservoir and fill with new fuel. Change fuel filter. When the engine is to stay inactive for a long period. 4. Remove belt. · In case of new brand engines. 8. Fill up the oil sump with protective oil SAE 20 W 20 6. 3. 7. 8. Fill the oil pan with new recomended grade of 15W40 engine oil in recomended quantity. at the most. 5. 6 inactivity months under shut shelter. Remarks: · Renew the engine conservation procedure after each 8 months of inactivity. 11. 6. Change engine lubricnting oil flter. Remove valves cover from cylinder heads and spray protective oil on the springs and rocker arms. Clean the outer parts of the engine. Reinstall covers. 7. ENgINE PREPARATION TO RETuRN FOR SERvIcE 1. 5. Clean the outer parts of the engine. 12. Drain fluid from cooling system and oil from oil sump.6 . Fill the radiator with clean water and coolant according to the recommended proportion. low pressure system). Operate the engine until to reach the operating temperature. do not consider items 1. 3. 2 and 3. Place an oil drain pan beneath the oil drain plug to collect the oil. possible death.OPERATION ANd MAINTENANcE dRAIN ENgINE FLuIdS ENgINE STARTINg Preparation draining the Oil cLEAN ENgINE ! Warning: To avoid serious personal injury. read all safety instructions in the “Safety Information” section of this manual. inspect drain plug and replace if necessary. Drain engine oil and dispose of used engine oil according to applicable laws. Remove oil pan drain plug (R ½”) and washer. Place a new washer onto drain plug and install to oil pan. Cap all turbocharger and manifold openings to prevent water and degreased agents from entering any engine components internally. Discard washer. 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. 2. Apply the torque of 55 to 75 N. or damage to the engine or Genset.7 1. 6 cylinders Engine . ! NOTE : Do not use high pressure or excessive hot water temperature as it may damage the engine components. 2. thinner or any product that derivates from petrol as these products may damage the wiring harness and other plastics made components. ! NOTE : Do not use solvent. 3.m. 1. Page . .........................................1 Trouble Shooting Chart..............FAILuREs DIAgNOsIs Diagnosis Failures Introduction.....................................................................................................................................................................................................2 ............... the.are.action.and. ·.these.problem. ! Attention :.present.before.trying.and. .the. Find.they.possible.which.the.1 .cause.engine. First. .and.may.causes.presented.some.main. 17-2 Page ..detail.the. ·. ·.for.obvious. corrections.any..Introduction Next..simplest.problems.probable.in.correct.problems.full.the.check.typical.problem..their. Study. 2 Mechanical .2 Engine Starts but doesnot keep running Fuel/ Oil Leaking from Exhaust Manifold Lubricating Oil Contaminated with Coolant Lubricating Oil Contaminated with Fuel High Oil Pressure Low oil Pressure Engine Surges ( Speed change) Excessive Fuel Consumption Excessive oil Consumption Engine Oil Spewing out from Breather Tube Cannot Reach rated RPM Engine Output Power Low Loss of Coolant Coolant Temperature Too High Excessive Blue Smoke Excessive White Smoke at idle Excessive Black Smoke at Idle Engine Missing Hard Starting or Failure to Start COMPLAINTS Trouble Shooting MAXXFORCE 7.Cause Restricted Air Intake High Exhaust Back Pressure Air System Air Leakage Between Yurbocharger and Intake Manifold Defective Turbocharger Charge Air Cooler Malfunctioning Air Filter Choked Low/ Out of Fuel Air in Fuel System Restricted Fuel Lines Injector Defective Injector Installed with More Than One Sealing Washer Broken fuel Pump Drive Shaft Throttle Linkage Worn or Incorrectly Adjusted Shutoff Lever partialy engaged Water in Fuel Fuel System High Pressure/ Fuel Leakage Fuel Filter Choked FIP Timing Incorrect FIP Rack Sticky Fuel Shutoff Not Actuating FIP Caliberation Defective FIP Internal Plunger Seal Leakage Fuel temperature High Fuel Return Line Restricted Fuel Lift Pump Defective Oil Pressure Transducer / Gauge Defective Incorrect Grade oil Defective oil Pump External / Internal Leakage Dirty oil Filter Faulty Cylinder Oil Control Lubricating System Oil Suction Line Restricted Leakage From Valve Stem Oil Seal Faulty Oil Pressure Regulator Crankcase Low or Out of Oil Oil Cooler Leakage Oil Cooler Pluged Turbocharger Drain Line Obstruction Oil Level Too High Insuffecient Coolant Defective Water Pump Faulty Thermostat Cooling System Damage Hose External coolant Leakage Low Coolant Capacity / Dirty radiator Leaking Radiator Radiator Pressure Cap incorrect Driving Technique Operation and Maintenance Practice Dirty Filters/ Breather Long Idle Periods Engine Overloaded Oil Needs Changing Engine Idle Speed Too low Cylinder Head Gasket Leak Blown Off Cracked Cylinder Head Valve Leakage / Valve Lash Bad Mechanical Adjustments or Repair Broken or Worn Piston Rings Engine Camshaft Out of Time Engine Compression Low Rocker Adjusting Screw Cup not seated properly on Push rod ball Loose Cylinder Cap Screw Worn or Scored Liners or Pistons Air Compressor Pumping Oil Page . NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ . 17 APPendIx A MN/ETD 30 REV 02 ENGINEERING TECHNICAL DOCUMENT TORQUE CHART ( 6. it must not be copied. 1 1 1 M14 Description Plug Hollow Bolt Plug Size 3/8” M8x1 1/2” Application Torque (Nm) 1st Bearing Cap to Block Application Water Drain Plug to Block Oil Ejector to Block Water Drain Plug to Block 50 . Description Size Application Torque(Nm) 2 Bolt M8x20 Oil Pump to Block 20 ± 5 15 ± 1 Oil Pump Water Pump Qty. 2 Description Size Bolt Qty. Range 170 to 282 Required Sealing Loctite 567 ** Loctite 567 Connecting Rod Qty. or retransmitted without previous authorization. Range 130 to 160 Camshaft Qty. Range 30 ̊± 2° 35 to 65 25 ± 4 4 Bolt M8x25 Gear to Camshaft 2 Bolt M8x16 Camshaft Lock to Block Qty. Description Torque (Nm) 1st 2nd Torq. Page . All rights reserved. wholly or partly.1 SHEET 1/10 .12 TCA MECHANICAL GENSET ENGINE) Engine Block Qty. 2 Description Bolt Size Application Torque (Nm) MJ 12x58 Connecting Rod to Crankshaft Size Application 1st 40 ± 5 2nd 80 ̊± 2° Torq.Group .5 15 + 5 2nd 155 ̊± 5° Torq.5 Torque(Nm) 10 + 5 10 ± 1. Description Size Application Torque(Nm) 2 Bolt M8x20 Water Pump to Block 20 ± 5 PRINTED COPIES ARE NOT CONTROLLED This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore. or retransmitted without previous authorization.ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Gear Housing Qty.5 7. 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 This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore. Page .2 SHEET 2/10 . it must not be copied. 10 3 2 1 3 1 1 Description Bolt Bolt Hollow Bolt Hollow Bolt Bolt Plug Plug Size M8x20 M8x50 M8x1 M8x1 M10x70 M10x1 M14x1.5 Application Gear Housing to Block Gear Housing to Block Lubrication pipe to Gear Housing Lubrication pipe to Block Intermediate Bearing with Gear to Block Gear Housing (Rear Half) Plug-Allen Tapered Torque(Nm) 25 ± 5 25 ± 5 7.5 Application Valve Lubrication pipe to Cylinder Head Valve drive Lubrication Pipe to Oil cooler Torque(Nm) 10 + 5 10 + 5 Valve Lubrication Pipes Qty. Description Size Application Torque(Nm) 16 9 1 Bolt Bolt Inspection Cover M8x16 M8x55 S65 X 4 Front Cover to Gear Housing Front Cover to Gear Housing to Block Inspection cover to front cover 25 ± 3 25 ± 3 20 ± 3 Application Alternator Bracket to Gear Housing Torque(Nm) Alternator Bracket Qty. Description Size 3 Bolt M10x35 1 Bolt M10x20 Pulley to Alternator Bracket 40 ± 6 40 ± 6 Water Outlet Pipe Qty. All rights reserved.5 ± 2. 6 1 Description Hollow Bolt Hollow Bolt Front Cover Qty. wholly or partly.5 ± 2.5 60 ± 5 10 ± 5 20 ± 3 Size M10x1 M12x1. Page . 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. it must not be copied.5 2 Bolt M8x20 2 Bolt M8x16 1 V band Clamp -- 25 ± 5 25 ± 5 20 ± 3 25 + 5 Cylinder Head Qty. PreTorque (Nm) Application Cylinder Head to Block Cylinder Head to Fan Bracket Cylinder Head mounting bolt 40+5 40+5 - Torque Torque Torque Torque Torque (Nm) Range 1 (°) 2 (°) 3 (°) 120 To 60+ 10 60± 3 60± 3 90± 3 260 120 To 60+ 10 60± 3 60± 3 90± 3 260 80 ± 10 - - - - Size Application Torque(Nm) M5x10 Lubrication pipe to Cylinder head 5±1 1 Description Socket head cap screw Nut M22 High pressure connector nut 50 + 5 1 Nut M8x10 Nut – Valve clearance adjustment 20 + 5 2 PRINTED COPIES ARE NOT CONTROLLED This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore. 4 4 Description Stud Stover Stud Size M10x25 M10 1 Hollow Bolt M14x1. or retransmitted without previous authorization.3 SHEET 3/10 .5 Plug. All rights reserved. Description Size 20 Bolt M14x152 2 Bolt M14 2 Engine lifting hook M12 Qty.5 1 Hollow Bolt M14x1. Connection Bypass for Non-AC application 25 + 5 Application Turbocharger to Exhaust Manifold Turbocharger Stud to Exhaust Manifold Turbocharger Inlet Lubrication Pipe to Turbocharger Turbocharger Inlet Lubrication Pipe to Block Turbocharger Lubrication Return Pipe to Turbocharger Turbocharger Elbow Bracket Torque(Nm) 6±2 70 ± 10 V band clamp elbow-turbo to Turbocharger 10 + 2 2 Turbocharging Qty. wholly or partly.MN/ETD 30 REV 02 ENGINEERING TECHNICAL DOCUMENT Qty. it must not be copied. Description Size Application Torque(Nm) 2 Bolt M10x30 Fuel Filter to Block 35 ± 4 2 Connection M14x1. Fuel Filter inlet for mechanical feed Pump 20 + 6 1 Hollow Bolt M14x1.5 Fuel inlet to Filter Head 20 + 6 1 Hollow Bolt M12x1. 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.5 Pipe.5 ± 2.5 Size Application M8x1 Pipe. Page . All rights reserved.5 1 Connector M8 Connector for Boost pressure 10 + 5 1 Box Nut M10x1 Tube.4 SHEET 4/10 2 .5 Gear to High Pressure Pump 180 ± 5 1 Hollow Screw M12 High Pressure Pump –Tube . Description 6 Connection Torque(Nm) 8±1 High Pressure Pipe Qty. Fuel Return to Cylinder Head Low Pressure Pipe Qty. wholly or partly. Injection Pump to Intake manifold 12.Fuel Return 22. or retransmitted without previous authorization.5 Pipe. 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 Nut M14x1.5 Pipe.MN/ETD 30 REV 02 ENGINEERING TECHNICAL DOCUMENT High Pressure Pump Qty. Fuel Filter outlet to VE Pump 20 + 6 1 Hollow Bolt M14x1. Fuel Filter inlet NRV 20 + 6 Fuel Filter PRINTED COPIES ARE NOT CONTROLLED This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore.5 ± 2. Description Size Application Torque(Nm) 1 Screw M6 Special Step Bolt Fuel injection Clamp 4± 1 2 Bolt M6 x 60 Valve Cover 8. wholly or partly. Page .Fastening Bridge Fuel Injector Torque (Nm) Relieve to (Nm) 1+0. or retransmitted without previous authorization. Fuel Injector and Valve Cover Qty.ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Assy. 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 This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore.5 0 Torque (Nm) Torque 1 (°) 4±1 90 Torque Torque Torque 2 (°) 3 (°) Range 90 30 7+6 Intake Manifold Qty. it must not be copied.5 SHEET 5/10 . Description 12 Stud M10x45 12 Stover Nut M10 Torque(Nm) 6±2 70 ± 10 Exhaust Elbow Qty. Descri ption Size 1 Screw M6 Application Screw.5 Tube-Intake Manifold to FIP 20 + 6 Size Application Exhaust Manifold to Cylinder Head Exhaust Manifold to stud Cylinder Head 1 Exhaust Manifold Qty.5 ± 1 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. All rights reserved. or retransmitted without previous authorization. Description Size Application Torque(Nm) 3 Bolt M8x20 Water Inlet connection 20 ± 3 Engine Breather Qty. Description Size Application Torque(Nm) 2 Bolt M8x20 Oil Suction Pipe to Block 25 ± 4 Water Inlet Manifold Qty. Description Size Application Torque(Nm) 1 Bolt M8x20 Breather to Block 25 ± 5 1 Bolt M8x16 Engine breather tube to Breather housing 10 + 2 Qty. Description Size Application 4 Cylindrical Bolt M16x65 Crankshaft Pulley to Crankshaft 9 Bolt M8 Damper to Crankshaft Pulley Torque (Nm) 1st 2nd 100 ± 10 275 ± 15 35 ± 5 Oil Suction Pipe Qty.MN/ETD 30 REV 02 ENGINEERING TECHNICAL DOCUMENT Crankshaft Pulley Qty. All rights reserved.6 SHEET 6/10 . Page . it must not be copied. 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. wholly or partly. PRINTED COPIES ARE NOT CONTROLLED This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore.5 25 ± 4 50 ± 8 86 ± 13 135 ± 20 207 ± 31 298 ± 45 418 ± 63 569 ± 85 12. For all other conditions use the special torques provided by the related procedures . wholly or partly. Page .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 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 Bolt Class ( Nm) 10. All rights reserved. it must not be copied. 8 Description Cylindrical Bolt Size Application M16x35 Flywheel to Crankshaft Torque (Nm) 1st 2nd 275 ± 15 100 ± 10 Flywheel Housing Qty. Description 10 Screw 1 Hollow Bolt Size M8x 40 M14X1.ENGINEERING TECHNICAL DOCUMENT MN/ETD 30 REV 02 Flywheel Qty.9 10 ± 1. Description Size Application Torque(Nm) 13 Bolt M12x30 Flywheel Housing to Block 100 ± 5 Lubricating Oil Flilter Head and Oil Cooler Qty.9 9±1 15 ± 2 37 ± 6 73 ± 11 124 ± 19 198 ± 30 304 ± 46 424 ± 64 595 ± 89 810 ± 122 8.5 18 ± 3 43 ± 7 84 ± 13 145 ± 22 231± 35 325 ± 49 497 ± 75 696 ± 104 948 ± 142 NOTE : This table is only applied when the Torque isn’t referred in the Service Manual. or retransmitted without previous authorization.7 SHEET 7/10 .8 6±1 10 ± 1. Hex.8 SHEET 8/10 2 .3 70 ± 10 Fan Assembly Qty. it must not be copied. M8x8 Intake curve to intake manifold 20 ± 3 2 Plug.5 X 5.3 ± 1. Hex. Flanged head M10X20 2 Screw. Flanged head Screw.3 25 ± 4 7.5 Spacer mounted on cylinder Head 50 ± 8 1 Bolt.142 4 Screw. flanged head SAE No. Serrated Hex. Flanged head Size M8x20 Application Fan Hub to Fan(30 inch) Torque(Nm) 25 ± 4 M10X70 Fan pulley to Fan Hub and Fan 50 ± 8 2 Bolt. Page .110 1 2 Application Clamping Hose .3 ± 1. Hex.5 X 11 Sensor fitted in water flow tube Max. Serrated Hex. Hex. Description Size 1 Clamp SAE J1 508 Type SLTB SAE No. Hex. wholly or partly. 20 PRINTED COPIES ARE NOT CONTROLLED This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore. Flanged head M10x50 Bolt to Fan shaft 50 ± 8 25 ± 4 50 ± 8 50 ± 8 2 40 + 6 25 ± 4 25 ± 4 Water Flow Tube Assembly Qty. Allen Tapered M22 X 1. Flanged head M8X80 Fan Bracket to Spacer mounted on cylinder Head bolts Fan Bracket to Timing case Housing Fan Bearing to Fan Bracket Tensioner Pulley to Lever belt Tensioner Lever belt tensioner to Fan Bracket Fan Bracket to Timing case 2 Hexagonal Spacer M12X1. Hex.8 For Plugging Heater Holes 30 ± 5 3 2 2 2 Air Cleaner Assembly Qty. Hex. Flanged head M10x50 4 Bolt.MN/ETD 30 REV 02 ENGINEERING TECHNICAL DOCUMENT GENSET ENGINE ADD-ON COMPONENTS Intake Curve Qty. All rights reserved.Air cleanerTurbocharger to Air Cleaner Assembly Air Cleaner Assembly to Air cleaner Mounting Bracket Clamping Hose . M8x20 Clamp SAE J1 508 Type SLTB Screw. Hex. Description Size Application Torque(Nm) M8x35 Intake curve to intake manifold 20 ± 3 M8x25 Intake curve to intake manifold 6±2 1 Screw. Flanged head Stud 1 Nut. Flanged head M8X35 1 Bolt. 6 6 Description Screw. Hex. Flanged head M8X25 2 Screw. Hex. Flanged head M10x35 1 Screw. Description Size Application Torque(Nm) 1 Temparature sensor cum Switch M14 X 1.Air cleanerTurbocharger to Turbocharger Air cleaner Mounting Bracket to Cylinder Block M12x30 Torque(Nm) 7. or retransmitted without previous authorization. Hex. Hex.8 Air compressor closing plate to Gear Case 45± 5 2 Intake Manifold Assembly Qty.25 X 8. Flanged M10 X 20 X 8. Flanged Head Size M8 x 30 X 1. Description Size Application Torque(Nm) 3 Screw. 3 Description Allen bolt Size M6X16X8. wholly or partly. Page .8 Plugging Compressor inlet Hole in Cylinder block 10+5 PRINTED COPIES ARE NOT CONTROLLED This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore.9 M8 x 25 X 1. Flanged M10X30X8.5X8.5 X 5.9 SHEET 9/10 2 . Description Size Application Torque(Nm) 1 Banjo bolt M12X1. Hex.8 Application Feed Pump mounting to Gear case Torque(Nm) 10 ± 1. it must not be copied. turbocharger Torque(Nm) 25 + 5 25 + 5 Gear Case Assembly Qty.8 Feed Pump Inlet/Outlet Feed Pump adapter to Timing case 23± 3 30 ± 4 2 Starter Motor Assembly Qty. All rights reserved.8 For Pluging Intake manifold Hole 10± 2 2 Feed Pump Assembly Qty. Hex. Description Size Application Torque(Nm) 1 Plug. Allen Tapered M12 X 1. or retransmitted without previous authorization.8 Application Elbow.MN/ETD 30 REV 02 ENGINEERING TECHNICAL DOCUMENT Fuel Filter Assembly Qty. Flanged M8 X 25X 1.8 Feed Pump mounting to Gear case 25 ± 4 2 1 Banjo bolt Adapter M14X1. Hex.25 X 8. Hex. Allen Tapered M14 X 1. 1 1 Description Screw.8 M14X1. Flanged Head Screw.5X8.25 X 10.5X8. Description Size Application Torque(Nm) 3 Screw.5 2 Screw. turbocharger Mounting bracket to turbocharger Turbocharger Mounting bracket to Elbow.8 Starter Motor (24V) Mounting 45± 5 2 Cylinder Block Qty.5 X 5.8 Fuel Pump end to NRV pipe 23 ± 3 2 Turbocharger Bracket Assembly Qty. Description Size Application Torque(Nm) 1 Plug. Flanged head 8 Size Application Torque(Nm) M12x30 Engine Mounting Foot to Cylinder Block 70 ± 10 Lubricating Oil Filter Head and Oil cooler Qty.3 ± 1.MN/ETD 30 REV 02 ENGINEERING TECHNICAL DOCUMENT Radiator & Intercooler Qty. 2010 Milind Khanolkar Prepared Sachin Mahajan Checked Amol Relkar Verified Cesar Almeida Approved PRINTED COPIES ARE NOT CONTROLLED This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore. turbocharger-intercooler Hose Clamp for Tube. Hex.3 7.3 7. Description Size 2 Screw.3 7.3 7.10 SHEET 10/10 2 . Release Date 24 Dec. it must not be copied. Flanged head M12 x 35 1 Screw.76 SAE No. Flanged head M10 x 110 Application Pull rod.3 7.3 7.3 Engine Mounting Foot Qty. Hex. Radiator side Hose clamp for Engine Water outlet pipe to hose at Radiator inlet Torque(Nm) Hose clamp on Engine Water inlet pipe 7. Alternator Bracket to Alternator (Charging) Main Alternator Bracket to Alternator (Charging) Torque(Nm) 20 ± 3 70 ± 10 40 ± 6 NOTE : This table is only applied when the Torque isn’t referred in the Service Manual. For all other conditions use the special torques provided by the related procedures . Alternator Bracket to Main Alternator Bracket Pull rod. 50 Alternator 24 V Assembly Qty.3 ± 1.3 7.3 ± 1.42 SAE No. Engine Oil Pressure sensor cum switch 1 Size Application Oil Pressure sensor cum switch mounted at Oil Filter Head M12x12 Torque(Nm) Max. Hex.42 SAE No. or retransmitted without previous authorization.3 ± 1.3 ± 1. All rights reserved. Flanged head M8 x 20 1 Screw. turbochargerintercooler to Intercooler inlet Hose Clamp for Engine Water Outlet pipe Hose clamp for Engine Water outlet pipe to Hose.48 Application Hose clamp for intake curve to intercooler Hose clamp for Elbow Turbocharger to Tube. Serrated Hex. 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 SAE No.76 SAE No.34 SAE No.76 SAE No. Engine Screw. wholly or partly. Page .3 ± 1.42 SAE No.3 ± 1.42 SAE No.3 ± 1.3 Hose clamp on small end of reducer hose at radiator outlet Hose Clamp on reducer hose at radiator outlet 7.3 ± 1. 11 .APPendIx A Page . NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ . NOTEs ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 6-9 ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ .