PDF Workshop Manual JCB, Navistar & Mahindra Acteon Engines - 3 MB
This comprehensive workshop manual covers a range of engines from JCB, Navistar, and Mahindra, including the Acteon series.
It provides detailed instructions for service, repair, and complete overhaul.
The manual includes specifications, diagnostic procedures, and assembly instructions.
It's an essential resource for any technician working on these specific power units.
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--- Page 3 ---
Group - 01
Workshop Manual
Engine Serial Number Identification and Location
The engine identification and serial number can be found in the following places:
1. Identification plate on the water pipe.
2. Engraving on the right side of the engine block, close to the cylinder head of the cylinder #3.
6. 12 T C E
Electronic
Aftercooler
Turbocharged
Series
Cylinders numbers
Page - 5
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Group - 01
Workshop Manual
LEFT VIEW (COLD SIDE)
Mechanical Components
1. Manifold, Intake
2. Oil cooler assembly
3. Oil filter
4. Fuel filter
5. High pressure pipes
Page - 15
--- Page 5 ---
Group - 02
Workshop Manual
OPERATION AND MAINTENANCE
Running-in
All MIM engines are assembled and tested in the factory, making sure its immediate operation.
However, it needs to be correctly ran-in, regarding that its performance and durability depends on the cares
taken during first operation phase.
As general rule, it is considered as running-in, a period of first 2,000 km for vehicular engines or the first 50 service
hours for stationary, industrial and agriculture engines. The vehicle or equipment under moderate operation has
decisive importance to its durability, service safety and economy.
During this period it is very important to follow these recommendations:
v Carefully check if engine oil level is correct;
v Carefully check if water level of the engine cooling system is correct;
v Avoid operate the engine at high speeds, that means do not apply extreme conditions of load or, considering
vehicle application, to “stretch out” the speeds;
v Avoid forcing the engine at low speeds;
v Avoid forcing the engine while it has not reached the normal operation temperature yet;
v Avoid operating over the limit of 3/4 (75%) of the maximum load of the vehicle or equipment;
v Avoid operating the engine at constant speeds for long periods of time;
v Avoid leaving the engine running at idling speed for a long period of time;
v Strictly follow the maintenance instructions.
Following these recommendations the useful life of the engine will be prolonged.
FUEL SPECIFICATIONS
LUBRICANT OIL
Oil Level Check
v Stop the engine and wait 30 minutes so that the oil can flow back to the carter.
v Make sure that the vehicle is levelled.
v Before pulling oil dipstick, clean the surroundings.
Page - 2
--- Page 6 ---
Group - 02
Workshop Manual
Tighten bolts to the standard torque value (General
Torque Guidelines).
Remove safety chain hooks from engine lifting eyes.
3-14
Page - 12
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Workshop Manual
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Page - 32
--- Page 13 ---
Group - 05
Workshop Manual
ENGINE BLOCK
Inspections and Measurements
LINER PROTRUSION
Liner over Engine Block Surface
Measure mm
Protrusion *0.03 - 0.10
*Affect emissions level
Page - 2
--- Page 15 ---
Group - 06
Workshop Manual
Disassembly Notes
After removing the carter, pistons and connecting Carefully remove crankshaft in order to do not hit on
rods, flywheel, pulley and gear housing, position the any part of the engine block, avoiding damaging it.
engine on the stand in upright position and loosen the The storage of the crankshaft must always be done in
main bearing caps. To remove the bearing caps use upright position, avoiding any warping possibility.
the fixation bolts.
5-2
Follow the sequence of loosening the main bearing
cap screws.
Remove the axial thrust ring from bearing #1 (flywheel
side).
Page - 1
--- Page 16 ---
Group - 06
Workshop Manual
Measure the crankshaft.The measurements must be Install bearing caps and tighten according specification.
taken twice at 90° and in the two edges of the bearing Measure using same procedure from bearings without
to check crankpins and main journals out-of roundness bearing shells to verify the radial force.
and taper.
The 1st measurement is made in the centre of the
bearing 0.036 – 0.096.
5-12
Compare the clearances obtained in the crankshaft
through the bore gauge.
Remove one of the bolts bearing and measure bearing
pre-tension.
Pre-tension: 0.05 - 0.15 mm.
Page - 11
--- Page 17 ---
Group - 07
Workshop Manual
CAMSHAFT
Inspections and Measurements
Visually check the tappets. Check if there are marks Measure the diameter and out-of-roundness of the
of excessive waste on the contact area with the cams tappets housing.
of the camshaft.
Measure the tappets bore diameter in cylinder block
! Attention: During its operation the tappets
perform a rotating movement,
responsible for a uniform distri-
bution of the force, uniforming
the waste. It must not have was-
te on only one area.
Visually check tappet lubrication holes.
Measure the camshaft bearing diameters.
! Attention: The lubrication holes of the ta-
ppets cannot be obstructed.
Page - 4
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Group - 08
Workshop Manual
PISTONS AND CONNECTING RODS
CONNECTING ROD WARPING
Maximum Torsion Maximum Warping
0.10 0.03
Page - 6
--- Page 19 ---
Group - 08
Workshop Manual
Lubricate the two inner halves of the bearing shells. Position the connecting rod stem in the crankshaft
crankpin and install the connecting rod cap. Tighten
the bolts according to specification.
1st 40 ± 5 N.m
2nd 80° ± 2°
Check the cap position at the time of assembly
7-16
Check if the connecting rod has free side movement.
Measure the side clearance.
Check if the oil injector is not hittong the piston skirt
Number punched on con rod and cap must be one side otherwise injector may brake or bend
Page - 15
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Group - 09
Workshop Manal
CYLINDER HEADS
Inspections and Measurements
Visually check cylinder heads for leaks. Measure the outer diameter of the valve stem in 3
different points:
v Upper part
v Central part
v Lower part
Check push rods. The push rods ends must not be
loosen or cracked. Check for excessive wear. Check if
the push rods are not warped.
Measure the outer diameter of the valve guide.
Cylinder heads surfaces must never be machined.
! Attention: Do not measure the diameter
on the lowered part of the
guide.
Page - 8
--- Page 21 ---
Group - 09
Workshop Manual
CYLINDER HEADS
Install the 4 valves. Put the valve retainers in the shown position.
Install the lower spring discs.
Using the special tool No. D7000597C1 and its spacer,
install the valve retainer in its housing.
Install the special tool No. D7000597C1 to slide the
valve retainer.
Page - 18
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Group - 09
Workshop Manual
CYLINDER HEADS
2. To adjust the valve cap and rocker arm follow the sequ ence below.
When the engine is cold, turn the crankshaft until cylinder 6 intake and exhaust valves are closed,
ensuring that camshaft is not acting the rocker arm that will be adjusted.
In this position check clearance for following valves and respective cylinder.
Cylinder no. 1 is to be counted from flywheel housing side.
Set cylinder no. 6 (damper side) at firing and follow the steps:
Set clearance in valve 3 of cylinder 2
Set clearance in valve 6 of cylinder 3 VALVE ADJUSTMENT Min. Max.
Set clearance in valve seven of cylinder 4
Set clearance in valve 10 of cylinder 5 Exhaust valve (mm) 0.20 0.40
Set clearance in valve 11 of cylinder 6
Set valve 12 of cylinder no.6 Intake valve (mm) 0.20 0.40
Feeler gage
Backing point Clearance
FIGURE 1 FIGURE 2
FLYWHEEL HOUSING
FIRING : - CYLINDER No. 6
Set clerance of valves which are circled.
DAMPER SIDE
CYL. 6 CYL. 5 CYL. 4 CYL. 3 CYL. 2 CYL. 1
IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. IN. EX.
SIDE
12 11 10 9 8 7 6 5 4 3 2 1
3. With a turnscrew, tighten the adjustment until remove clearances between feeler gauge
and both of contact front. (rocker arm and valve cap) Certifying that still can be removed.
After this operation, tighten with 20 + 6 Nm the adjustment nut.
Note that it is necessary to insert the feeler with fingers for removing any scrub, compressing the
analysis just in contact zone between the rocker arm and valve cap .
Page - 29
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Group - 10
Workshop Manual
Assembly
Lock the engine with the special tool No. D7000600C1. Install the gear housing tightening the fixation bolts
With the starter removed install the tool as indicated. crosswise according to the specification.
Torque: 25 ± 5 Nm
Install the idle bearing without the disk and the thrust
ring for a perfect centralization of the intermediary
piece. ! Attention: The centralization of the gear
housing is important to guarantee
the specified clearances of the
distribution gears.
9-8
! Attention: When removing/installing only
water pump, flock the crankshaft
and timing gears.