OPERATION AND MAINTENANCE MANUAL

7.2 MECHANICAL
 IntroductIon

Presentation

Introduction................................................................................................................................................1

How.to.Use.this. Manual ......................................................................................................................... 1

Important.Safety.Remarks........................................................................................................................ 2 - 3

Generafl.Instructfions............................................................................................................................... 3

Cleaning.General.Instructions................................................................................................................... 4

Engine.Serial.Number.Identification.and.Location....................................................................................5

Cylinder.Numeration..................................................................................................................................6

Engine Identification................................................................................................................................. 7

Engine Exploded View.............................................................................................................................. 8

Engine Technical Data.............................................................................................................................. 9 - 10

Engine Description.................................................................................................................................... 11 - 22
 Introduction

This.manual.contains.complete.information.and.specification.to.assembly.and.disassembly.MAXXFORCE.7.2 .
engines.and.all.components.manufactured.by.MaHIndraI 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.
I
effective.in.the.moment.of.its.print..MaHIndra 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.conve-
nience,.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.otherin-
juries.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.com-
partments..

• 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.ten-
sion.peaks.The.standard.procedure.is.always.first.to.connect.the.cable.on.the.negative.pole.and.later.on.the.
positive.pole..Take.care.to.do.not.invert.the.poles..

Page - 3
 IntroductIon

cleaning General Instructions

cleanInG WItH acIdS and SolventS

Several.solvents.and.acid.substances.can.be.used.to.clean.the.parts.of.the.engine..
MaHIndra navIStar enGIneS Pvt ltd. does not recommend any specific substance. always follow
the instructions of the manufacturer of the product.
Remove.all.gaskets,.sealing.rings,.and.with.a.brush.of.steel.or.rasper,.the.sludge.deposits,.carbon,.etc.,.before.
placing.the.parts.in.the.cleaning.tank..Be.careful.to.do.not.damage.the.surfaces.of.the.sealing.elements.seats..
Flush.all.parts.with.hot.water.after.cleaning..Completely.dry.them.with.compressed.air..Remove.water.from.screw.
holes.and.from.lubrication.inner.grooves..
In.case.the.parts.are.not.to.be.used.soon.after.the.cleaning,.dip.them.in.an.appropriate.anti-oxidation.compound.
That.compound.must.be.removed.of.the.parts.before.installation.in.the.engine..
The.following.parts.cannot.be.cleaned.with.vapour:.

1.. Electric.and.electronics.components;.

2.. Electric.harness;.

3.. Fuel.injectors;.

4.. High.pressure.pump;.

5.. Belts,.pipes.and.hoses;.

6.. Bearings..

Page - 4
 engine Serial number Identification and location

The.engine.identification.and.serial.number.can.be.found.in.the.following.places:.

1.. Identification.plate.on.the.water.pipe..

2.. Engraving.on.the.right.side.of.the.engine.block,.close.to.the.cylinder.head.of.the.cylinder.#3..

6. 12 t c e
Electronic.

Aftercooler.

Turbocharged

Series

Cylinders.numbers.

Page - 5
 IntroductIon

cylinders numeration

The.cylinders.order.starts.from.the.flywheel,.according.to.the.illustration.below..

FIRST CYLINDER

During.the.assembly,.check.the.numbers.on.the.block.(A).and.on.the.bearings.(B),.that.must.be.the.same.number,.
corresponding.to.the.correct.block.
The.bearing.number.must.start.from.flywheel.to.front.side.

Page - 6
1-8
engine Identification

enGIne SerIal nuMber

The.engine.serial.number.is.stamped.in.the.right.and.rear.side.of.the.engine.block. In the upper side, close to the
cylinder.head.gasket.
. . . . . . . .

6.12 TCA Engine Data Plate:

enGIne acceSSorIeS
The.following.engine.accessories.have.manufacturer’s.labels.or.identification.plates:
• Turbocharger
• Fuel.Injection. Pump (Stanadyne Rotory)

Labels.or.identification.plates.include.information.and.specifications.helpful.to.vehicle.operators.and.technicians.

Page - 7
Engine Exploded View

Page - 8
 ENGINE TECHNICAL SPECIFICATION

Engine series No 6.12 TCA 6.12 TCA 6.12 TCA 6.12 TCE
Engine Model S12-III S12-II S12-I SE12-I
Prime rating KVA 125 140 160 180
No. of cylinder No 6 6 6 6
Type of construction Inline / V type Inline
Displacement Ltrs 7.12
Bore mm 105
Stroke mm 137
kW 114.8 128.1 146.5 163.0
Rated output
hp 156 174 199 221.2
kW 125.6 139.9 160.0 178.0
Standby output
hp 170.6 190.1 217.5 242
Tolerance on rated output power % ±5 ±5 ±5 ±5
Rated speed rpm 1500 1500 1500 1500
Method of Starting of engine 24V ELEC
Aspiration NA/TC/TCA Turbocharged Aftercooler
Compression Ratio 16.8:1 16.8:1 16.8:1 16.8:1
Brake Mean Effective Pressure (bmep)
1)Rated Bar 12.9 14.4 16.4 18.3
2)Maximum 14.1 15.7 18 20
Firing Order 1-5-3-6-2-4
●COOLING SYSTEM
Method of Jacket cooling Radiator
Heat Removal By Water
Dimensions of radiator (L X H X W ) mm 831x390.5x1135
Qty of coolant(Engine + Radiator) Ltr 25 25 25 25
Air Flow at Radiator Outlet CFM 10000 11800 11800 13200
Fan Power KW 6 7 7 8
Tripping Temperature Deg C 105
●FUEL SYSTEM OF ENGINE
Fuel oil High speed Diesel(HSD IS 1460:2005)
Fuel Filter type ) paper element
Spin-on type with
Filtration capacity Micron 5
Filter Change period hrs 500
Specific fuel consumption at
100%load 202 198 197 193
g/kW-h
75%load 200 197 197 195
50%load 214 212 207 202
Specific fuel consumption at
100%load 148.7 145.7 145.0 142.0
g/hp-h
75%load 147.2 145.0 145.0 143.5
50%load 157.5 156.0 152.4 148.7
Tolerance on SFC % +5 +5 +5 +5
Fuel consumption at Ltrs/h
100%load 27.45 30.01 34.15 37.18
75%load 20.38 22.39 25.61 28.18
50%load 14.54 16.06 17.94 19.46
 ENGINE TECHNICAL SPECIFICATION

Engine series No 6.12 TCA 6.12 TCA 6.12 TCA 6.12 TCE
Engine Model S12-III S12-II S12-I SE12-I
Prime rating KVA 125 140 160 180
1)FUEL INJECTION PUMP
Make STANADYNE MAKE Bosch Make
Type Rotary HPCR
2)GOVERNER DATA
MECHANICAL ECU Controlled
Type
(3- 5%) (Isochronous)
Response time
As per IS10002
Recovery time
●LUBE OIL SYSTEM
Lube Oil Consumption at 100% Load Lit/hr 0.014 0.015 0.017 0.02
Recommended lube oil 15W40 API CI4
Lub oil filter type Full flow: Spin on cartridge type with Paper
Filtration capacity Microns element
15
Lube oil change period hours 500
Maximum lube oil temperatorure Deg C Min:-10 & Max:125
Lube oil pressure kg/cm2 Must be greater than 1.2 at idling condition &
Lube oil system capacity lit 3.5 at rated
19.8 speed
●EXHAUST SYSTEM
Exhaust silencer type Residential Type
Exhaust noise level (with Silencer) @ 3M dB Complies with CPCB norms
Max. Permissible back pressure in Exhaust mm of Hg 75
Exhaust gas flow kg/hr 558 603 664 800
Exhaust gas temperature (Max ) Deg C 600 650
●HEAT REJECTION DETAILS
Heat Rejection to coolant kW 59.73 62.22 70.98 78
Heat Rejection to CAC kW 14.74 19.33 22.49 32.9
Heat Rejection to exhaust kW 82.39 101.19 110.58 127.9
Heat Rejection from engine surface kW 12.1 12.89 14.38 16.07
●AIR INTAKE SYSTEM
Intake filter type Dry type Air cleaner
Air intake restriction - with clean element mm of H2O 230
Air intake restriction - with dirty element mm of H20 600
Filtration capacity Microns 20
Maximum Intake manifold temperature Deg C 55
Combustion air inlet flow rate kg/hr 535 580 637 750
●ENGINE NOISE LEVEL
At 1Mtr < 75 dBA for genset with canopy
●DIMENSIONS & WEIGHT DETAILS
LengthXWidthXHeight (With Radiator) mm 1727X932X1274.4
Dry engine weight-with flywheel & flywheel
kg 598.6 610
housing
Weight to power ratio Kg/Kw 5.21 4.67 4.09 3.74
 Fuel System
2-2

Description 6 cylinders
Maximum fuel inlet restriction
0.6 to 1.2 bar
(for gears pump)

Fuel pressure range in the

fuel filter outlet (at crank 9.7 to 12.8 bar
speed)
Range of fuel pressure in fuel
filter fuel inlet (at operation 10.5 to 13 bar
speed)
Maximum pressure load
≤0.8 bar
reduction in the fuel filter

lubrication System

Description MaxxForce 7.2

Oil pressure
• Nominal speed 5.3 bar (hot engine)
• Idling speed 3.5 bar (hot engine)
Oil temperature
• Nominal 90 - 110 °C
• Maximum 120 °C
Oil capacity
19.8 l

cooling System

Description MaxxForce 7.2

Volume of water in the
engine, without radiator 9l

Water temperature
• Nominal 80 - 90 °C
• Maximum 100 °C

thermostat

Opening Total Maximum opening

Thermostat beginning opening course
0304CAV00010N 79 ± 2°C 90°C 10.0 mm

Page - 9
 engine Description

FeatureS
2-4
MAXXFORCE 7.2 is in-line six cylinder engines with 7.2 Litre displacement.

The firing order of the cylinders is 1–5–3–6–2–4

The cylinder head has four valves per cylinder with cross flow for improved air flow. The head gasket is mated in
metal-rubber and is individual for each cylinder head. The fuel Injector is centrally located between the four valves
and directs fuel over the piston bowl for improved performance and reduced emissions. The overhead valve train
includes mechanical roller lifters, push rods, rocker arms, and dual valves that open using a valve bridge.
To improve the components durability and engine performance this engine uses the hot and cold side concept for
components distribution.
Cold side (left engine side)
• Fuel Supply System
• Intake Air Manifold

Hot side (right engine side)

• Turbocharger system
• Exhaust manifold

A one piece oil pan withstands high-pressure loads during diesel operation.
Manufactured in stamped steel, the oil pan has a compact size and lightweight.
Seven main bearings support the crankshaft for MAXXFORCE 7.2 engines respectively.
One insert bushing support the camshaft for each engine, the other support is assembeled in the
engine block. The rear oil seal carrier is part of the flywheel housing. The open oil pan breather assembly uses a
road draft tube to vent oil pan pressure and an oil separator that returns oil to the oil pan.
Manufactured with forged steel and new shape to improve its strength, the pistons are mated with fractured cap
joint connecting rods. Replaceable rolled radius wet cylinder liners are used with the pistons.
The new model of viscous damper for the MAXXFORCE 7.2 engine offers fns to assist in the
refrigeration.
A lube oil pump, mounted onto the front of the engine block, is driven directly by the crankshaft. All engines use
an enlarged oil cooler and cartritge type spin on filter.
An electric feed pump / mechanical feed pump draws fuel from the fuel tank through a fuel filter assembly that includes a
strainer, filter element, drain valves, and water in fuel (WIF) sensor. After filtering, fuel goes to Stanadyne rotary pump and the
high pressure fuel goes to the injectors..

The new water pump was designed with seven vanes to increase the water flow.

Page - 10
 technIcal Data

acceSSorIeS FeatureS

The alternator is used to charge the battery and to power a Genset system when the engine is running, driven
by the pulley system and the belt accessories. It’s located in the cold side in the front of the block on the upper
position.
The starter motor is an electric motor that initiates rotational motion in an internal combustion engine before it can
power itself. On the MAXXFORCE engines it’s located in the cold side, next to the Flywheel.
Turbocharger is an air compressor used for forced- induction of an internal combustion engine
The purpose of a turbocharger is to increase the air mass entering the engine to create more power. In the
MAXXFORCE engine it's located on the hot side , next to the waterpipe.

Page - 11
 engine component locations

2-6

toP VIeW
1. Coolant temperature sensor (ECT)

2. Valve cover

Page - 12
 technIcal Data

5 4

Front VIeW
1. Water bypass tube assembly thermostat outlet

2. Alternator

3. Pulley

4. Vibration damper

5. Front cover

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 1

3
4
2

leFt VIeW (colD SIDe)

Mechanical components

1. Manifold, Intake

2. Oil cooler assembly

3. Oil filter

4. Fuel filter

5. High pressure pipes

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 4 3
2

2-10

7 1

rIGht VIeW (hot SIDe)

1. Oil dipstick

2. Turbo inlet pipe

3. Turbo outlet pipe

4. Exhaust manifold

5. Turbo exhaust curve

6. Flywheel housing

7. Cylinder block

Page - 17
 technIcal Data

rear VIeW
1. Flywheel
2. Lube Oil sump
3. Flywheel Housing
4. Water Outlet tube

Page - 18
 NOTEs

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 OPERATION ANd MAINTENANcE

Operation and Maintenance

Engine Operation .....................................................................................................................................

Cooling Fluid and Coolant ........................................................................................................................

Water Pump Checking ............................................................................................................................

Maintenance Table....................................................................................................................................

Conservation for Inactive Engines for Long Periods .................................................................................

Starting Engine Preparation .....................................................................................................................

Oil Element .............................................................................................................................................

 Engine Operation

Start / Stop

· Before operating the MAXXFORCE 7.2 engine check:

3-2 · Water level.

· Fuel level.

· Lubricant level.

· Soon after to start the engine, heat it up at medium speed, without load.Watch lubricant oil pressure and water
temperature.

· It is recommended to start the engine without accelerating, keeping the engine at idling speed for 30 seconds
in order to pre-lubricate the turbocharger.

· Before stopping the engine, run about 30 seconds at idling speed so that the turbo decrease its speed.

cold Start
The difficulty of start at very low temperatures can happen due to the collapse of the filter because paraffin formation
or lack of ignition of the fuel.
The following actions can be observed:

· Use winter fuel, which does not form paraffinic flakes at low temperatures, or;

· Case the winter fuel is not available, it is necessary that the filter has a heater on the cylinder head to allow
fuel flow before the start.

Turbocharger cares

· Almost all failures in turbochargers are caused by lubrication deficiency (delay in lubrication, restriction or lack
of oil, intake of impurities in the oil, etc.) and objects or impurities entrance through intake.

· To maximize the turbo lifetime follow these cautions:

· Do not accelerate the engine immediately after the start.

· Wait 30 seconds with the engine at idling speed before stop it.

· Pre-lubricate the turbocharger after oil change or other service that evolves oil drain. Crank the engine a few
times before start the engine. Run the engine and allow it to run at idling speed for a period of time to establish
a complete circulation and oil pressure before apply high speeds and load.

· In low temperatures or when the engine is being reactivated after a long period without operation, start the
engine and let it running at idling speed before operating at high speeds.

· Avoid operating the engine at idling speed for long periods of time.

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 OPERATION ANd MAINTENANcE

Running-in
All MIM engines are assembled and tested in the factory, making sure its immediate operation.
However, it needs to be correctly ran-in, regarding that its performance and durability depends on the cares
taken during first operation phase.
As general rule, it is considered as running-in, a period of first 2,000 km for vehicular engines or the first 50 service
hours for stationary, industrial and agriculture engines. The vehicle or equipment under moderate operation has
decisive importance to its durability, service safety and economy.
During this period it is very important to follow these recommendations:
· Carefully check if engine oil level is correct;
· Carefully check if water level of the engine cooling system is correct;
· Average load factor in 24hours should not exeed 75% load of the Rated capacityand in every 12hours 10%
Over load permitted for one hour.
· Avoid leaving the engine running at idling speed for a long period of time;
· Strictly follow the maintenance instructions.
Following these recommendations the useful life of the engine will be prolonged.

FUEL SYSTEM
FuEL SPEcIFIcATIONS - HSd IS 1460:2005

· Drain water and sediments from water seperator and fuael tank every day.
· Fill the fuel to the fuel tank if necessary.
· Change fuel filter periodically as for maintenance plan (Refer Maintenance Table)

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 FuEL INjEcTION SySTEM

Page - 3
 FuEL INjEcTION SySTEM

Page - 2
 NOTEs

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·

LuBRIcANTINg OIL

Oil Level check

· 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.
· If necessary, Topup up to the ' H' mark, without exceeding it.
Use the same oil Brand and Grade.
· Do not operate the engine with the level below the ' L' mark.
· Use only recommended lubricant oil ( 15W40 API CI4 ).
· Do not mix different oil brands.

Oil change
· Change the Lubricating oil as per Maintenance Plan.
· The oil must be hot for easy drain.
· Remove the carter plug and washer drain the oil.
· Install the plug with a new washer and tighten according to the specification.
· Fill with recommended lubricant oil up to ' H' mark of the dipstick.

! Attention: Always use MNEPL recommended genuine engine oil

check Lubricant oil condition

The lubricant oil is very important for a good conservation of the inner engine components. Lubricanting oil
contaminated with sand, soil, dust, water or fuel causes problems to the engine.
Check the appearance of the engine lubricant oil. A dark coloration and low viscosity means presence of fuel in
the lubricanting oil.The presence of foaming or a milky coloration indicates presence of water in the oil.

Lubricant Oil Specifications

It must be used multiviscous type lubricant oil that accomplish, at least, to the SAE 15W40 API CI-4 (or upper)
specifications and to the recommended viscosities.

! Attention: Do not mix different oil brand / grade. Use only

MNEPL recomended oil

Page -3
 Oil Filter change
· 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).
3-10 · 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 2. Using the wrench indicated, unscrew the filter
washer. Drain engine oil and dispose of used
engine oil according to applicable laws.

Page - 8
 INSTALLATION
1. Clean area around oil filter head, clean gasket 4. Tighten the filter untill the gasket contacts the filter
surface of filter head. head surface.

2. Lubricate oil filter gasket with fresh engine oil.

3. Fill the oil filter with fresh engine oil.

5. Use oil filter wrench to tighten the filter
an additional 3/4 of a turn.

6. Operate the engine and check for leakages

Page - 9
 Lubrication system

OIL LubRIcATION cIRcuIT

12-2

Page - 1
 OPERATION ANd MAINTENANcE

cooling Fluid and coolant

! Attention: · Do not open the expansion reservoir cap while the engine is hot.
· Check the level when the engine is cold.

· Check the level of the cooling system daily. If the level is not correct, add clean water and
MWM coolant according to the proportion recommended on the bottle.

· Carefully open the first stage of the cap relieving the vapour pressure.

· Check for leaks through cooling piping.

· Check the nominal pressure of the cap in case of change.

Water Pump check

Check the inspection hole located on
the left side of the engine block (seen
by the flywheel side). If there are signs
of water or oil leakage, probably there
is leakage through the water pump or
through the sealing rings. Check and
change, if necessary.

Note: Image is shown with gear housing removed

If water is coming from this hole, it means there is a
leakage coming from the water pump.

Page -4
 NOTEs

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Cooling System

COOLINg CIRCuIT

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 OPERATION ANd MAINTENANcE

Maintenance Table

Remarks:
1)
This table is only for guidance. The Maintenance Table of the Genset prevails over this table.
2) If the engine stays inactive for a long time, it must perform an idling speed test fortnightly, until to reach the
operation temperature.
3) Independent of the intervals indicated for engine lubricant oil changes, it must be changed at each 6 months.
4) Electronic parts (phase, speed, air pressure, temperature, oil pressure and water temperature sensors) are
maintenance-free and checked by recommended diagnose scanner for errors stored in failure memory.

Note: Mentioned parts are under evaluation and maintenance fequency can get changed after evaluation.

Page - 5
 NOTEs

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 Edited by Foxit Reader
Copyright(C) by Foxit Corporation,2005-2009
For Evaluation Only.

conservation for Inactive Engines for Long Period

MNEPL engines are produced protected for, at the most, 6 inactivity months under shut shelter.
When the engine is to stay inactive for a long period, it is necessary to follow these cares:
1. Clean the outer parts of the engine.

3-8 2. Operate the engine until to reach the operating temperature.

3. Drain cooling system and lubricant oil.
4. Fill the radiator with clean water and coolant according to the recommended proportion.
5. Fill up the oil sump with protective oil SAE 20 W 20
6. Drain fuel system (reservoir, low pressure system).
7. Operate the engine for 15 minutes at 2/3 of the nominal speed, without load, using a mixture of fuel with 15%
of the protective oil SAE 20 W 20.
8. Drain fluid from cooling system and oil from oil sump. The fuel mixture can stay in the system
9. Remove valves cover from cylinder heads and spray protective oil on the springs and rocker arms. Reinstall
covers.
10. Apply protective oil on machined surfaces.
11. Remove belt.
12. Seal all the holes of the engine, to avoid dust and water penetration.

Remarks:
· Renew the engine conservation procedure after each 8 months of inactivity.
· In case of new brand engines, do not consider items 1, 2 and 3.

ENgINE PREPARATION TO RETuRN FOR SERvIcE

1. Before operating an engine which stayed inactive for a long period, follow these procedures:
2. Clean the outer parts of the engine.
3. Fill the cooling system with clean water and coolant in the recomended proportion
4. Change engine lubricnting oil flter.
5. Fill the oil pan with new recomended grade of 15W40 engine oil in recomended quantity.
6. Install belt and adjust tension.
7. Remove valve covers and lubricate rocker arms with engine oil. Reinstall covers.
8. Drain the fuel mixture from the reservoir and fill with new fuel.
9. Change fuel filter.

Page - 6
 OPERATION ANd MAINTENANcE

dRAIN ENgINE FLuIdS

ENgINE STARTINg Preparation
draining the Oil
cLEAN ENgINE
1. Place an oil drain pan beneath the oil drain plug to
collect the oil.
! Warning: To avoid serious personal injury,
possible death, or damage to 2. Remove oil pan drain plug (R ½”) and washer.
the engine or Genset, read all Drain engine oil and dispose of used engine oil
safety instructions in the “Safety according to applicable laws.
Information” section of this
manual. 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
1. Cap all turbocharger and manifold openings 75 N.m.
to prevent water and degreased agents from
entering any engine components internally.
6 cylinders Engine
2. Use an appropriate detergent mixed in the correct
ratio of water and applies to engine using a warm
water and moderate pressure washer or similar
cleaning equipment.

! NOTE
: Do not use high pressure or excessive
hot water temperature as it may damage
the engine components.

! NOTE
: Do not use solvent, thinner or any
product that derivates from petrol as
these products may damage the wiring
harness and other plastics made
components.

Page - 7
 FAILuREs DIAgNOsIs

Diagnosis Failures

Introduction..............................................................................................................................................1

Trouble Shooting Chart............................................................................................................................2

 Introduction

Next.they.are.presented.some.typical.problems.which.the.engine.may.present,.their.probable.causes.and.possible.
corrections.for.these.problems.

! Attention :. ·. Study.in.full.detail.the.problem.before.trying.any.action..
. ·. First.check.the.simplest.and.obvious..

. ·. Find.the.main.cause.and.correct.the.problem..

17-2

Page - 1
 Engine Oil Spewing out from Breather Tube

Lubricating Oil Contaminated with Coolant

Fuel/ Oil Leaking from Exhaust Manifold

Engine Starts but doesnot keep running

Lubricating Oil Contaminated with Fuel
Engine Surges ( Speed change)
Hard Starting or Failure to Start

Coolant Temperature Too High

Excessive White Smoke at idle
Excessive Black Smoke at Idle

Excessive Fuel Consumption

Excessive oil Consumption
Trouble Shooting

Engine Output Power Low

Cannot Reach rated RPM

Excessive Blue Smoke
MAXXFORCE 7.2 Mechanical

High Oil Pressure

Low oil Pressure
Loss of Coolant
Engine Missing
COMPLAINTS
Cause

Restricted Air Intake

High Exhaust Back Pressure

Air Air Leakage Between Yurbocharger and Intake Manifold

System 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
High Pressure/ Fuel Leakage
System
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 Oil Suction Line Restricted

System 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 Damage Hose

System External coolant Leakage

Low Coolant Capacity / Dirty radiator

Leaking Radiator

Radiator Pressure Cap incorrect

Driving Technique

Dirty Filters/ Breather

Operation and
Maintenance Long Idle Periods
Practice 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 Broken or Worn Piston Rings

Adjustments Engine Camshaft Out of Time
or
Repair Engine Compression Low
Rocker Adjusting Screw Cup not seated properly on Push
rod ball
Loose Cylinder Cap Screw

Worn or Scored Liners or Pistons

Air Compressor Pumping Oil

Page - 2
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 Group - 17

APPendIx A

MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

TORQUE CHART ( 6.12 TCA MECHANICAL GENSET ENGINE)

Engine Block
Qty. Description Size Application Torque (Nm)
1st 2nd Torq. Range
2 Bolt M14 Bearing Cap to Block
50 - 5 155 ̊± 5° 170 to 282

Qty. Description Size Application Torque(Nm) Required Sealing

1 Plug 3/8” Water Drain Plug to Block 10 + 5 Loctite 567
1 Hollow Bolt M8x1 Oil Ejector to Block 10 ± 1.5 **
1 Plug 1/2” Water Drain Plug to Block 15 + 5 Loctite 567

Connecting Rod
Qty. Description Size Application Torque (Nm)
MJ Connecting Rod to 1st 2nd Torq. Range
2 Bolt
12x58 Crankshaft 40 ± 5 80 ̊± 2° 130 to 160

Camshaft
Qty. Description Size Application Torque (Nm)
1st 2nd Torq. Range
4 Bolt M8x25 Gear to Camshaft
15 ± 1 30 ̊± 2° 35 to 65
2 Bolt M8x16 Camshaft Lock to Block 25 ± 4

Oil Pump
Qty. Description Size Application Torque(Nm)

2 Bolt M8x20 Oil Pump to Block 20 ± 5

Water Pump
Qty. Description Size Application Torque(Nm)

2 Bolt M8x20 Water Pump to Block 20 ± 5

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Page - 1
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

Gear Housing
Qty. Description Size Application Torque(Nm)
10 Bolt M8x20 Gear Housing to Block 25 ± 5
3 Bolt M8x50 Gear Housing to Block 25 ± 5
2 Hollow Bolt M8x1 Lubrication pipe to Gear Housing 7.5 ± 2.5
1 Hollow Bolt M8x1 Lubrication pipe to Block 7.5 ± 2.5
3 Bolt M10x70 Intermediate Bearing with Gear to Block 60 ± 5
1 Plug M10x1 Gear Housing (Rear Half) 10 ± 5
1 Plug M14x1.5 Plug-Allen Tapered 20 ± 3

Valve Lubrication Pipes

Qty. Description Size Application Torque(Nm)
6 Hollow Bolt M10x1 Valve Lubrication pipe to Cylinder Head 10 + 5
1 Hollow Bolt M12x1.5 Valve drive Lubrication Pipe to Oil cooler 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
Qty. Description Size Application Torque(Nm)
Alternator Bracket to
3 Bolt M10x35 40 ± 6
Gear Housing
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

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Page - 2
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

Qty. Description Size Application Torque(Nm)

1 Hollow Bolt M12 Water outlet tube to degassing tank 20 ± 3

1 Nipple M22 Nipple Bypass connection for AC application 40 ± 5 2

1 Plug M22X1.5 Plug, Connection Bypass for Non-AC application 25 + 5

Turbocharging
Qty. Description Size Application Torque(Nm)
4 Stud M10x25 Turbocharger to Exhaust Manifold 6±2
4 Stover Stud M10 Turbocharger Stud to Exhaust Manifold 70 ± 10
Turbocharger Inlet Lubrication Pipe to
1 Hollow Bolt M14x1.5 25 ± 5
Turbocharger
1 Hollow Bolt M14x1.5 Turbocharger Inlet Lubrication Pipe to Block 25 ± 5
Turbocharger Lubrication Return Pipe to
2 Bolt M8x20 20 ± 3
Turbocharger
2 Bolt M8x16 Turbocharger Elbow Bracket 25 + 5

1 V band Clamp -- V band clamp elbow-turbo to Turbocharger 10 + 2

Cylinder Head
Pre-
Torque Torque
Qty. Description Size Application Torque Torque Torque Torque
(Nm) Range
(Nm) 1 (°) 2 (°) 3 (°)
Cylinder Head to 120 To
20 Bolt M14x152 40+5 60+ 10 60± 3 60± 3 90± 3
Block 260
Cylinder Head to Fan 120 To
2 Bolt M14 40+5 60+ 10 60± 3 60± 3 90± 3
Bracket 260
Engine lifting Cylinder Head
2 M12 - 80 ± 10 - - - -
hook mounting bolt

Qty. Description Size Application Torque(Nm)

Socket head
2 M5x10 Lubrication pipe to Cylinder head 5±1
cap screw
1 Nut M22 High pressure connector nut 50 + 5
1 Nut M8x10 Nut – Valve clearance adjustment 20 + 5

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Page - 3
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

High Pressure Pump

Qty. Description Size Application Torque(Nm)
High Pressure Pump adaptor
3 Stud M8 X 30 8±1
to Gear Housing
3 Nut M8 High Pressure Pump to Gear Housing 38 ± 3
1 Nut M14x1.5 Gear to High Pressure Pump 180 ± 5 2
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

Low Pressure Pipe

Qty. Description Size Application Torque(Nm)

6 Connection M8x1 Pipe, Fuel Return to Cylinder Head 8±1

High Pressure Pipe

Qty. Description Size Application Torque(Nm)
Nut high pressure tube to
6 Nut M12 15 + 5
fuel injection pump
Nut high pressure tube to
6 Nut M14 25 + 5
Connector high pressure tube

Fuel Filter
Qty. Description Size Application Torque(Nm)
2 Bolt M10x30 Fuel Filter to Block 35 ± 4
2 Connection M14x1.5 Fuel inlet to Filter Head 20 + 6
1 Hollow Bolt M12x1.5 Pipe, Fuel Filter outlet to VE Pump 20 + 6
Pipe, Fuel Filter inlet for mechanical
1 Hollow Bolt M14x1.5 20 + 6
feed Pump
1 Hollow Bolt M14x1.5 Pipe, Fuel Filter inlet NRV 20 + 6

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Page - 4
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

Assy, Fuel Injector and Valve 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

Descri Torque Relieve Torque Torque Torque Torque Torque

Qty. Size Application
ption (Nm) to (Nm) (Nm) 1 (°) 2 (°) 3 (°) Range

Screw- Fastening
1 Screw M6 1+0.5 0 4±1 90 90 30 7+6
Bridge Fuel Injector

Intake Manifold
Qty. Description Size Application Torque(Nm)

Intake Manifold to
12 Bolt M8x35 24 ± 2
Cylinder Head
Intake Manifold to
12 Bolt M8x80 24 ± 2
Cylinder Head
1 Hollow Bolt M12X1.5 Tube-Intake Manifold to FIP 20 + 6

Exhaust Manifold
Qty. Description Size Application Torque(Nm)
Exhaust Manifold to
12 Stud M10x45 6±2
Cylinder Head
Exhaust Manifold to stud
12 Stover Nut M10 70 ± 10
Cylinder Head

Exhaust Elbow
Qty. Description Size Application Torque(Nm)
4 Stud M10 Exhaust Elbow to Turbocharger 6 ± 2
Exhaust Elbow to
4 Stover Nut M10 60 ± 10
Turbocharger

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Page - 5
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

Crankshaft Pulley
Qty. Description Size Application Torque (Nm)

Crankshaft Pulley to 1st 2nd

4 Cylindrical Bolt M16x65
Crankshaft 100 ± 10 275 ± 15
9 Bolt M8 Damper to Crankshaft Pulley 35 ± 5

Oil Suction Pipe

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)

3 Bolt M8x20 Water Inlet connection 20 ± 3

Engine Breather
Qty. Description Size Application Torque(Nm)

1 Bolt M8x20 Breather to Block 25 ± 5

Engine breather tube to

1 Bolt M8x16 10 + 2
Breather housing

Oil Pan

Qty. Description Size Application Torque(Nm)

34 Bolt M8x16 Oil Pan to Block 25 + 5

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Page - 6
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

Flywheel
Qty. Description Size Application Torque (Nm)
1st 2nd
8 Cylindrical Bolt M16x35 Flywheel to Crankshaft
100 ± 10 275 ± 15

Flywheel Housing
Qty. Description Size Application Torque(Nm)
13 Bolt M12x30 Flywheel Housing to Block 100 ± 5

Lubricating Oil Flilter Head and Oil Cooler

Qty. Description Size Application Torque(Nm)
10 Screw M8x 40 oil cooler to block 25 ± 3
1 Hollow Bolt M14X1.5 Adapter 25 + 5

Standard Torque Table for Normal Steel Bolts

(According to DIN 2230)
Bolt Class ( Nm)
Nominal Size
8.8 10.9 12.9
M5 6±1 9±1 10 ± 1.5
M6 10 ± 1.5 15 ± 2 18 ± 3
M8 25 ± 4 37 ± 6 43 ± 7
M10 50 ± 8 73 ± 11 84 ± 13
M12 86 ± 13 124 ± 19 145 ± 22
M14 135 ± 20 198 ± 30 231± 35
M16 207 ± 31 304 ± 46 325 ± 49
M18 298 ± 45 424 ± 64 497 ± 75
M20 418 ± 63 595 ± 89 696 ± 104
M22 569 ± 85 810 ± 122 948 ± 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 .
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Page - 7
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

GENSET ENGINE ADD-ON COMPONENTS

Intake Curve
Qty. Description Size Application Torque(Nm)
Screw, Hex. Flanged
3
head
M8x35 Intake curve to intake manifold 20 ± 3 2
1 Stud M8x25 Intake curve to intake manifold 6±2 2
1 Nut, Hex. M8x8 Intake curve to intake manifold 20 ± 3 2
2 Plug, Allen Tapered M22 X 1.5 X 5.8 For Plugging Heater Holes 30 ± 5
Air Cleaner Assembly
Qty. Description Size Application Torque(Nm)
Clamping Hose ,Air cleaner-
Clamp SAE J1 508 SAE No.-
1 Turbocharger to Air Cleaner 7.3 ± 1.3
Type SLTB 142
Assembly
Air Cleaner Assembly to
4 Screw, Hex. M8x20 25 ± 4
Air cleaner Mounting Bracket
Clamp SAE J1 508 SAE No.- Clamping Hose ,Air cleaner-
1 7.3 ± 1.3
Type SLTB 110 Turbocharger to Turbocharger
Screw, Serrated Hex. Air cleaner Mounting Bracket to
2 M12x30 70 ± 10
flanged head Cylinder Block
Fan Assembly
Qty. Description Size Application Torque(Nm)
6 Screw, Hex. Flanged head M8x20 Fan Hub to Fan(30 inch) 25 ± 4
Screw, Serrated Hex.
6 M10X70 Fan pulley to Fan Hub and Fan 50 ± 8
Flanged head
Fan Bracket to Spacer mounted
2 Bolt, Hex. Flanged head M8X35 25 ± 4
on cylinder Head bolts
1 Bolt, Hex. Flanged head M10x50 Fan Bracket to Timing case 50 ± 8
Housing Fan Bearing to Fan
4 Bolt, Hex. Flanged head M10x35 50 ± 8
Bracket
Tensioner Pulley to Lever belt 2
1 Screw, Hex. Flanged head M10X20 40 + 6
Tensioner
Lever belt tensioner to Fan
2 Screw, Hex. Flanged head M8X25 25 ± 4
Bracket
2 Screw, Hex. Flanged head M8X80 Fan Bracket to Timing 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
Water Flow Tube Assembly
Qty. Description Size Application Torque(Nm)

1
Temparature sensor
cum Switch
M14 X 1.5 X 11 Sensor fitted in water flow tube Max. 20 2
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Page - 8
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

Fuel Filter Assembly

Qty. Description Size Application Torque(Nm)
1 Banjo bolt M12X1.5X8.8 Fuel Pump end to NRV pipe 23 ± 3 2
Turbocharger Bracket Assembly
Qty. Description Size Application Torque(Nm)
Screw, Hex. Flanged M8 x 30 X Elbow, turbocharger Mounting bracket
1 25 + 5
Head 1.25 X 10.9 to turbocharger
Screw, Hex. Flanged M8 x 25 X Turbocharger Mounting bracket to
1 25 + 5
Head 1.25 X 8.8 Elbow, turbocharger

Gear Case Assembly

Qty. Description Size Application Torque(Nm)
Air compressor closing plate to Gear
3 Screw, Hex. Flanged M10X30X8.8 45± 5 2
Case

Intake Manifold Assembly

Qty. Description Size Application Torque(Nm)

1 Plug, Allen Tapered M12 X 1.5 X 5.8 For Pluging Intake manifold Hole 10± 2 2
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 2
1 Adapter M14X1.5X8.8 Feed Pump adapter to Timing case 30 ± 4

Starter Motor Assembly

Qty. Description Size Application Torque(Nm)

3 Screw, Hex. Flanged M10 X 20 X 8.8 Starter Motor (24V) Mounting 45± 5 2

Cylinder Block
Qty. Description Size Application Torque(Nm)
Plugging Compressor inlet Hole in
1 Plug, Allen Tapered M14 X 1.5 X 5.8
Cylinder block
10+5 2

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Page - 9
 MN/ETD 30
ENGINEERING TECHNICAL DOCUMENT
REV 02

Radiator & Intercooler

Qty. Description Size Application Torque(Nm)
SAE No.- Hose clamp for intake curve to
2 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
76 intercooler
SAE No.- Hose clamp for Elbow Turbocharger to
2 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
76 Tube, turbocharger-intercooler
SAE No.- Hose Clamp for Tube, turbocharger-
2 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
76 intercooler to Intercooler inlet
SAE No.- Hose Clamp for Engine Water Outlet
2 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
42 pipe
SAE No.- Hose clamp for Engine Water outlet pipe
1 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
42 to Hose, Radiator side
SAE No.- Hose clamp for Engine Water outlet pipe
1 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
34 to hose at Radiator inlet
SAE No.-
2 Clamp SAE J1 508 Type SLTB Hose clamp on Engine Water inlet pipe 7.3 ± 1.3
42
SAE No.- Hose clamp on small end of reducer hose
1 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
42 at radiator outlet
SAE No.- Hose Clamp on reducer hose at radiator
1 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
48 outlet

Engine Mounting Foot

Qty. Engine Size Application Torque(Nm)
Screw, Serrated Hex.
8 M12x30 Engine Mounting Foot to Cylinder Block 70 ± 10
Flanged head
Lubricating Oil Filter Head and Oil cooler
Qty. Engine Size Application Torque(Nm)
Oil Pressure sensor Oil Pressure sensor cum switch mounted
1
cum switch
M12x12
at Oil Filter Head
Max. 50 2
Alternator 24 V Assembly
Qty. Description Size Application Torque(Nm)
Pull rod, Alternator Bracket to Main
2 Screw, Hex. Flanged head M8 x 20 20 ± 3
Alternator Bracket
Pull rod, Alternator Bracket to
1 Screw, Hex. Flanged head M12 x 35 70 ± 10
Alternator (Charging)
Main Alternator Bracket to
1 Screw, Hex. Flanged head M10 x 110 40 ± 6
Alternator (Charging)
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 Milind Khanolkar Sachin Mahajan Amol Relkar Cesar Almeida
24 Dec. 2010 Prepared Checked Verified Approved
PRINTED COPIES ARE NOT CONTROLLED SHEET
This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore, it must not be copied, 10/10
wholly or partly, or retransmitted without previous authorization. All rights reserved.

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