Navistar O & M Manual

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.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
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.manufacturers.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
Engine Model
Prime rating
No. 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 6.12 TCA 6.12 TCA

6.12 TCE
S12-III
S12-II
S12-I
SE12-I
125
140
160
180
KVA
No
6
6
6
6
Inline
Inline / V type
7.12
Ltrs
105
mm
mm
137
kW
114.8
128.1
146.5
163.0
hp
156
174
199
221.2
kW
125.6
139.9
160.0
178.0
hp
170.6
190.1
217.5
242
%
5
5
5
5
rpm
1500
1500
1500
1500
24V ELEC
Turbocharged Aftercooler
NA/TC/TCA
16.8:1
16.8:1
16.8:1
16.8:1
No
Bar
mm
Ltr
CFM
KW
Deg C
12.9
14.1
25
10000
6
14.4
15.7
16.4
18
1-5-3-6-2-4
Radiator
By Water
831x390.5x1135
25
25
11800
11800
7
7
105
18.3
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
148.7
147.2
157.5
+5
145.7
145.0
156.0
+5
145.0
145.0
152.4
+5
142.0
143.5
148.7
+5
27.45
20.38
14.54
30.01
22.39
16.06
34.15
25.61
17.94
37.18
28.18
19.46
ENGINE TECHNICAL SPECIFICATION

Engine series
Engine Model
Prime rating
1)FUEL INJECTION PUMP
Make
Type
2)GOVERNER DATA
No
KVA
6.12 TCA 6.12 TCA 6.12 TCA

S12-III
S12-II
S12-I
125
140
160
6.12 TCE
SE12-I
180
STANADYNE MAKE
Rotary
Bosch Make
HPCR
MECHANICAL
(3- 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. 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 - with clean element
Air intake restriction - 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
0.014
0.015
0.017
0.02
15W40 API CI4
Full flow: Spin on cartridge type with Paper
element
15
500
Min:-10 & Max:125
Must be greater than 1.2 at idling condition &
3.5 at rated
19.8 speed
558
59.73
14.74
82.39
12.1
535
Residential Type
Complies with CPCB norms
75
603
664
800
600
650
62.22
19.33
101.19
12.89
70.98
22.49
110.58
14.38
Dry type Air cleaner

230
600
20
55
580
637
78
32.9
127.9
16.07
750
< 75 dBA for genset with canopy

1727X932X1274.4
mm
598.6
kg
Kg/Kw
5.21
4.67
610
4.09
3.74
Fuel System
2-2
Description
6 cylinders
Maximum fuel inlet restriction

(for gears pump)
0.6 to 1.2 bar
Fuel pressure range in the

fuel filter outlet (at crank
speed)
9.7 to 12.8 bar
Range of fuel pressure in fuel

filter fuel inlet (at operation
speed)
10.5 to 13 bar
Maximum pressure load

reduction in the fuel filter
0.8 bar
lubrication System
Description
MaxxForce 7.2
Oil pressure
Nominal speed
Idling speed
5.3 bar (hot engine)

3.5 bar (hot engine)
Oil temperature
Nominal
Maximum
90 - 110 C
120 C
Oil capacity
19.8 l
cooling System
MaxxForce 7.2
Description
Volume of water in the
engine, without radiator
9l
Water temperature
Nominal
Maximum
80 - 90 C
100 C
thermostat
Thermostat
0304CAV00010N
Opening
beginning
Total
opening
Maximum opening
course
79 2C
90C
10.0 mm
Page - 9
engine Description
2-4
FeatureS
MAXXFORCE 7.2 is in-line six cylinder engines with 7.2 Litre displacement.
The firing order of the cylinders is 153624
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. Its 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 its 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
2
1
toP VIeW
1. Coolant temperature sensor (ECT)
2. Valve cover
Page - 12
technIcal Data
Front VIeW
1. Water bypass tube assembly thermostat outlet
2. Alternator
3. Pulley
4. Vibration damper
5. Front cover
Page - 14
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
Page - 15
2-10
5
7
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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6-9
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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
3-2
Before operating the MAXXFORCE 7.2 engine check:
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.
Page - 1
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)
Page - 2
FuEL INjEcTION SySTEM
Page - 3
FuEL INjEcTION SySTEM
Page - 2
NOTEs
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6-9
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LuBRIcANTINg OIL
Oil Level check
3-4
Stop the engine and wait 30 minutes so that the oil can
flow back to the carter.
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
3-10
Remove the old filter.
Clean the sealing area of the flter with a clean cloth.
Prime the new filter with clean and fresh oil and fix.(Use always GENIUNE spares).
Lubricate the flter gasket and tighten it.
Run the engine and check the oil leakages.
Stop the engine and, after 30 minutes, check oil level Topup if Necessary.
Oil Element
REMOvAL
1. Remove the drain plug (R ) and discard the
washer. Drain engine oil and dispose of used
engine oil according to applicable laws.
2. Using the wrench indicated, unscrew the filter
Page - 8
INSTALLATION
1. Clean area around oil filter head, clean gasket
surface of filter head.
2.
3.
4. Tighten the filter untill the gasket contacts the filter

head surface.
Lubricate oil filter gasket with fresh engine oil.
Fill the oil filter with fresh engine oil.
5. Use oil filter wrench to tighten the filter

an additional 3/4 of a turn.
6. Operate the engine and check for leakages
Page - 9
Lubrication system
OIL LubRIcATION cIRcuIT
12-2
Page - 1
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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6-9
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Cooling System
COOLINg CIRCuIT
Page - 1
NOTEs
____________________________________________________________________
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6-9
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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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6-9
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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
dRAIN ENgINE FLuIdS
ENgINE STARTINg Preparation
draining the Oil
cLEAN ENgINE
Warning:
To avoid serious personal injury,

possible death, or damage to
the engine or Genset, read all
safety instructions in the Safety
Information section of this
manual.
1. Cap all turbocharger and manifold openings

to prevent water and degreased agents from
entering any engine components internally.
2. Use an appropriate detergent mixed in the correct
ratio of water and applies to engine using a warm
water and moderate pressure washer or similar
cleaning equipment.
NOTE
:
Do not use high pressure or excessive

hot water temperature as it may damage
the engine components.
NOTE
:
Do not use solvent, thinner or any

product that derivates from petrol as
these products may damage the wiring
harness and other plastics made
components.
Page - 7
1. Place an oil drain pan beneath the oil drain plug to

collect the oil.
2. Remove oil pan drain plug (R ) and washer.
Drain engine oil and dispose of used engine oil
according to applicable laws.
3. Discard washer, inspect drain plug and replace if
necessary. Place a new washer onto drain plug
and install to oil pan. Apply the torque of 55 to
75 N.m.
6 cylinders Engine
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
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 - 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 7.2 Mechanical
NOTEs
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6-9
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Group - 17
APPendIx A
MN/ETD 30
REV 02
ENGINEERING TECHNICAL DOCUMENT
TORQUE CHART ( 6.12 TCA MECHANICAL GENSET ENGINE)

Engine Block
Qty.
2
Description
Size
Bolt
Qty.
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 - 5
Torque(Nm)
10 + 5
10 1.5
15 + 5
2nd
155 5
Torq. Range
170 to 282
Required Sealing
Loctite 567
**
Loctite 567
Connecting Rod
Qty.
2
Description
Bolt
Size
Application
Torque (Nm)
MJ
12x58
Connecting Rod to
Crankshaft
Size
Application
1st
40 5
2nd
80 2
Torq. Range
130 to 160
Camshaft
Qty.
Description
Torque (Nm)
1st
2nd
Torq. Range
30 2
35 to 65
25 4
Bolt
M8x25
Gear to Camshaft
Bolt
M8x16
Camshaft Lock to Block
Qty.
Description
Size
Application
Torque(Nm)
Bolt
M8x20
Oil Pump to Block
20 5
15 1
Oil Pump
Water Pump
Qty.
Description
Size
Application
Torque(Nm)
Bolt
M8x20
Water Pump to Block
20 5
PRINTED COPIES ARE NOT CONTROLLED

This is document is property of MAHINDRA NAVISTAR ENGINES LTD Therefore, it must not be copied,
wholly or partly, or retransmitted without previous authorization. All rights reserved.
Page - 1
SHEET
1/10
MN/ETD 30
REV 02
Gear Housing
Qty.
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 2.5
7.5 2.5
60 5
10 5
20 3
Size
M10x1
M12x1.5
Application
Valve Lubrication pipe to Cylinder Head
Valve drive Lubrication Pipe to Oil cooler
Torque(Nm)
10 + 5
10 + 5
Valve Lubrication Pipes

Qty.
6
1
Description
Hollow Bolt
Hollow Bolt
Front Cover
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
Bolt
M10x35
Bolt
M10x20
Pulley to Alternator Bracket
40 6
40 6
Water Outlet Pipe

Qty.
Description
Size
Application
Torque(Nm)
12
Bolt
M8x55
Water Outlet Pipe to Cylinder Head
25 4
Bolt
M8x30
Connection water outlet
25 3
Bolt
M8x30
Connection by pass
25 3

Page - 2
SHEET
2/10
MN/ETD 30
REV 02
Qty.
Description
Size
Application
Torque(Nm)
Hollow Bolt
M12
Water outlet tube to degassing tank
20 3
Nipple
M22
Nipple Bypass connection for AC application
40 5
Plug
M22X1.5
Plug, 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)
62
70 10
V band clamp elbow-turbo to Turbocharger
10 + 2
Turbocharging
Qty.
4
4
Description
Stud
Stover Stud
Size
M10x25
M10
Hollow Bolt
M14x1.5
Hollow Bolt
M14x1.5
Bolt
M8x20
Bolt
M8x16
V band Clamp
--
25 5
25 5
20 3
25 + 5
Cylinder Head
Qty.
Description
Size
20
Bolt
M14x152
Bolt
M14
Engine lifting
hook
M12
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
51
Description
Socket head
cap screw
Nut
M22
High pressure connector nut
50 + 5
Nut
M8x10
Nut Valve clearance adjustment
20 + 5

Page - 3
SHEET
3/10
MN/ETD 30
REV 02
High Pressure Pump

Qty.
Description
Size
Application
Torque(Nm)
Stud
M8 X 30
High Pressure Pump adaptor

to Gear Housing
81
Nut
M8
High Pressure Pump to Gear Housing
38 3
Nut
M14x1.5
Gear to High Pressure Pump
180 5
Hollow Screw
M12
High Pressure Pump Tube ,Fuel Return
22.5 2.5
Connector
M8
Connector for Boost pressure
10 + 5
Box Nut
M10x1
Tube, Injection Pump to Intake manifold
12.5 2.5
Size
Application
M8x1
Pipe, Fuel Return to Cylinder Head
Low Pressure Pipe

Qty.
Description
Connection
Torque(Nm)
81
High Pressure Pipe

Qty.
Description
Size
Application
Torque(Nm)
Nut
M12
Nut high pressure tube to

fuel injection pump
15 + 5
Nut
M14
Nut high pressure tube to

Connector high pressure tube
25 + 5
Qty.
Description
Size
Application
Torque(Nm)
Bolt
M10x30
Fuel Filter to Block
35 4
Connection
M14x1.5
Fuel inlet to Filter Head
20 + 6
Hollow Bolt
M12x1.5
Pipe, Fuel Filter outlet to VE Pump
20 + 6
Hollow Bolt
M14x1.5
Pipe, Fuel Filter inlet for mechanical

feed Pump
20 + 6
Hollow Bolt
M14x1.5
Pipe, Fuel Filter inlet NRV
20 + 6
Fuel Filter

Page - 4
SHEET
4/10
MN/ETD 30
REV 02
Assy, Fuel Injector and Valve Cover

Qty.
Description
Size
Application
Torque(Nm)
Screw
M6
Special Step Bolt Fuel injection Clamp
4 1
Bolt
M6 x 60
Valve Cover
8.5 1
Qty.
Descri
ption
Size
Screw
M6
Application
Screw- Fastening
Bridge Fuel Injector
Torque
(Nm)
Relieve
to (Nm)
1+0.5
Torque
(Nm)
Torque
1 ()
41
90
Torque Torque Torque

2 ()
3 () Range
90
30
7+6
Intake Manifold
Qty.
Description
Size
Application
Torque(Nm)
12
Bolt
M8x35
Intake Manifold to
Cylinder Head
24 2
12
Bolt
M8x80
Intake Manifold to
Cylinder Head
24 2
Hollow Bolt
M12X1.5
Tube-Intake Manifold to FIP
20 + 6
Size
Application
Exhaust Manifold to
Cylinder Head
Exhaust Manifold to stud
Cylinder Head
Exhaust Manifold
Qty.
Description
12
Stud
M10x45
12
Stover Nut
M10
Torque(Nm)
62
70 10
Exhaust Elbow
Qty.
Description
Size
Application
Torque(Nm)
Stud
M10
Exhaust Elbow to Turbocharger
6 2
Stover Nut
M10
Exhaust Elbow to
Turbocharger
60 10

Page - 5
SHEET
5/10
MN/ETD 30
REV 02
Crankshaft Pulley
Qty.
Description
Size
Application
Cylindrical Bolt
M16x65
Crankshaft Pulley to
Crankshaft
Bolt
M8
Damper to Crankshaft Pulley
Torque (Nm)
1st
2nd
100 10
275 15
35 5
Oil Suction Pipe

Qty.
Description
Size
Application
Torque(Nm)
Bolt
M8x20
Oil Suction Pipe to Block
25 4
Water Inlet Manifold

Qty.
Description
Size
Application
Torque(Nm)
Bolt
M8x20
Water Inlet connection
20 3
Engine Breather
Qty.
Description
Size
Application
Torque(Nm)
Bolt
M8x20
Breather to Block
25 5
Bolt
M8x16
Engine breather tube to

Breather housing
10 + 2
Qty.
Description
Size
Application
Torque(Nm)
34
Bolt
M8x16
Oil Pan to Block
25 + 5
Oil Pan

Page - 6
SHEET
6/10
MN/ETD 30
REV 02
Flywheel
Qty.
8
Description
Cylindrical Bolt
Size
Application
M16x35
Flywheel to Crankshaft
Torque (Nm)
1st
2nd
275 15
100 10
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
10
Screw
Hollow Bolt
Size
M8x 40
M14X1.5
Application
Torque(Nm)
oil cooler to block
25 3
Adapter
25 + 5
Standard Torque Table for Normal Steel Bolts

(According to DIN 2230)
Nominal Size
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
Bolt Class ( Nm)

10.9
91
15 2
37 6
73 11
124 19
198 30
304 46
424 64
595 89
810 122
8.8
61
10 1.5
25 4
50 8
86 13
135 20
207 31
298 45
418 63
569 85
12.9
10 1.5
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 isnt referred in the Service Manual. For all other conditions
use the special torques provided by the related procedures .

Page - 7
SHEET
7/10
MN/ETD 30
REV 02
GENSET ENGINE ADD-ON COMPONENTS
Intake Curve
Qty.
Description
Size
Application
Torque(Nm)
M8x35
Intake curve to intake manifold
20 3
M8x25
62
Screw, Hex. Flanged

head
Stud
Nut, Hex.
M8x8
20 3
Plug, Allen Tapered
M22 X 1.5 X 5.8
For Plugging Heater Holes
30 5
2
2
2
Air Cleaner Assembly

Qty.
Description
Size
Clamp SAE J1 508

Type SLTB
SAE No.142
Screw, Hex.
M8x20
Clamp SAE J1 508

Type SLTB
Screw, Serrated Hex.
flanged head
SAE No.110
1
2
Application
Clamping Hose ,Air cleanerTurbocharger to Air Cleaner
Assembly
Air Cleaner Assembly to
Air cleaner Mounting Bracket
Clamping Hose ,Air cleanerTurbocharger to Turbocharger
Air cleaner Mounting Bracket to
Cylinder Block
M12x30
Torque(Nm)
7.3 1.3
25 4
7.3 1.3
70 10
Fan Assembly
Qty.
6
6
Description
Screw, Hex. Flanged head
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
Bolt, Hex. Flanged head
M8X35
M10x50
M10x35
M10X20
M8X25
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
Hexagonal Spacer
M12X1.5
Spacer mounted on cylinder Head
50 8
M10x50
Bolt to Fan shaft
50 8
25 4
50 8
50 8
40 + 6
25 4
25 4
Water Flow Tube Assembly

Qty.
Description
Size
Application
Torque(Nm)
Temparature sensor
cum Switch
M14 X 1.5 X 11
Sensor fitted in water flow tube
Max. 20

Page - 8
SHEET
8/10
MN/ETD 30
REV 02
Fuel Filter Assembly

Qty.
Description
Size
Application
Torque(Nm)
Banjo bolt
M12X1.5X8.8
Fuel Pump end to NRV pipe
23 3
Turbocharger Bracket Assembly

Qty.
1
1
Description
Screw, Hex. Flanged
Head
Screw, Hex. Flanged
Head
Size
M8 x 30 X
1.25 X 10.9
M8 x 25 X
1.25 X 8.8
Application
Elbow, turbocharger Mounting bracket
to turbocharger
Turbocharger Mounting bracket to
Elbow, turbocharger
Torque(Nm)
25 + 5
25 + 5
Gear Case Assembly

Qty.
Description
Size
Application
Torque(Nm)
Screw, Hex. Flanged
M10X30X8.8
Air compressor closing plate to Gear

Case
45 5
Intake Manifold Assembly

Qty.
Description
Size
Application
Torque(Nm)
Plug, Allen Tapered
M12 X 1.5 X 5.8
For Pluging Intake manifold Hole
10 2
Feed Pump Assembly

Qty.
3
Description
Allen bolt
Size
M6X16X8.8
Application
Feed Pump mounting to Gear case
Torque(Nm)
10 1.5
Screw, Hex. Flanged
M8 X 25X 1.25 X 8.8
Feed Pump mounting to Gear case
25 4
2
1
Banjo bolt
Adapter
M14X1.5X8.8
M14X1.5X8.8
Feed Pump Inlet/Outlet

Feed Pump adapter to Timing case
23 3
30 4
Starter Motor Assembly

Qty.
Description
Size
Application
Torque(Nm)
Screw, Hex. Flanged
M10 X 20 X 8.8
Starter Motor (24V) Mounting
45 5
Cylinder Block
Qty.
Description
Size
Application
Torque(Nm)
Plug, Allen Tapered
M14 X 1.5 X 5.8
Plugging Compressor inlet Hole in

Cylinder block
10+5

Page - 9
SHEET
9/10
MN/ETD 30
REV 02
Radiator & Intercooler

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

at radiator outlet
Hose Clamp on reducer hose at radiator
outlet
7.3 1.3
7.3 1.3
Engine Mounting Foot

Qty.
Engine
Flanged head
Size
Application
Torque(Nm)
M12x30
Engine Mounting Foot to Cylinder Block
70 10
Lubricating Oil Filter Head and Oil cooler

Qty.
Engine
Oil Pressure sensor
cum switch
Size
Application
Oil Pressure sensor cum switch mounted
at Oil Filter Head
M12x12
Torque(Nm)
Max. 50
Alternator 24 V Assembly
Qty.
Description
Size
M8 x 20
M12 x 35
M10 x 110
Application
Pull rod, Alternator Bracket to Main
Alternator Bracket
Pull rod, 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 isnt referred in the Service Manual. For all other conditions
use the special torques provided by the related procedures .
Release Date
24 Dec. 2010
Milind Khanolkar
Prepared
Sachin Mahajan
Checked
Amol Relkar
Verified
Cesar Almeida
Approved

Page - 10
SHEET
10/10
APPendIx A
Page - 11
NOTEs
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6-9
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NOTEs
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6-9
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____________________________________________________________________

Navistar O & M Manual

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OPERATION AND MAINTENANCE MANUAL

How to use this Manual

Information on Metric System

Important Safety remarks

cleaning General Instructions

engine Serial number Identification and location

6.12 TCA Engine Data Plate:

Fuel.Injection. Pump (Stanadyne Rotory)

Engine Exploded View

ENGINE TECHNICAL SPECIFICATION

6.12 TCA 6.12 TCA 6.12 TCA

High speed Diesel(HSD IS 1460:2005)

ENGINE TECHNICAL SPECIFICATION

6.12 TCA 6.12 TCA 6.12 TCA

Dry type Air cleaner

< 75 dBA for genset with canopy

Maximum fuel inlet restriction

0.6 to 1.2 bar

Fuel pressure range in the

9.7 to 12.8 bar

Range of fuel pressure in fuel

Maximum pressure load

5.3 bar (hot engine)

engine component locations

leFt VIeW (colD SIDe)

rIGht VIeW (hot SIDe)

OPERATION ANd MAINTENANcE

Operation and Maintenance

Before operating the MAXXFORCE 7.2 engine check:

To maximize the turbo lifetime follow these cautions:

Do not accelerate the engine immediately after the start.

OPERATION ANd MAINTENANcE

Carefully check if engine oil level is correct;

Carefully check if water level of the engine cooling system is correct;

Strictly follow the maintenance instructions.

FuEL INjEcTION SySTEM

FuEL INjEcTION SySTEM

Before pulling oil dipstick, clean the surroundings.

If necessary, Topup up to the ' H' mark, without exceeding it.

Use only recommended lubricant oil ( 15W40 API CI4 ).

Do not mix different oil brands.

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.

Always use MNEPL recommended genuine engine oil

check Lubricant oil condition

Lubricant Oil Specifications

Do not mix different oil brand / grade. Use only

Oil Filter change

Remove the old filter.

Clean the sealing area of the flter with a clean cloth.

Lubricate the flter gasket and tighten it.

Run the engine and check the oil leakages.

2. Using the wrench indicated, unscrew the filter

4. Tighten the filter untill the gasket contacts the filter