O&M Manual For 4.12TCA & 6.12TCA

Operation and Maintenance Manual

mPower 4.12 & 6.12 TCA
Mahindra Heavy Engines Pvt. Ltd.

Part No : 0301BAV0003LA Plot NO# A-1/1, Chakan Industrial Area
Rev Date : 01-05-2013 PHASE- IV, Village Nigoje, Chakan
Rev No : 01 Tal Khed, Dist Pune -410501
General Information
INDEX
Introduction 5
Important Safety Remarks INDEX 6-8
General Instructions 9-10
Cleaning Instructions 11
Engine Serial No Identification and Location 12
Engine Identification 13-14
Cylinder Numeration 15
Engine Accessories 16
Engine Exploded View 17-20
Engine Technical Data 21-28
Engine Specifications 29-30
Engine Features 31-32
3
General Information
INDEX
Accessories Features 33
Engine Views 34-37
Engine Operation 38-40
Fuel specifications 41
De-Aeration of fuel system 42
Lubrication System 43-49
Coolant System 50-54
Maintenance Table Genset engines 55
Maintenance Table Industrial engine 56
Conservation of Inactive engines for Long period 58-59
Troubleshooting 60-93
4
Introduction
This manual was developed to supply the customers with all information in order to provide the correct operation and
maintenance for the mPOWER 4.2 TCAand6.12 TCA series engines manufactured by Mahindra Heavy Engines Pvt. Ltd.
mPOWER engines have several variations as it is catered to several applications. Due to this, the information presented in this
manual is general and does not intend to cover each possible application. The information of the Original Equipment
manufacturers where the mPOWER engine is installed prevails over the information contained in this manual.
Read and follow all safety instructions. Consult the item ATTENTION 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 as
indicated in the procedures.
The specifications and information presented in this manual are the ones which is effective at the moment of its print.
Mahindra Heavy Engines Pvt. Ltd. reserves the right of making changes in the product at any moment without prior
intimation, this to incur in any further obligation. In case of any difference in the engine or information of this manual, contact
MHEPL Authorized Distributor or the factory.
The components used in MHEPL engines are produced with latest generation technology with high level of quality standards.
When parts changes are necessary, it is recommended to use only MHEPL genuine spare parts for longer durability and
efficient engine performance.
5
Important Safety Remarks
Attention: Incorrect procedures and lack of care can cause burns, cuts, mutilation,
asphyxia or other injuries and even death.
Carefully read all safety procedures and remarks, before performing any activity on 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.
a] 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.
b] Always use individual protection equipments (safety eyeglasses, gloves, shoes, etc) while you are working.
c] Remember that parts in movement can cause cuts, mutilation and strangling.
d] Do not use loosen or ripped clothes. Remove jewellery and watches before working.
e] In case of industrial engines, place a “Do Not Operate” warning in the operator compartment or on the controls
6
g] 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.
h] 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.
i] If the engine was in operation and the cooling fluid is hot, leave the engine to cool down before slowly open the cover o f
the reservoir to relief the pressure of the cooling system
j] Do not work with materials that are lifted by jacks or cranes.
k] Always use correct blocks, stands or brackets to position the engine before performing any repair.
l] 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.
m] 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.
7
m] Never leave the engine operating in a closed and non ventilated area. The engine exhaust gases are harmful to health.
n] The MNEPL recommended 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.
o] 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.
p] 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.
q] To avoid burns, pay attention to hot spots on engines that have just been stopped, and to hot piping and compartments.
r] Always use tools in good conditions. Make sure that you know how to handle the tools before beginning any repair. U s e
ONLY genuine MNEPL spare parts.
s] Some international public health institutions proved that used lubricant oil can be cancerous and contaminates the
human reproducer system. Avoid inhaling vapors ingesting or keeping prolonged contact with these substances.
8
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.
a] Use good quality fuel, free of water and impurities
b] Use only recommended lubricant oil
c] In case of any irregularity seek for a dealer or authorized service personnel of the equipment manufacturer or MHEPL.
Avoid that outsiders make any service in the engine because this cancels the warranty agreement.
d] To use a parallel battery to start the engine ,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, not to invert the poles .
9
Attention :
a] Never perform service on any component of system while the engine is running.
b] Do not smoke while in servicing on the fuel system or any other system of the engine.
c] Avoid contact while electric components that may produce sparks.
d] Always check fuel tank, piping, hoses and other components of the fuel system for leakages.
e] Do not bleed the fuel injection system with the engine in operation. The high pressure in the system can cause s e r i o u s
injuries if disassembled.
10
Cleaning General Instructions

Several solvents and acid substances can be used to clean the parts of the engine Mahindra Heavy Engines (P) 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 not to 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] Fuel Injection pump;
5] Belts, pipes and hoses;
6] Bearings
11
Engine Serial Number Identification and location

The engine identification and serial number can be found in the following places:
1. Identification plate on the inlet manifold
2. Engraving on the right side of the engine block, close to the cylinder head of the cyl #3
6.12 TCA Engine Data Plate
12
Engine Identification
4. 12 TC A
After cooler
Turbo Charged
Series
No of Cylinders
13
Engine Identification
6. 12 TC A
After cooler
Turbo Charged
Series
No of Cylinders
14
Cylinders Numeration
The cylinders order starts from the flywheel, according to the illustration below.
FIRST CYLINDER
15
Engine Accessories
The following engine accessories have manufacturer’s labels or identification plates:
• Turbocharger
• Fuel Injection Pump (Stanadyne rotary)
• Fuel Injection Pump (Bosch Rotary for specific industrial application)
• Starter Motor 24V (Lucas)
• Starter Motor 12V (Bosch)
• Charging Alternator 24V (Lucas)
• Charging Alternator 12V (Bosch)
• Air Compressor (for specific applications only)
Labels or identification plates include information and specifications helpful to equipment operators and technicians.
16
17
18
1 ENGINE BLOCK 31 VALVE COVER 61 FRONT OIL SEAL 90 THEMOSTAT CONNECT HOSE 118 ACCELERM OR BRACKET 148 FLYWHEEL
2 CYLINDER HEAD GASKET 32 VALVE COVER BOLT 62 FRONT COVER GASKET 91 NIPPLE 119 FIP BRACKET BOLT 149 RING GEAR
3 SEAT-INTAKE VALVE 33 VALVE SETTING NUT 63 FRONT COVER 92 WATER OUTLET TUBE BOLT 120 FUEL FILTER 150 FLYWHEEL HOUSING
4 INTAKE VALVE 34 SEAT-PIVOT ROCKER ARM 64 FRONT COVER BOLT 93 O'RING 121 FUEL FILTER ADAPTER 151 REAR OIL SEAL
5 EXHAUST VALVE 35 FASTNING BRIDGE 65 DAMPER 94 WATER OUTLET TUBE 122 NON RETURN VALVE 152 COVER PLATE
6 SEAT-EXHAUST VALVE 36 LINER RING 66 DAMPER RING 95 BY-PASS CONNECTION BOLT 123 FILTER TO FIP PIPE 153 COVER PLATE BOLT
7 CYLINDER HEAD 37 LINER 67 INSPECTION COVER 96 SEALING WASHER 124 FUEL RETURN PIPE 154 BOLT-FLYWHEEL
8 LINER 0-RING 38 CONNECTING ROD 68 CRANK SHAFT PULLEY 97 BANJO BOLT 125 BANJO BOLT 155 OIL PAN
9 FUEL INJECTOR 39 CONNECTING ROD BOLT 69 V-BELT 98 CONNECTION BY-PASS 126 SEALING WASHER 156 OIL PAN GASKET
10 ENGINE LIFTING HOOK 40 CONNECTING ROD BEARING 70 CRANKSHAFT PULLEY BOLT 99 EXHAUST MANIFOLD NUT 127 FUEL RETURN TUBE 157 OIL PAN BOLT
11 CYLINDER HEAD BOLT 41 CONNECTING ROD BUSHING 71 FRONT COVER BOLT 100 EXHAUST ELBOW GASKET 128 INJECTOR CONNECTOR 158 OIL SUCTION TUBE
12 WELCH PLUG 42 CIRCLIP 72 NUT 101 EXHAUST MANIFOLD STUD 129 THRUST BEARING UPPER 159 DRAIN PLUG
13 TURBO OIL OUTLET GASKET 43 PISTON 73 A/C COMPRESSOR BRACKET 102 EXHAUST MANIFOLD GASKET 130 HOLLOW BOLT 160 DRAIN PLUG WASHER
14 SPRING RETAINER - LOWER 44 PISTON RINGS KIT 74 A/C COMPRESSOR 103 EXHAUST MANIFOLD 131 OIL PRESSURE SWITCH 161 PISTON PIN
15 CYLINDER HEAD BOLT 45 CRANK SHAFT 75 INTERMEDIATEGEAR 104 TURBOCHARGER ELBOW 132 OIL TUBE-FILTER TO MAIN 162 INTAKE DUCT BOLT
16 VALVE SPRING 46 BEARING CAP 76 TENSIONER PULLEY BOLT TUBE LINE 163 INTAKE ROCKER ARM
17 SPRING RETAINER - UPPER 47 BEARING CAP BOLT 77 ALTERNATOR BOLT 105 TURBO ELBOW BRACKET 133 PLUG 164 NIPPLE
BOLT 134 PLUG
18 VALVE LOCK 48 CRANKSHAFT GEAR 78 ALTERNATOR 165 CYLINDER HEAD
106 TURBO OIL RETURN TUBE 135 OIL FILTER HEAD LUBRICATION BOLT
19 VALVE SEAL 49 MAIN BEARING - LOWER 79 ALTERNATOR._BRACKET
107 T-BOLT CLAMP 136 OIL FILTER HEAD BOLT 166 SEALING WAHSER
20 ROCKER SHAFT 50 CRANKSHAFT BUSHING - 80 CLOSING PLATE
FRONT 108 TURBOCHARGER 137 OIL MAIN LINE BRACKET 167 TEE CONNECTION VALVE
21 EXHAUST ROCKER ARM 81 CLOSING PLATE GASKET
51 DEFLECTOR 109 EXHAUST COVER NUT 138 OIL TUBE- MAIN LINE TO 168 TURBO OIL RETURN TUBE
22 INJECTOR HOLDER 82 AIR COMPRESSOR ASSY.
52 LUBRICANT OIL EJECTOR 110 EXHAUST ELBOW CYLINDER HEAD CONNECTION
23 SPL. SCREW INJECTOR 83 HOSE-WATER OUTLET TUBE
HOLDER 53 CAM SHAFT TO COMPRESSOR 111 TURBO BRACKET 139 IDLER SHAFT 169 EXHAUST COVER STUD
24 A/C COMPRESSOR BRACKET 54 CAMSHAFT BUSHING 84 BREATHER HOSE CLIP & BOLT 112 EXHAUST MANIFOLD TURBO 140 BANJO BOLT 170 BANJO UNION
BOLT STUD 141 SEALING WASHER 171 SEALING WASHER
55 WATER PUMP GEAR 85 SEALING WASHER
25 INTERMEDIATE ROCKER ARM 113 TURBO ELBOW BRACKET 142 HIGH PRESSURE TUBE 172 BANJO BOLT
56 WATER PUMP 86 WATER TEMPERATURE
26 FASTNING BRIDGE BOLT SENSOR 114 EXHAUST MANIFOLD TURBO 143 INTAKE MANIFOLD 173 HOSE-COMPRESSOR TO
57 GEAR CASE NUT
27 PUSH ROD 87 WATER OUTLET CON PIPE 144 INTAKE COVER GASKET WATER OUTLET TUBE
58 FIP GEAR 115 FUEL PUMP
28 VALVE SETTING SCREW 88 BANJO UNION 145 INTAKE COVER 174 TIMING CASE CONNECTION
59 GEAR CASE LUBRICATION 116 FIP GASKET
29 TAPPET PIPE 89 SPRING CLAMP THEMOSTAT 146 INTAKE MANIFOLD BOLT 175 CLAMP IN BUSH, MAIN
CONNECTION HOSE 117 FIP BRACKET BEARING
30 VALVE COVER GASKET 60 TENSIONER PULLEY 147 INTAKE MANIFOLD GASKET
19
176 CAMSHAFT LOCK PLATE 191 MAIN BEARING UPPER 206 OIL COOLER BOLT 220 EXHAUST COVER WASHER 234 THRUST BEARING LOWER 249 GASKET
177 DOWEL PIN 192 CRANK SHAFT DOWEL PIN 207 OIL FILTER 221 TURBO OIL OUTLET FLANGE 235 FIP BOLT 250 PILOT BEARING
178 GASKET 193 WATER INLET PIPE GASKET 208 BANJO CONNECTION 222 BREATHER TUBE 236 FIP WOODRUFF KEY 251 CONNECTOR ADAPTER
179 CLOSING PLATE BOLT 194 WATER INLET PIPE 209 HIGH PRESSURE PIPE BOLT 223 WATER PUMP SCREW 237 GEAR CASE BANJO BOLT 252 RADIATOR ELBOW O'RING
180 ALTERNATOR PULL ROD 195 WATER INLET PIPE BOLT 210 HIGH PRESSURE PIPE NUT 224 OIL SUCTION TUBE, O'RING 238 WASHER
181 TENSIONER LEVER WASHER 196 BREATHER HOSE 211 HIGH PRESSURE PIPE 225 CAMSHAFT GEAR 239 TURBO OIL RETURN HOSE
182 TENSIONER LEVER BOLT 197 BREATHER HOUSING RING BRACKET 226 CAMSHAFT BOLT 240 IDLER SHAFT BUSH
183 FIP INTERMEDIATE GEAR 198 BREATHER HOUSING 212 TURBO INLET OIL TUBE 227 VALVE CAP 241 GEAR CASE BOLT
184 FIP NUT 199 BREATHER HOUSING BOLT 213 CONNECTION, FUEL RETURN 228 A/C COMPRESSOR BOLT 242 TURBO HOSE PIPE CLAMP
185 IDLER GEAR 200 FLYWHEEL HOUSING CAP 214 BANJO UNION 229 CRANK SHAFT PULLEY 243 OIL PUMP
186 ALTENATOR BRACKET BOLT 201 HIGH PRESSURE NUT, BIG 215 OIL FILTER BOLT DOWEL PIN 244 OIL PUMP BOLT
187 ALTERNATOR BUSH 202 OIL PIPE BOLT 216 PIVOT PIN 230 IDLER SHAFT WASHER 245 THERMOSTAT
188 ALTERNATOR PULLEY 203 TURBOCHARGER BOLT 217 HIGH PRESSURE PIPE NUT 231 IDLER SHAFT BOLT 246 THEROMOSTAT O'RING
189 O'RING 204 OIL FILTER HEAD PLUG 218 TURBO OIL RETURN BOLT 232 IDLER SHAFT DOWEL PIN 247 O'RING
190 EXHUAST MANIFOLD 205 OIL FILTER HEAD PLUG 219 TURBO BRACKET BOLT 233 GEAR CASE PLUG 248 INJECTOR WASHER
20
Engine Specifications
Engine make / model no. No 4.12 TC 4.12 TCA 4.12 TCA
Prime rating KVA 62.5 82.5 100
No. of cylinder No 4 4 4
Type of construction Inline / V type Inline
Displacement Ltrs 4.8
Bore mm 105
Stroke mm 137
Rated output kW 59 77 94
hp 80 105 128
Standby output kW 65 85 103
hp 88 115 140
Tolerance on rated output power % ±5
Rated speed rpm 1500
Method of Starting of engine 12V ELEC
Aspiration NA/TC/TCA TC TCA
Compression Ratio 16.8:1
Brake Mean Effective Pressure (bmep) Bar
1) Rated 10.00 13.02 15.85
2) Maximum 10.90 14.35 17.49
21
Firing Order 1-3-4-2

● COOLING SYSTEM
Method of Jacket cooling Radiator
Heat Removal By Water
Qty of coolant(Engine + Radiator) Ltr 12 18 18
Fan Power KW 2.0 3.0 5.0
● FUEL SYSTEM OF ENGINE
Fuel oil High speed Diesel(HSD IS 1460:2005)
Fuel Filter type Spin-on type with paper element
Filtration capacity Micron 5
Filter Change period hrs 500
1) FUEL INJECTION PUMP
Make STANADYNE MAKE
Type Rotary
2) GOVERNER DATA
Type MECHANICAL (3- 5%)
Response time As per IS10002
Recovery time
22
●LUBE OIL SYSTEM

Lube Oil Consumption at 100% Load Lit/hr 0.012 0.014 0.015
Recommended lube oil 15W40 API CH4/ CI4+
Lub oil filter type Full flow: Spin on cartridge type with Paper element
Filtration capacity Microns 15
Lube oil change period hours 500
Maximum lube oil temperature Deg C Min:-10 & Max:125
Lube oil pressure kg/cm2 Must be greater than 1.2
Lube oil system capacity lit 15
●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 55
Exhaust gas flow kg/hr 332.9 489 505
Exhaust gas temperature (Max ) Deg C 550
●HEAT REJECTION DETAILS
Heat Rejection to coolant kW 34 39 47
23
Heat Rejection to CAC kW ---------- 10 14
Heat Rejection to exhaust kW 48 54 63
Heat Rejection from engine surface kW 5 6 8
●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
Maximum Intake manifold temperature Deg C 50
Combustion air inlet flow rate kg/hr 318.12 349.93 424.16
●ENGINE NOISE LEVEL
At 1Mtr < 75 dBA for genset with canopy
●DIMENSIONS & WEIGHT DETAILS
Dry engine weight-with flywheel & kg 354
flywheel housing
Weight to power ratio Kg/Kw 6.00 4.59 3.77
24
Engine make / model no. No 6.12 TCA 6.12 TCA 6.12 TCA
Prime rating KVA 125 140 160
No. of cylinder No 6 6 6
Type of construction Inline / V type Inline
Displacement Ltrs 7.12
Bore mm 105
Stroke mm 137
Rated output kW 114.8 128.1 146.5
hp 156 174 199
Standby output kW 125.6 139.9 160.0
hp 170.6 190.1 217.5
Tolerance on rated output power % ±5 ±5 ±5
Rated speed rpm 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
Brake Mean Effective Pressure (bmep) Bar
1)Rated 12.9 14.4 16.4
2)Maximum 14.1 15.7 18
Firing Order 1-5-3-6-2-4
25
●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
Air Flow at Radiator Outlet CFM 10000 11800 11800
Fan Power KW 6 7 7
●FUEL SYSTEM OF ENGINE
Fuel oil High speed Diesel(HSD IS 1460:2005)
Fuel Filter type Spin-on type with paper element
Filtration capacity Micron 5
Filter Change period hrs 500
1)FUEL INJECTION PUMP
Make STANADYNE MAKE
Type Rotary
2)GOVERNER DATA
Type MECHANICAL (3- 5%)
Response time As per IS10002
26
Recovery time
●LUBE OIL SYSTEM
Lube Oil Consumption at 100% Load Lit/hr 0.014 0.015 0.017
Recommended lube oil 15W40 API CH4/ CI4
Lub oil filter type Full flow: Spin on cartridge type with Paper element
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 & 3.5 at rated speed
Lube oil system capacity lit 19.8
●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
Exhaust gas temperature (Max ) Deg C 600
●HEAT REJECTION DETAILS
Heat Rejection to coolant kW 59.73 62.22 70.98
27
Heat Rejection to CAC kW 14.74 19.33 22.49

Heat Rejection to exhaust kW 82.39 101.19 110.58
Heat Rejection from engine surface kW 12.1 12.89 14.38
●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
Maximum Intake manifold temperature Deg C 55
Combustion air inlet flow rate kg/hr 535 580 637
●ENGINE NOISE LEVEL
At 1Mtr < 75 dBA for genset with canopy
●DIMENSIONS & WEIGHT DETAILS
Length X Width X Height (With Radiator) mm 1727X932X1274.4
Dry engine weight-with flywheel & kg 598.6
flywheel housing
Weight to power ratio Kg/Kw 5.21 4.67 4.09
28
Maximum longitudinal working inclination (Angle):
Reference values. For specific installations consult the factory.
O
4 Cylinder engines-20
O
6 Cylinder engines-20
29
Maximum transversal working inclination (Angle):
Reference values only. For specific installations consult the factory.
• 4 & 6 Cylinder engines-30O
Maximum transversal installation inclination (Angle):

Reference values only. For specific installations consult the factory.
• 4 & 6 Cylinder engines-15O
30
Engine Features
mPOWER 4.8 Liter is in-line four cylinder engines with 4.8 Liter displacement and mPOWER 7.2 Liter is in-line six cylinder
engines with 7.2 Liter displacement.
The firing order of the cylinders is 1-3-4-2 and 1-5-3-6-2-4 for mPOWER 4.8 Liter and7.2Liter engine respectively.
• 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 valve train includes tappets, push rods, rocker arms, and dual valves for inlet and exhaust.
• A one piece oil pan withstands high-pressure loads during diesel operation. Manufactured in stamped steel, the oil pan
has a compact size and light weight.
• Seven and five main bearings support the crankshaft of mPOWER 7.2 Liter and 4.8 Liter engines respectively.
• The rear oil seal carrier is part of the flywheel housing.
• The open oil pan breather assembly uses a tube to vent oil pan pressure and 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 liners are used with the pistons.
31
• Viscous damper is used for the mPOWER 4.8 and 7.2 engine to absorb torsional vibrations.
• A lube oil pump mounted in the front of the engine block is driven directly by the crankshaft.
• All engines use an enlarged oil cooler and cartridge type spin on filter.
• An electric feed pump/mechanical feed pump draws fuel from the fuel tank through a fuel strainer, filter element, drain
valves and water in fuel sensor. After filtering fuel goes to high pressure pump and high pressure fuel goes to injectors.
• The new water pump is designed with seven vanes to increase the water flow.
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
32
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 mPOWER engines it’s located in the cold side, next to the Flywheel.
The 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 mPOWER engine it's located on the
hot side , below the coolant manifold.
33
Engine Front View
1. Fan
2. Alternator
3. Tensioner Pulley
4. Vibration damper
5. Front cover
34
Left View (Cold Side)
1 Manifold, Intake
2 Oil cooler assembly
3 Engine Oil filter
4 Fuel filter
5. High pressure pipes
6. Fuel Injection Pump
35
Right View (Hot Side)
1 Oil dipstick
2 Turbo inlet
3 Turbo outlet
4 Exhaust manifold
5 Turbo exhaust curve
6 Flywheel housing
7 Cylinder block
8 Water outlet tube
36
Engine Rear View
1 Flywheel
2 Lube Oil sump
3 Air Filter
37
Engine Operation
Start / Stop
1 Before operating the mPOWER 4.8 Liter and 7.2 Liter, engine check,
• Coolant level.
• Fuel level.
• Lubricating oil level.
• The air filter cleanliness (By observing service indicator).
2 Soon after the engine start, heat it up without load. Watch lubricant oil pressure and water temperature.
3 It is recommended to start the engine at no load speed for 3 min. in order to pre lubricate the turbocharger.
4 Before stopping the engine, run about 3 minutes at no load condition so that the turbo speed is decreased.
Cold Start
The difficulty of start at very low temperatures can happen due to the collapse of the filter because of paraffin formation or
lack of ignition of the fuel.
38
The following tips will be useful:
1 Use winter fuel, which does not form paraffinic flakes at low temperatures, or;
2 Incase 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:
1 Do not run the engine in full load condition immediately after the start.
2 Before stopping the engine run at no load condition for 3 minutes.
3 In low temperatures or when the engine is being reactivated after a long period without operation, start the engine and
let it running at no load speed before operating at high loads.
4 Avoid operating the engine at No load conditions for long period of time.
39
Running-in
All MHEPL 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:
1 Carefully check if engine oil level is correct;
2 Carefully check if water level of the engine cooling system is correct;
3 Average load factor in 24 hours should not exceed 75% load of the Rated capacity and in every 12 hours 10% Over load
permitted for one hour.
4 Avoid leaving the engine running at no load condition for a long period of time;
5 Strictly follow the maintenance instructions.
6 Following these recommendations the life of the engine will be prolonged.
40
Fuel Specifications - HSD IS 1460:2005

S. No Characteristic BSII BSIII BSIV
3 0
1 Density Kg/m 15 C 820-800 820-845 820-845
2 Sulphur Content mg/kg max 500 350 50
3(a) Cetane Number minimum and / or 48 51 51
3(b) Cetane Index or 46 and 46 and 46
4 Polycyclic Aromatic Hydrocarbon - 11 11
5 Distillation 85 - -
0
(a) Reco. Min. At 350 C 95 - -
0
(b) Reco. Min. At 370 C - 360 360
o
(c) 95%Vol Reco at 0 C max
• Drain water and sediments from water separator and fuel tank every day.
• Fill the fuel to the fuel tank if necessary.
• Change fuel filter periodically as for maintenance plan (Refer Maintenance Table)
41
De-aeration of low pressure fuel circuit. (Removal of air trap in fuel system)
After the maintenance of low pressure system or in case of engine shutting down due to lack of fuel, remove the air trapped in
the fuel low pressure system for smooth engine operation.
Procedure:
• Loosen the bleed screw available on the fuel filter head.
• Manually pump the mechanical feed pump available on the fuel water separator and observing the fuel oozing out
with air bubbles.
• Repeatthis procedure until clean fuel free from bubbles is observed.
• Tighten the bleed screw with specified torque and
• start the engine.
After the engine starts, leave the engine for a few minutes, in idle speed. In case of engine fail to start, repeat the above
procedure and, then start the engine again.
Note: Place a tray below the fuel filter to collect the fuel spilling out of bleed screw.
42
Lubricating Oil Circuit
43
Attention: Always use MHEPL recommended genuine engine oil.

Lubricant Oil Specifications
It must be used multi viscous type lubricant oil
that accomplish, at least, to the SAE15W40 API
CI-4 (or upper) specifications and to the
recommended viscosities.
Note: For CEV-III compliance equipments use

SAE 15W40 API CI-4 Plus grade oil only.
Attention: Do not mix different oil brand / grade.
44
Lubricating Oil
Oil Level Check
1. Stop the engine and wait 30 minutes so that the oil can flow back to the engine oil
sump.
2. Before pulling oil dipstick, clean the surroundings.
3. Do not operate the engine with the level below the ' L' mark.
4. Use only recommended lubricant oil (15W40 API CI4 ).
5. For CEV-III compliance equipments use SAE 15W40 API CI-4 Plus grade oil only.
6. Do not mix different oil brands. Do not change the oil brand frequently.
Oil Change
1 Change the Lubricating oil as per Maintenance Plan.
2 The oil must be hot for easy drain.
3 Remove the carter plug and washer to drain the oil.
4 Install the plug with a new washer and tighten according to the specification.
5 Fill with recommended lubricant oil up to ' H' mark of the dipstick.
45
Oil Filter Change

1 Remove the old filter.
2 Clean the sealing area of the filter with a clean cloth.
3 Prime the new filter with clean and fresh oil and fix.(Use always GENIUNE spares).
4 Lubricate the filter gasket and tighten it.
5 Run the engine and check the oil leakages.
6 Stop the engine and, after 30 minutes, check oil level Topup if Necessary.
Check Lubricant oil Condition

1 The lubricant oil is very important for a good conservation of the inner engine components.
2 Lubricating oil contaminated with sand, soil, dust, water or fuel causes problems to the engine.
3 Check the appearance of the engine lubricant oil. A dark coloration and low viscosity means presence of fuel in the
lubricating oil.
4 The presence of foaming or a milky coloration indicates presence of water in the oil.
46
Engine Oil Filter Element Removal
1. Remove the drain plug (R ½”) and discard the washer. Drain
engine oil and dispose of used engine oil according to
applicable laws.
2. Using the oil filter wrench as indicated and unscrew the filter
47
Engine Oil Filter Element Installation

1 Clean area around oil filter head, clean gasket surface of filter head.
2 Lubricate oil filter gasket with fresh engine oil. -2
3 Fill the oil filter with fresh engine oil. - 3
4 Tighten the filter until the gasket contacts the filter head surface. - 4
5 Use oil filter wrench to tighten the filter an additional 3/4 of a turn. - 5
6 Operate the engine and check for leakages
48
Engine Oil Filter Element Removal

(For specific 4 cyl engines only)
1. Remove the drain plug and discard the washer. Drain

engine oil and dispose of used engine oil according to
applicable laws.
2. Using the spanner as indicated and unscrew the filter.

Remove the filter cartridge and discard it.
49
Cooling Fluid and Coolant :
Attention:
1. Do not open the expansion reservoir cap while the engine is hot.
2. Check the level when the engine is cold.
3. Check the level of the cooling system daily. If the level is not correct, add clean water and recommended coolant
according to the proportion recommended on the bottle.
4. Carefully open the first stage of the cap relieving the vapour pressure.
5. Check for leaks through cooling piping.
6. Check the nominal pressure of the cap in case of change.
50
Coolant System
51
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 the mechanical seal of water pump is damaged and the water pump need to
be replaced without delay.
52
Thermostat Test Procedure

Test the thermostat and check its operation conditions according to the procedure below:
• Place the thermostat in a container and fill with water up the valve stays totally immersed.
• Position a dial indicator gauge on the stem of the thermostat and adjust a pre-load of 1 mm.
• Install a thermometer of scale 0-100 °C immersed into the water to note temperature reading.
• Gradually heat the water up.
• Take note of the temperatures at the beginning and final of the thermostat opening course (beginning and end of
the dial indicator gauge movement), and the final total course of the dial indicator gauge (fully open).
• Compare the values found with the table below with respect to part No. Change the thermostat if the temperature
of the beginning of opening is out of the specified values and / or the total operation course as specified below.
Thermostat Valve Function

Part No Start opening at Fully opened at Min Opening dimension
0304CAV00010N 79 +/-2°C 94°C 8 mm
0304CAV00110N 83 +/- 2°C 95°C 8 mm
53
Cooling system cleaning

• Remove the cap from the engine radiator top tank or from the expansion reservoir of the equipment.
• Drain the cooling system fluid through the radiator drain plug.
• Flush the whole system until to leave only clean water.
• Close the system and fill with clean water.
• Operate the engine until to reach the normal operation temperature and leave it running for 15 minutes.
• Stop the engine and waitto cool down.
• Open the drain, remove the radiator cap and leave the water to flow out all again.
• Close the drain outlet and fill the system with clean water and MNEPL recommended coolant according to the
recommended proportion.
• Run the engine till operating temperature and checkfor leaks.
54
Maintenance Plan: mPOWER 4.8 &
6.12 TCA Genset Engines
55
Maintenance Plan: mPOWER 4.8 &
56
6.12 TCA Industrial Engines
Remarks:
1. This table is only for guidance. The Maintenance Table of the Genset OEM prevails over this table.
2. If the engine stays inactive for a long time, it must perform an no load test fortnightly, until to reach the operation
temperature.
3. Independent of the intervals indicated for engine lubricant oil changes, it must be changed at every 6 months.
Note: Mentioned parts are under evaluation and maintenance frequency can get changed after evaluation.
57
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:
• Clean the outer parts of the engine.
• Operate the engine until to reach the operating temperature.
• Drain cooling system and lubricant oil.
• Fill the radiator with clean water and coolant according to the recommended proportion.
• Fill up the oil sump with protective oil SAE 20 W 20.
• Drain fuel system (reservoir, low pressure system).
• 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.
• Drain fluid from cooling system and oil from oil sump. The fuel mixture can stay in the system
• Remove valves cover from cylinder heads and spray protective oil on the springs and rocker arms. Reinstall covers.
• Apply protective oil on machined surfaces.
• Remove belt.
• Seal all the holes of the engine, to avoid dust and water penetration.
58
Remarks:
1. Renew the engine conservation procedure after each 8 months of inactivity.
2. In case of new brand engines, do not consider items 1, 2 and 3.
Engine Preparation for Return to Service

Before operating an engine which stayed inactive for a long period, follow these procedures:
1. Clean the outer parts of the engine.
2. Fill the cooling system with clean water and coolant in the recommended proportion
3. Change engine lubricating oil filter.
4. Fill the oil pan with new recommended grade of 15W40 engine oil in recommended quantity.
5. Install belt and adjust tension.
6. Remove valve covers and lubricate rocker arms with engine oil. Reinstall covers.
7. Drain the fuel mixture from the reservoir and fill with new fuel.
8. Change fuel filter.
59
Engine Starting Preparation

Clean Engine
To avoid serious personal injury, possible death, or damage to the engine or Genset, read all safety
Warning: 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.
Do not use high pressure or excessive hot water temperature as it may damage the engine
NOTE 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.
60
Failure Diagnosis or Troubleshooting

General Information
A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known about
a complaint, the faster and easier the problem can be solved. The Troubleshooting Symptom Charts are organized so that a
problem can be located and corrected by doing the easiest and most logical things first. Complete all steps in the sequence
shown from top to bottom.
It is not possible to include all the solutions to problems that can occur; however, these
charts are designed to stimulate a thought process that will lead to the cause and correction of the problem. Follow these
basic troubleshooting steps:
a Get all the facts concerning the complaint.
b Analyze the problem thoroughly.
c. Relate the symptoms to the basic engine systems and components.
d Consider any recent maintenance or repair action that can relate to the complaint.
e Double-check before beginning any disassembly.
f Solve the problem by using the symptom charts and doing the easiest things first.
g Determine the cause of the problem and make a thorough repair.
h After repairs have been made, operate the engine to make sure the cause of the complaint has been corrected
61
Trouble/Concern List
S. No. SYMPTOM PROBABLE CAUSES
1 Low starting speed 01-02-03
2 Engine does not start 05-06-07-08-09-10-14-15-16-17-22-23-2526-27- 29-40-
53-67
3 Difficult start - (engine does not starts quickly) 01-02-03-05-07-08-09-10-14-15-16-17-1822-25-26- 27-
29-40-53-67
4 Lack of power / Performance 07-08-09-10-14-15-16-17-18-19-20-21- 2223-25-26-27-
29-32-44-53-54-56-57-67
5 Engine misfiring 07-08-09-10-14-15-16-17-19-20-21-22- 2324-26-29-32-
44-53-67
6 Excessive fuel consumption 09-14-15-17-18-21-22-23-25-26-27- 29-3257-60-67
7 Black smoke 09-14-15-17-18-21-22-23-25-26-27-29-5354-57-60-67
8 Bluish-white smoke 04-14-15-17-19-21-22-23-25-26-27-28-2939-40-44
62
S. No. SYMPTOM PROBABLE CAUSES
9 Low oil pressure 04-29-30-31-32-33-34-36-37-38-52
10 Engine with beats inside 14-17-22-23-25-26-28-29-30-33-36-39-4053-67
11 Excessive vibration 10-15-17-29-41-42-43-62-67
12 High oil pressure 04-32-35
13 Engine Overheating 09-14-18-19-39-44-45-46-47-48-51-58-6364-65-67
14 Cylinder low compression 19-25-27-28-39-49-67
15 Bluish-white smoke 09-14-19-22-23-25-26-27-28-40-53
16 Engine starts and stops 04-29-30-31-32-33-34-36-37-38-52
63
S.No. SYMPTOM PROBABLE CAUSES
17 Engine with beats inside 08-09-10-17-29
18 Engine over speeds 29-49-55-67
19 High lubricating oil consumption 04-12-13-15-25-27-28-39-49-54-55-58-5960-66
20 Water mixed in lubricating oil 10-19-50
21 Oil mixed to the water 50
22 Irregular idle speed 07-08-09-10-16-17-29-59
23 Shut-off the engine after vehicle stop 06-07-08-10-17-29
24 Engine with abnormal explosions 10-17-20-29
64
List of probable causes
No. Probable Cause Action
1 Battery with low charge Charge battery or replace it
2 Electrical connections with bad contacts Clean and retighten connections
3 Faulty starter motor Replace starter motor
4 Inappropriate lubricating oil Use appropriate oil
5 Low starting speed Check connections, battery and starter
6 Fuel tank empty Fill tank up with fuel
7 Fuel feed piping obstructed Clean up the system
8 Fuel filter obstructed Clean fuel filter or replace the element
9 Restriction in air intake system Open up intake system or clean air filter element
65
10 Air in fuel system Bleed the system, Check for leaks in the low pressure
fuel circuit. Arrest the leaks if any.
11 Leaks through the cylinders liners sealing rings Replace
12 Irregular ring seating Replace
13 High oil level in oil pan Correct
14 Incorrect camshaft gear timing Correct gear timing
15 Cylinder low compression Measure compression and correct fault
16 Fueltank breather pipe obstructed Open up breather pipe
17 Inappropriate fuel Use recommended fuel
18 Faulty nozzles Check type of nozzles or correct them
66
19 Leak in cylinder head gasket Replace gasket and check for leak cause
20 Overheating Check cooling system, engine timing and operation and
installation conditions
21 Engine too cold Check thermostat valve
22 Incorrect valve clearance Adjust valve clearance
23 Valve sticking Correct valve operation
24 Incorrect high pressure pipes Replace
25 Cylinder wear Correct
26 Valve and valve seats burned out Overhaul or replace
27 Rings broken, worn or stuck Replace
67
28 Valve stems and guides worn down Replace
29 Failure on electronic injection system Perform diagnosis of the system according e "Engine
Diagnoses Manual"
30 Bearing damaged or worn down Replace
31 Low oil level in oil pan Top up
32 Throttle locked or with limited movement Free or correct accelerator links
33 Lubricating oil pump with inner wear Replace
34 Oil pump relief valve locked open Release and correct
35 Oil pump relief valve locked closed Release and correct
36 Relief valve spring broken Replace
68
37 Faulty oil pump suction pipe Correct
38 Lubricating oil filter clogged Replace element
39 Scuffed piston Repair cylinder
40 Incorrect height of piston in relation to the block surface Use appropriate pistons
41 Damaged fan Replace
42 Faulty engine cushions Replace / Correct assembly
43 Flywheel housing or flywheel misaligned Align
44 Faulty thermostat Replace
45 Obstruction in water galleries / Cylinder liner with deposits Clean up system
69
46 Loosen fan belt Tighten
47 Radiator internally or externally clogged Clean up
48 Faulty water pump Replace
49 Oil pan breather pipe clogged Clean up
50 Leak in lubricating oil exchanger Repair
51 Cooling system without enough water Top level up
52 Oil pump suction pipe mesh clogged Clean up
53 Valve spring broken Replace
54 Turbocharger damaged or dirty Clean up or replace
55 Leaks through turbocharger oil seals Replace seals
56 Exhaust manifold connected to turbocharger Replace gaskets
leaking through the gaskets
70
57 Low turbocharged air pressure Check turbocharger. Repair leaks
58 Outerleaks (gaskets, seals, etc.) Repair
59 Inappropriate engine mounting angle Correct
60 Engine is overloaded Operate the engine under the load limit
61 Balanceris out of position(for specificengines only) Correct
62 Faulty damper Replace
63 Liner collar protrusion below the specification/leakage Correct
through liner collar
64 Bad thermostat resting in carcass Correct
65 Lack or incorrect additive proportion in cooling system Correct
66 Leakage through valve guide seal Correct
67 Faulty high pressure pump Replace
71
Engine Block
Qty. Description Size Application Torque (Nm) SC/CC
Torq.
1 st 2 nd
Range
2 Bolt M14 Bearing Cap to Block CC
170 to
50 - 5 155 °± 5°
282
Required SC/CC
Qty. Description Size Application Torque(N m)
Sealing
Water Drain Plug to
1 Plug 3/8” 10 + 5
Block Loctite 567
1 Hollow Bolt M8x1 Oil Ejector to Block 10 ± 1.5 **
Water Drain Plug to
1 Plug 1/2” 15 + 5
Block Loctite 567
Plug, Allen M22x1.
1 To plug TC oil return 40 ± 5
Straight 5
72
Connecting Rod
Torq.
1 st 2 nd
MJ Connecting Rod to Range
2 Bolt CC
12x58 Crankshaft 130 to
40 ± 5 80 °± 2°
160
Camshaft
1 st 2 nd Torq. Range
4 Bolt M8x25 Gear to Camshaft
15 ± 1 30 °± 2° 35 to 65 SC
2 Bolt M8x16 Camshaft Lock to Block 25 ± 4
Water Pump
Descriptio
Qty. Size Application Torque(N m) SC/CC
n
2 Bolt M8x20 Water Pump to Block 20 ± 5
73
Gear Housing
Torque(N
Qty. Description Size Application SC/CC
m)
10 Bolt M8x20 Gear Housing to Block 30 ± 5
3 Bolt M8x50 Gear Housing to Block 30 ± 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

Torque(N
m)
5 Hollow Bolt M10x1 Valve Lubrication pipe to Cylinder Head 10 + 5
74
Front Cover
Torque(N
m)
16 Bolt M8x16 Front Cover to Gear Housing 30 ± 3
9 Bolt M8x55 Front Cover to Gear Housing to Block 30 ± 3
Inspection
1 S65 X 4 Inspection cover to front cover 20 ± 3
Cover
Alternator Bracket
Torque(N
m)
Alternator Bracket to
3 Bolt M10x35 40 ± 6
Gear Housing
1 Bolt M10x20 Pulley to Alternator Bracket 40 ± 6
Water Flow Tube Assembly

Torque
(Nm)
Temparature
M14 X 1.5 X
1 sensor cum Sensor fitted in water flow tube Max. 20
11
Switch
75
Water Outlet Pipe

Qty. Description Size Application Torque(N m) SC/CC
Water Outlet Pipe
8 Bolt M8x55 25 ± 4
to Cylinder Head
Connection water
2 Bolt M8x30 25 ± 3
outlet
2 Bolt M8x30 Connection by pass 25 ± 3

Water outlet tube
1 Hollow Bolt M12 20 ± 3
to degassing tank
Nipple Bypass
1 Nipple M22 connection for AC 40 ± 5
application
Plug, Connection
1 Plug M22X1.5 Bypass for Non-AC 25 + 5
application
76
Cylinder Head
Torq
Pre -
Applicatio ue Torqu Torq Torqu Torque
Qty. Description Size Torque SC/CC
n e ue e Range
(Nm)
(Nm) 1 (°) 2 (°) 3 (°)
Cylinder 60+ 120 To
14 Bolt M14x152 40+5 60± 3 60± 3 90± 3 CC
Head to Block 10 260
Cylinder 60+ 120 To
2 Bolt M14 40+5 60± 3 60± 3 90± 3 CC
Head to Block 10 260
Cylinder
Engine lifting Head 80 ±
2 M12 - - - - -
hook mounting 10
bolt

Socket head Lubrication pipe to Cylinder
2 M5x10 5±1
cap screw head
1 Nut M22 High pressure connector nut 50 + 5
Nut – Valve clearance
1 Nut M8x10 20 + 5
adjustment
77
High Pressure Pump

High Pressure Pump adaptor
3 Stud M8 X 30 8±1
to Gear Housing
High Pressure Pump to Gear
3 Nut M8 38 ± 3 SC
Housing
1 Nut M14x1.5 Gear to High Pressure Pump 180 ± 5 SC
High Pressure Pump –Tube ,Fuel
1 Hollow Screw M12 22.5 ± 2.5
Return
1 Connector M8 Connector for Boost pressure 10 + 5
Tube, Injection Pump to Intake
1 Box Nut M10x1 12.5 ± 2.5
manifold
Low Pressure Pipe

Pipe, Fuel Return to Cylinder
6 Connection M8x1 8±1
Head
78
High Pressure Pipe

Nut high pressure tube to
6 Nut M12 15 + 5 SC
fuel injection pump
Nut high pressure tube to
6 Nut M14 25 + 5 SC
Connector high pressure tube
Fuel Filter
2 Bolt M10x30 Fuel Filter to Block 35 ± 4
2 Connection M14x1.5 Fuel inlet to Filter Head 20 + 6
Pipe, Fuel Filter outlet to VE
1 Hollow Bolt M12x1.5 20 + 6
Pump
Pipe, Fuel Filter inlet for
1 Hollow Bolt M14x1.5 20 + 6
mechanical feed Pump
1 Hollow Bolt M14x1.5 Pipe, Fuel Filter inlet NRV 20 + 6
79
Assy, Fuel Injector and Valve Cover
Descriptio
Qty. Size Application Torque(N m) SC/CC
n
Special Step Bolt Fuel injection
1 Screw M6 4± 1 SC
Clamp
2 Bolt M6 x 60 Valve Cover 8.5 ± 1
Torqu
Torqu Torqu
Descri Torque Relieve Torque Torque e
Qty. Size Application e e SC/CC
ption (Nm) to (Nm) (Nm) 1 (°) Rang
2 (°) 3 (°)
e
Screw - Fastening
1 Screw M6 Bridge Fuel 1+0.5 0 4 ±1 90 90 30 7+6
Injector
Intake Manifold
Intake Manifold to
8 Bolt M8x35 24 ± 2
Cylinder Head
Intake Manifold to
8 Bolt M8x80 24 ± 2
Cylinder Head
1 Hollow Bolt M12X1.5 Tube -Intake Manifold to FIP 20 + 6
80
Exhaust Manifold
Exhaust Manifold to
8 Stud M10x45 6±2
Cylinder Head
Exhaust Manifold to stud
8 Stover Nut M10 70 ± 10
Cylinder Head
Exhaust Elbow
Exhaust Elbow to
3 Stud M8 6 ± 2
Turbocharger
Exhaust Elbow to
3 Stover Nut M8 35 ± 4
Turbocharger
81
Crankshaft Pulley
M16x6 Crankshaft Pulley to 1 st 2 nd

4 Cylindrical Bolt CC
5 Crankshaft 100 ± 10 275 ± 15
9 Bolt M8 Damper to Crankshaft Pulley 35 ± 5
Oil Suction Pipe
2 Bolt M8x20 Oil Suction Pipe to Block 25 ± 4
Water Inlet Manifold
3 Bolt M8x25 Water Inlet connection 20 ± 3
82
Engine Breather
1 Bolt M8x35 Breather to Block 25 ± 5
Engine breather tube to

1 Bolt M8x16 10 + 2
Breather housing
Oil Pan
25 Bolt M8x16 Oil Pan to Block 25 + 5

1 Bolt M8x30 Oil Pan to Block 25 + 5
Drain Plug engine oil
1 Plug M18X1.5 65 ± 10
sump
Bracket oil filling tube to
1 Bolt M12x20 30 ± 5
flywheel housing
Bracket oil filling tube to
1 Bolt M6x16 10 ± 5
oil filling tube
83
Flywheel
Cylindrical Flywheel to 1 st 2 nd
6 M16x35 CC
Bolt Crankshaft 100 ± 10 275 ± 15
Flywheel Housing
13 Bolt M12x30 Flywheel Housing to Block 100 ± 5
Lubricating Oil Flilter Head andOil Cooler
10 Screw M8x 40 oil cooler to block 25 ± 3

1 Hollow Bolt M14X1.5 Adapter 25 + 5
Oil Pump
2 Bolt M8x20 Oil Pump to Block 20 ± 5 SC
84
Turbocharger
Turbocharger to Exhaust
4 Bolt M8x30 30 ± 4
Manifold
Torque
(Nm)
Turbocharger Inlet
1 Hollow Bolt M12x1.5 Lubrication Pipe to 30 ± 4
Turbocharger
Turbocharger Inlet
1 Hollow Bolt M14x1.5 37 ± 3
Lubrication Pipe to Block
Turbocharger Lubrication
2 Bolt M6x16 10 + 3
Return Pipe to Turbocharger
SCREW, HEX
2 FLANGED M8 x 20 20+3
HEAD
SCREW, HEX
2 FLANGED M8 x 20 20+3
HEAD
85
Intake Curve
Screw, Hex. Intake curve to intake
3 M8x35 20 ± 3
Flanged head manifold
Intake curve to intake
1 Stud M8x48 6±2
manifold
Screw, Hex. Intake curve to intake
4 M8x25 20 ± 3
Flanged head manifold
Intake curve to intake
1 Nut, Hex. M8x8 20 ± 3
manifold
Plug, Allen
2 M22 X 1.5 X 5.8 For Plugging Heater Holes 30 ± 5
Tapered
Air Cleaner Assembly
Torque
(Nm)
Clamping Hose ,Air cleaner -
Clamp SAE J1 508 SAE No.-
1 Turbocharger to Air Cleaner 7.3 ± 1.3
Type SLTB 124
Assembly
Air Cleaner Assembly to
4 Screw, Hex. M10x20 25 ± 4
Air cleaner Mounting Bracket
Clamp SAE J1 508 Clamping Hose ,Air cleaner -
1 SAE No.- 42 7.3 ± 1.3
Type SLTB Turbocharger to Turbocharger
Screw, Serrated Hex. Air cleaner Mounting Bracket to
2 M10x20 50 ± 8
flanged head Cylinder Block
86
Fan Assembly
Screw, Hex. Flanged
6 M8x20 Fan Hub to Fan(28 inch) 25 ± 4 SC
head
Screw, Serrated Hex.
6 M10X70 Fan pulley to Fan Hub and Fan 50 ± 8 SC
Flanged head
1 Bolt, Hex. Flanged head M10x50 Fan Bracket to Timing case 50 ± 8
Housing Fan Bearing to Fan
4 Bolt, Hex. Flanged head M10x30 50 ± 8
Bracket
Screw, Serrated Hex.
1 M10X70 Auto Tensioner to Fan bracket 50 ± 8
Flanged head
Screw, Hex. Flanged
2 M8X80 Fan Bracket to Timing case 25 ± 4
head
1 Bolt, Hex. Flanged head M10x40 Fan Bracket to Timing case 50 ± 8
1 Bolt, Hex. Flanged head M10x40 Bolt to Fan shaft 50 ± 8
87
Fuel Filter Assembly

1 Banjo bolt M12X1.5X8.8 Fuel Pump end to NRV pipe 23 ± 3
Turbocharger Bracket Assembly

Screw, Hex. Flanged M8 x 30 X Elbow, turbocharger Mounting
1 25 + 5
Head 1.25 X 10.9 bracket to turbocharger
Screw, Hex. M8 x 25 X Turbocharger Mounting bracket
1 25 + 5
Flanged Head 1.25 X 8.8 to Elbow, turbocharger
Gear Case Assembly

Screw, Hex. Air compressor closing plate to
3 M10X30X8.8 45± 5
Flanged Gear Case
88
Intake Manifold Assembly

Plug, Allen
1 M12 X 1.5 X 5.8 For Pluging Intake manifold Hole 10± 2
Tapered
Feed Pump Assembly

Feed Pump mounting to Gear
3 Allen bolt M6X16X8.8 10 ± 1.5
case
Screw, Hex. M8 X 25X 1.25 X Feed Pump mounting to Gear
2 25 ± 4
Flanged 8.8 case
2 Banjo bolt M14X1.5X8.8 Feed Pump Inlet/Outlet 23± 3
Feed Pump adapter to Timing
1 Adapter M14X1.5X8.8 30 ± 4
case
89
Radiator & Intercooler
Qty
Description Size Application Torque(N m) SC/CC
.
Clamp SAE J1 508 Type SAE Hose clamp for intake curve to
2 7.3 ± 1.3
SLTB No.- 76 intercooler
Hose clamp for Elbow
Clamp SAE J1 508 Type SAE
2 Turbocharger to Tube, 7.3 ± 1.3
SLTB No.- 76
turbocharger -intercooler
Clamp SAE J1 508 Type SAE Hose Clamp for Tube, turbocharger -
2 7.3 ± 1.3
SLTB No.- 76 intercooler to Intercooler inlet
SAE No.- Hose Clamp for Engine Water
2 Clamp SAE J1 508 Type SLTB 7.3 ± 1.3
42 Outlet pipe
SAE No.- Hose clamp for Engine Water outlet
42 pipe to Hose, Radiator side
SAE No.- Hose clamp for Engine Water
34 outlet pipe to hose at Radiator inlet
SAE No.- Hose clamp on Engine Water inlet
42 pipe
SAE No.- Hose clamp on small end of reducer
42 hose at radiator outlet
SAE No.- Hose Clamp on reducer hose at
48 radiator outlet
SAE No.- HOSE, TURBOCHARGER - 7.3 ± 1.3
1 Clamp SAE J1 508 Type SLTB
72 INTERCOOLER
SAE No.- HOSE, AIR CLEANER- 7.3 ± 1.3
1 CLAMP SAE J1 508 TYPE SLTB -
54 TURBOCHARGER
Mounted on the water inlet
2 M8X12 Engine water inlet tube connection 10± 2
connection tube
90
Engine Mounting Foot

Qty. Engine Size Application Torque(N m) SC/CC
Screw, Serrated M12x3
8 Engine Mounting Foot to Cylinder Block 70 ± 10
Hex. Flanged head 0
Cylinder Block
M14 X 1.5 Plugging Compressor inlet
1 Plug, Allen Tapered 10+5
X 5.8 Hole in Cylinder block
Starter Motor Assembly

M10 X 30 X
3 Screw, Hex. Flanged Starter Motor (24V) Mounting 45± 5
8.8
91
Lubricating Oil Filter Head and Oil cooler

Torque
(Nm)
Oil Pressure sensor Oil Pressure sensor cum switch
1 M12x12 Max. 50
cum switch mounted at Oil Filter Head
Alternator 24 V Assembly– Electronic Genset

Screw, Hex. Flanged Pull rod, Alternator Bracket to
2 M8 x 20 20 ± 3
head Main Alternator Bracket
Screw, Hex. Flanged Pull rod, Alternator Bracket to
1 M12 x 35 70 ± 10
head Alternator (Charging)
Screw, Hex. Flanged Main Alternator Bracket to
1 M10 x 110 40 ± 6
head Alternator (Charging)
92
Alternator Bracket- 12V
Alternator Bracket to
1 Bolt M8x80 30 ± 5
Alternator Bush
Alternator bracket to casting
1 Bolt M8x20 20 ± 3
bracket
Standard Torque Table for Normal Steel Bolts

(According to DIN 2230)
Bolt Class ( Nm)
Nominal Size SC/CC
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
93
NOTES
94
NOTES
95
NOTES
96
Delivery date OEM Name
For Genset Application
Model (From Serial No. Plate) Serial No. (From serial No. plate)
Month Day Year
Commissioning Date
Month Day Year

Alternator Kva
MHEPL COPY
Owner Surname or Company Name Voltage Phase
First Name Title
Street / P. O BOX (1)

Genset No For Off High Way application only
Street / P. O BOX (2) Model (From Serial No. Plate) Serial No. (From serial No. plate)
City State / Province
Zip Code / Post Code Country
Telephone (Area Code / Number) Mobile phone No. Equipment No. Chassis No.
Email address Transmission No.
Dealer Name
Commissioning Certified by:
Address
City Name
State/Prov. ZIP / Post Code

Sign
Telephone No. (Area code/Phone No.)
Dealer Name
E-Mail Address
73
74
Month Day Year
Commissioning Date
Month Day Year

Alternator Kva

OEM COPY
First Name Title

Dealer Name
Address
City Name

Sign
Dealer Name
E-Mail Address
76
Month Day Year
Commissioning Date
Month Day Year

OWNER'S COPY
Alternator Kva
First Name Title

Dealer Name
Address
City Name

Sign
Dealer Name
E-Mail Address

O&M Manual For 4.12TCA & 6.12TCA

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

O&M Manual For 4.12TCA & 6.12TCA

Enviado por

Direitos autorais:

Formatos disponíveis

Operation and Maintenance Manual

Operation and Maintenance Manual

Mahindra Heavy Engines Pvt. Ltd.

c] Avoid contact while electric components that may produce sparks.

Cleaning General Instructions

Engine Serial Number Identification and location

1. Identification plate on the inlet manifold

6.12 TCA Engine Data Plate

Firing Order 1-3-4-2

●LUBE OIL SYSTEM

Heat Rejection to CAC kW 14.74 19.33 22.49

• 4 & 6 Cylinder engines-30O

Maximum transversal installation inclination (Angle):

• 4 & 6 Cylinder engines-15O

Engine Front View

Left View (Cold Side)

Right View (Hot Side)

Engine Rear View

The following tips will be useful:

To maximize the turbo lifetime follow these cautions:

2 Before stopping the engine run at no load condition for 3 minutes.

Fuel Specifications - HSD IS 1460:2005

Lubricating Oil Circuit

Attention: Always use MHEPL recommended genuine engine oil.

Note: For CEV-III compliance equipments use

Attention: Do not mix different oil brand / grade.

Oil Filter Change

Check Lubricant oil Condition

Engine Oil Filter Element Removal

Engine Oil Filter Element Installation

Engine Oil Filter Element Removal

1. Remove the drain plug and discard the washer. Drain

2. Using the spanner as indicated and unscrew the filter.

Cooling Fluid and Coolant :

Water Pump Check

Note: Image is shown with gear housing removed

Thermostat Test Procedure

Thermostat Valve Function

Cooling system cleaning

Engine Preparation for Return to Service

Engine Starting Preparation

Failure Diagnosis or Troubleshooting

37 Faulty oil pump suction pipe Correct

38 Lubricating oil filter clogged Replace element

39 Scuffed piston Repair cylinder

41 Damaged fan Replace

42 Faulty engine cushions Replace / Correct assembly

43 Flywheel housing or flywheel misaligned Align

44 Faulty thermostat Replace

45 Obstruction in water galleries / Cylinder liner with deposits Clean up system

Valve Lubrication Pipes

Water Flow Tube Assembly

Water Outlet Pipe

Qty. Description Size Application Torque(N m) SC/CC

Qty. Description Size Application Torque(N m) SC/CC

High Pressure Pump

Qty. Description Size Application Torque(N m) SC/CC

High Pressure Pipe

M16x6 Crankshaft Pulley to 1 st 2 nd

Qty. Description Size Application Torque(N m) SC/CC

2 Bolt M8x20 Oil Suction Pipe to Block 25 ± 4

Water Inlet Manifold

Qty. Description Size Application Torque(N m) SC/CC