OPERATION AND MAINTENANCE MANUAL
MaxxForce 4.8I
MaxxForce 4.8P
MaxxForce 7.2I
MaxxForce 7.2P
Operation and Maintenance Manual
Operation and Maintenance Manual
MAXXFORCE 4.8 & 7.2
Part No : 972P00602101
Rev Date : 01-2014
Av. das Nações Unidas, 22.002
ZIP CODE - 04795-915
São Paulo - SP - Brazil
Operation and Maintenance Manual
Operation and Maintenance Manual
General Information
INDEX
Introduction
Important Safety Remarks
General Instructions
Cleaning Instructions
Engine Serial No Identification and Location
Engine Identification
Cylinder Numeration
Engine Accessories
Engine Exploded View
Engine Technical Data
Engine Specifications
Engine Features
INDEX
5
6-8
9-10
11
12
13-14
15
16
17-20
21-28
29-30
31-32
3
Operation and Maintenance Manual
General Information
INDEX
Accessories Features
Engine Views
Engine Operation
Fuel specifications
De-Aeration of fuel system
Lubrication System
Coolant System
Maintenance Table Genset engines
Maintenance Table Industrial engine
Conservation of Inactive engines for Long period
Troubleshooting
4
33
34-37
38-40
41
42
43-49
50-54
55
56
58-59
60-93
Operation and Maintenance Manual
Introduction
This manual was developed to supply the customers with all information in order to provide the correct operation and
maintenance for the MAXXFORCE 4.8 & 7.2 series engines manufactured by Navistar, Inc.
MAXXFORCE 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 MAXXFORCE 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.
Navistar, Inc. 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 Authorized Distributor or the
factory.
The components used in MAXXFORCE engines are produced with latest generation technology with high level of quality
standards. When parts changes are necessary, it is recommended to use only genuine spare parts for longer durability and
efficient engine performance.
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Operation and Maintenance Manual
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
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Operation and Maintenance Manual
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.
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Operation and Maintenance Manual
m] Never leave the engine operating in a closed and non ventilated area. The engine exhaust gases are harmful to health.
n]
The 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 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.
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Operation and Maintenance Manual
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 factory.
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 .
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Operation and Maintenance Manual
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.
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Operation and Maintenance Manual
Cleaning General Instructions
Several solvents and acid substances can be used to clean the parts of the engine Navistar, Inc. 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 antioxidation 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
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Operation and Maintenance Manual
Engine Serial Number Identification and location
The engine identification and serial number can be found in the following places:
1.
Identification plate on the inlet manifold
2.
Engraving on the right side of the engine block, close to the cylinder head of the cyl #3
MF 7.2 Data Plate
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Operation and Maintenance Manual
Engine Identification
4. 12 TC A
After cooler
Turbo Charged
Series
No of Cylinders
13
Operation and Maintenance Manual
Engine Identification
6. 12 TC A
After cooler
Turbo Charged
Series
No of Cylinders
14
Operation and Maintenance Manual
Cylinders Numeration
The cylinders order starts from the flywheel, according to the illustration below.
FIRST CYLINDER
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Operation and Maintenance Manual
Engine Accessories
The following engine accessories have manufacturer’s labels or identification plates:
•
Turbocharger
•
Fuel Injection Pump
•
Fuel Injection Pump
•
Starter Motor 24V
•
Starter Motor 12V
•
Charging Alternator 24V
•
Charging Alternator 12V
•
Air Compressor (for specific applications only)
Labels or identification plates include information and specifications helpful to equipment operators and technicians.
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Operation and Maintenance Manual
17
Operation and Maintenance Manual
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Operation and Maintenance Manual
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
10 ENGINE LIFTING HOOK
11
CYLINDER HEAD BOLT
12 WELCH PLUG
39 CONNECTING ROD BOLT
69 V-BELT
98 CONNECTION BY-PASS
126 SEALING WASHER
156 OIL PAN GASKET
40 CONNECTING ROD BEARING
70 CRANKSHAFT PULLEY BOLT
99 EXHAUST MANIFOLD NUT
127 FUEL RETURN TUBE
157 OIL PAN BOLT
41 CONNECTING ROD BUSHING
71 FRONT COVER BOLT
100 EXHAUST ELBOW GASKET
128 INJECTOR CONNECTOR
158 OIL SUCTION TUBE
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
104 TURBOCHARGER ELBOW
TUBE
132 OIL TUBE-FILTER TO MAIN
LINE
163 INTAKE ROCKER ARM
105 TURBO ELBOW BRACKET
BOLT
133 PLUG
164 NIPPLE
134 PLUG
165 CYLINDER HEAD
LUBRICATION BOLT
15 CYLINDER HEAD BOLT
45 CRANK SHAFT
75 INTERMEDIATEGEAR
16 VALVE SPRING
46 BEARING CAP
76 TENSIONER PULLEY BOLT
17 SPRING RETAINER - UPPER
47 BEARING CAP BOLT
77 ALTERNATOR BOLT
18 VALVE LOCK
48 CRANKSHAFT GEAR
78 ALTERNATOR
19 VALVE SEAL
49 MAIN BEARING - LOWER
79 ALTERNATOR._BRACKET
20 ROCKER SHAFT
50 CRANKSHAFT BUSHING FRONT
80 CLOSING PLATE
81 CLOSING PLATE GASKET
22 INJECTOR HOLDER
51 DEFLECTOR
82 AIR COMPRESSOR ASSY.
23 SPL. SCREW INJECTOR
HOLDER
52 LUBRICANT OIL EJECTOR
21 EXHAUST ROCKER ARM
162 INTAKE DUCT BOLT
106 TURBO OIL RETURN TUBE
135 OIL FILTER HEAD
107 T-BOLT CLAMP
136 OIL FILTER HEAD BOLT
166 SEALING WAHSER
108 TURBOCHARGER
137 OIL MAIN LINE BRACKET
167 TEE CONNECTION VALVE
109 EXHAUST COVER NUT
138 OIL TUBE- MAIN LINE TO
CYLINDER HEAD
168 TURBO OIL RETURN TUBE
CONNECTION
110 EXHAUST ELBOW
53 CAM SHAFT
83 HOSE-WATER OUTLET TUBE
TO COMPRESSOR
111 TURBO BRACKET
139 IDLER SHAFT
169 EXHAUST COVER STUD
54 CAMSHAFT BUSHING
84 BREATHER HOSE CLIP & BOLT
112 EXHAUST MANIFOLD TURBO
STUD
140 BANJO BOLT
170 BANJO UNION
141 SEALING WASHER
171 SEALING WASHER
113 TURBO ELBOW BRACKET
142 HIGH PRESSURE TUBE
172 BANJO BOLT
143 INTAKE MANIFOLD
173 HOSE-COMPRESSOR TO
WATER OUTLET TUBE
24 A/C COMPRESSOR BRACKET
BOLT
55 WATER PUMP GEAR
85
SEALING WASHER
25 INTERMEDIATE ROCKER ARM
56 WATER PUMP
86
WATER TEMPERATURE
SENSOR
87
WATER OUTLET CON PIPE
26 FASTNING BRIDGE BOLT
57 GEAR CASE
27 PUSH ROD
58 FIP GEAR
28 VALVE SETTING SCREW
29 TAPPET
59 GEAR CASE LUBRICATION
PIPE
30 VALVE COVER GASKET
60 TENSIONER PULLEY
88 BANJO UNION
89 SPRING CLAMP THEMOSTAT
CONNECTION HOSE
114 EXHAUST MANIFOLD TURBO
NUT
115 FUEL PUMP
116 FIP GASKET
117 FIP BRACKET
144 INTAKE COVER GASKET
145 INTAKE COVER
174 TIMING CASE CONNECTION
146 INTAKE MANIFOLD BOLT
175 CLAMP IN BUSH, MAIN
BEARING
147 INTAKE MANIFOLD GASKET
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Operation and Maintenance Manual
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
225 CAMSHAFT GEAR
239 TURBO OIL RETURN HOSE
226 CAMSHAFT BOLT
240 IDLER SHAFT BUSH
227 VALVE CAP
241 GEAR CASE BOLT
182 TENSIONER LEVER BOLT
197 BREATHER HOUSING RING
211 HIGH PRESSURE PIPE
BRACKET
183 FIP INTERMEDIATE GEAR
198 BREATHER HOUSING
212 TURBO INLET OIL TUBE
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
243 OIL PUMP
244 OIL PUMP BOLT
245 THERMOSTAT
186 ALTENATOR BRACKET BOLT
201 HIGH PRESSURE NUT, BIG
215 OIL FILTER BOLT
229 CRANK SHAFT PULLEY
DOWEL PIN
187 ALTERNATOR BUSH
202 OIL PIPE BOLT
216 PIVOT PIN
230 IDLER SHAFT WASHER
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
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Operation and Maintenance Manual
Engine Specifications
Engine make / model no.
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
No
KVA
No
Inline / V type
Ltrs
mm
mm
kW
hp
kW
hp
%
rpm
NA/TC/TCA
MF 4.8
62.5 / 82.5 / 100
4
Inline
4.8
105
137
59 / 77 / 94
80 / 105 / 128
65 / 85 / 103
88 / 115 / 140
±5
1500
12V ELEC
TC / TCA
16.8:1
Bar
10.00 / 13.02 / 15.85
10.90 / 14.35 / 17.49
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Operation and Maintenance Manual
Engine Specifications
MF 4.8
Firing Order
● COOLING SYSTEM
Method of Jacket cooling
Heat Removal
Qty of coolant(Engine + Radiator)
Fan Power
● FUEL SYSTEM OF ENGINE
Fuel oil
Fuel Filter type
Filtration capacity
Filter Change period
1) FUEL INJECTION PUMP
Make
Type
2) GOVERNER DATA
Type
Response time
Recovery time
22
1-3-4-2
Ltr
KW
Radiator
By Water
12 / 18
2.0 / 3.0 / 5.0
Micron
hrs
High speed Diesel(HSD IS 1460:2005)
Spin-on type with paper element
5
500
STANADYNE MAKE
Rotary
MECHANICAL (3- 5%)
As per IS10002
Operation and Maintenance Manual
Engine Specifications
MF 4.8
●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 temperature
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
Lit/hr
Microns
hours
Deg C
kg/cm2
lit
0.012 / 0.014 / 0.015
15W40 API CH4/ CI4+
Full flow: Spin on cartridge type with Paper element
15
500
Min:-10 & Max:125
Must be greater than 1.2
15
dB
mm of Hg
kg/hr
Deg C
Residential Type
Complies with CPCB norms
55
332.9 / 489 / 505
550
kW
34 / 39 / 47
23
Operation and Maintenance Manual
Engine Specifications
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
Dry engine weight-with flywheel &
flywheel housing
Weight to power ratio
24
kW
kW
kW
MF 4.8
10 / 14
48 / 54 / 63
5/6/8
mm of H2O
mm of H20
Microns
Deg C
kg/hr
Dry type Air cleaner
230
600
20
50
318.12 / 349.93 / 424.16
< 75 dBA for genset with canopy
kg
354
Kg/Kw
6.00 / 4.59 / 3.77
Operation and Maintenance Manual
Engine Specifications
Engine make / model no.
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
No
KVA
No
Inline / V type
Ltrs
mm
mm
kW
hp
kW
hp
%
rpm
NA/TC/TCA
MF 7.2
125 / 140 / 160
6
Inline
7.12
105
137
114.8 / 128.1 / 146.5
156 / 174 / 199
125.6 / 139.9 / 160.0
170.6 / 190.1 / 217.5
±5
1500
24V ELEC
Turbocharged Aftercooler
16.8:1
Bar
12.9 / 14.4 / 16.4
14.1 / 15.7 / 18
1-5-3-6-2-4
25
Operation and Maintenance Manual
Engine Specifications
MF 7.2
●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
●FUEL SYSTEM OF ENGINE
Fuel oil
Fuel Filter type
Filtration capacity
Filter Change period
1)FUEL INJECTION PUMP
Make
Type
2)GOVERNER DATA
Type
Response time
26
mm
Ltr
CFM
KW
Radiator
By Water
831x390.5x1135
25
10000 / 11800 / 11800
6/7/7
Micron
hrs
High speed Diesel(HSD IS 1460:2005)
Spin-on type with paper element
5
500
STANADYNE MAKE
Rotary
MECHANICAL (3- 5%)
As per IS10002
Operation and Maintenance Manual
Engine Specifications
MF 7.2
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
Lit/hr
Microns
hours
Deg C
kg/cm2
lit
0.014 / 0.015 / 0.017
15W40 API CH4/ 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 speed
19.8
dB
mm of Hg
kg/hr
Deg C
Residential Type
Complies with CPCB norms
75
558 / 603 / 664
600
kW
59.73 / 62.22 / 70.98
27
Operation and Maintenance Manual
Engine Specifications
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
Length X Width X Height (With Radiator)
Dry engine weight-with flywheel &
flywheel housing
Weight to power ratio
28
kW
kW
kW
MF 7.2
14.74 / 19.33 / 22.49
82.39 / 101.19 / 110.58
12.1 / 12.89 / 14.38
mm of H2O
mm of H20
Microns
Deg C
kg/hr
Dry type Air cleaner
230
600
20
55
535 / 580 / 637
< 75 dBA for genset with canopy
mm
kg
1727X932X1274.4
598.6
Kg/Kw
5.21 / 4.67 / 4.09
Operation and Maintenance Manual
Engine Specifications
Maximum longitudinal working inclination (Angle):
Reference values. For specific installations consult the factory.
O
4 Cylinder engines-20
O
6 Cylinder engines-20
29
Operation and Maintenance Manual
Engine Specifications
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
Operation and Maintenance Manual
Engine Features
MAXXFORCE 4.8 Liter is in-line four cylinder engines with 4.8 Liter displacement and MAXXFORCE 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 MAXXFORCE 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 MAXXFORCE 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
Operation and Maintenance Manual
•
Viscous damper is used for the MAXXFORCE 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
Operation and Maintenance Manual
Accessories Features
The Alternator is used to charge the battery and to power a Genset system when the engine is running, driven by the pulley
system and the belt accessories. It’s located in the cold side in the front of the block on the upper position.
The Starter motor is an electric motor that initiates rotational motion in an internal combustion engine before it can power
itself. On the MAXXFORCE engines it’s located in the cold side, next to the Flywheel.
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 MAXXFORCE engine it's located on
the hot side , below the coolant manifold.
33
Operation and Maintenance Manual
Engine Front View
1. Fan
2. Alternator
3. Tensioner Pulley
4. Vibration damper
5. Front cover
34
Operation and Maintenance Manual
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
Operation and Maintenance Manual
Right View (Hot Side)
1
2
3
4
5
6
7
8
36
Oil dipstick
Turbo inlet
Turbo outlet
Exhaust manifold
Turbo exhaust curve
Flywheel housing
Cylinder block
Water outlet tube
Operation and Maintenance Manual
Engine Rear View
1
2
3
Flywheel
Lube Oil sump
Air Filter
37
Operation and Maintenance Manual
Engine Operation
Start / Stop
1
Before operating the MAXXFORCE 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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
Running-in
All 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
Operation and Maintenance Manual
Fuel Specifications - HSD IS 1460:2005
S. No
Characteristic
3
0
1
Density Kg/m 15
C
2
Sulphur Content mg/kg max
3(a)
Cetane Number minimum and / or
3(b)
Cetane Index
4
Polycyclic Aromatic Hydrocarbon
5
Distillation
(a)
(b)
(c)
0
Reco. Min. At 350
C
0
Reco. Min. At 370 C
BSII
BSIII
BSIV
820-800
820-845
820-845
500
350
50
48
51
51
or 46
and 46
and 46
-
11
11
85
-
-
95
-
-
-
360
360
0
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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
Lubricating Oil Circuit
43
Operation and Maintenance Manual
Attention: Always use 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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
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 GENUINE 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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
Coolant System
51
Operation and Maintenance Manual
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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
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 recommended coolant according to the
recommended proportion.
•
Run the engine till operating temperature and checkfor leaks.
54
Maintenance Plan: MAXXFORCE 4.8 &
7.2 Genset Engines
Operation and Maintenance Manual
55
Maintenance Plan: MAXXFORCE 4.8 &
7.2 Industrial Engines
Operation and Maintenance Manual
56
Operation and Maintenance Manual
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
Operation and Maintenance Manual
Conservation for Inactive Engines for Long Period
MAXXFORCE 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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
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.
NOTE
NOTE
60
Do not use high pressure or excessive hot water temperature as it may damage the engine
components.
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.
Operation and Maintenance Manual
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
Operation and Maintenance Manual
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- 29-4053-67
3
Difficult start - (engine does not starts quickly)
01-02-03-05-07-08-09-10-14-15-16-17-1822-25-26- 2729-40-53-67
4
Lack of power / Performance
07-08-09-10-14-15-16-17-18-19-20-21- 2223-25-26-2729-32-44-53-54-56-57-67
5
Engine misfiring
07-08-09-10-14-15-16-17-19-20-21-22- 2324-26-29-3244-53-67
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
Operation and Maintenance Manual
Trouble/Concern List
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
Operation and Maintenance Manual
Trouble/Concern List
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
Operation and Maintenance Manual
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
Operation and Maintenance Manual
List of probable causes
No.
Probable Cause
Action
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
Operation and Maintenance Manual
List of probable causes
No.
Probable Cause
Action
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
Operation and Maintenance Manual
List of probable causes
No.
Probable Cause
Action
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
Operation and Maintenance Manual
List of probable causes
No.
Probable Cause
Action
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
Operation and Maintenance Manual
List of probable causes
No.
Probable Cause
Action
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
leaking through the gaskets
Replace gaskets
70
Operation and Maintenance Manual
List of probable causes
No.
Probable Cause
Action
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
through liner collar
Correct
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
Operation and Maintenance Manual
Engine Block
Qty.
Description
Size
Application
Torque (Nm)
1 st
2
Bolt
M14
2 nd
Bearing Cap to Block
50 - 5
Qty.
Description
Size
1
Plug
3/8”
1
Hollow Bolt
M8x1
1
Plug
1/2”
1
72
Plug, Allen
Straight
M22x1.
5
Application
Water Drain Plug to
Block
Oil Ejector to Block
Water Drain Plug to
Block
To plug TC oil return
155 °± 5°
Torque(N m)
10 + 5
SC/CC
Torq.
Range
170 to
282
Required
Sealing
Loctite 567
**
10 ± 1.5
15 + 5
Loctite 567
40 ± 5
CC
SC/CC
Operation and Maintenance Manual
Connecting Rod
Qty.
2
Description
Bolt
Size
MJ
12x58
Application
Connecting Rod to
Crankshaft
Torque (Nm)
1 st
40 ± 5
SC/CC
Torq.
Range
130 to
160
2 nd
80 °± 2°
CC
Camshaft
Qty.
Description
Size
Application
4
Bolt
M8x25
Gear to Camshaft
2
Bolt
M8x16
Camshaft Lock to Block
Torque (Nm)
1 st
15 ± 1
2 nd
30 °± 2°
25 ± 4
Torq. Range
35 to 65
SC/CC
SC
Water Pump
Qty.
Descriptio
n
Size
Application
Torque(N m)
2
Bolt
M8x20
Water Pump to Block
20 ± 5
SC/CC
73
Operation and Maintenance Manual
Gear Housing
Qty.
Description
Size
Application
Torque(N
m)
10
3
2
1
3
1
1
Bolt
Bolt
Hollow Bolt
Hollow Bolt
Bolt
Plug
Plug
M8x20
M8x50
M8x1
M8x1
M10x70
M10x1
M14x1.5
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
30 ± 5
30 ± 5
7.5 ± 2.5
7.5 ± 2.5
60 ± 5
10 ± 5
20 ± 3
SC/CC
Valve Lubrication Pipes
Qty.
Description
Size
Application
Torque(N
m)
5
Hollow Bolt
M10x1
Valve Lubrication pipe to Cylinder Head
10 + 5
74
SC/CC
Operation and Maintenance Manual
Front Cover
Application
Torque(N
m)
M8x16
Front Cover to Gear Housing
30 ± 3
M8x55
Front Cover to Gear Housing to Block
30 ± 3
S65 X 4
Inspection cover to front cover
20 ± 3
Qty.
Description
Size
16
Bolt
9
Bolt
Inspection
Cover
1
SC/CC
Alternator Bracket
Qty.
Description
Size
Application
Torque(N
m)
3
Bolt
M10x35
Alternator Bracket to
Gear Housing
40 ± 6
1
Bolt
M10x20
Pulley to Alternator Bracket
40 ± 6
SC/CC
Water Flow Tube Assembly
Qty.
Description
Size
Application
Torque
(Nm)
1
Temparature
sensor cum
Switch
M14 X 1.5 X
11
Sensor fitted in water flow tube
Max. 20
SC/CC
75
Operation and Maintenance Manual
Water Outlet Pipe
Qty.
Description
Size
8
Bolt
M8x55
2
Bolt
M8x30
2
Bolt
M8x30
Qty.
Description
Size
1
Hollow Bolt
M12
1
Nipple
M22
1
Plug
M22X1.5
76
Application
Water Outlet Pipe
to Cylinder Head
Connection water
outlet
Torque(N m)
25 ± 4
25 ± 3
Connection by pass
25 ± 3
Application
Torque(N m)
Water outlet tube
to degassing tank
Nipple Bypass
connection for AC
application
Plug, Connection
Bypass for Non-AC
application
SC/CC
20 ± 3
40 ± 5
25 + 5
SC/CC
Operation and Maintenance Manual
Cylinder Head
Qty.
Description
Size
Applicatio
n
Pre Torque
(Nm)
Torq
ue
(Nm)
Torqu
e
1 (°)
Torq Torqu
ue
e
2 (°)
3 (°)
Torque
Range
SC/CC
14
Bolt
M14x152
Cylinder
Head to Block
40+5
60+
10
60± 3 60± 3
90± 3
120 To
260
CC
2
Bolt
M14
Cylinder
Head to Block
40+5
60+
10
60± 3 60± 3
90± 3
120 To
260
CC
2
Engine lifting
hook
-
80 ±
10
-
-
Qty.
2
1
1
Description
Socket head
cap screw
Nut
Nut
M12
Size
M5x10
M22
M8x10
Cylinder
Head
mounting
bolt
Application
Lubrication pipe to Cylinder
head
High pressure connector nut
Nut – Valve clearance
adjustment
-
-
Torque(N m)
SC/CC
5±1
50 + 5
20 + 5
77
Operation and Maintenance Manual
High Pressure Pump
Qty.
Description
Size
3
Stud
M8 X 30
3
Nut
M8
1
Nut
M14x1.5
1
Hollow Screw
M12
1
Connector
M8
1
Box Nut
M10x1
Application
High Pressure Pump adaptor
to Gear Housing
High Pressure Pump to Gear
Housing
Gear to High Pressure Pump
High Pressure Pump –Tube ,Fuel
Return
Connector for Boost pressure
Tube, Injection Pump to Intake
manifold
Torque(N m)
SC/CC
8±1
38 ± 3
SC
180 ± 5
SC
22.5 ± 2.5
10 + 5
12.5 ± 2.5
Low Pressure Pipe
Qty.
6
78
Description
Connection
Size
Application
M8x1
Pipe, Fuel Return to Cylinder
Head
Torque(N m)
8±1
SC/CC
Operation and Maintenance Manual
High Pressure Pipe
Qty.
Description
Size
Application
Torque(N m)
SC/CC
6
Nut
M12
Nut high pressure tube to
fuel injection pump
15 + 5
SC
6
Nut
M14
Nut high pressure tube to
Connector high pressure tube
25 + 5
SC
Qty.
Description
Size
Application
Torque(N m)
SC/CC
2
Bolt
M10x30
Fuel Filter to Block
35 ± 4
2
Connection
M14x1.5
20 + 6
1
Hollow Bolt
M12x1.5
Fuel inlet to Filter Head
Pipe, Fuel Filter outlet to VE
Pump
1
Hollow Bolt
M14x1.5
Pipe, Fuel Filter inlet for
mechanical feed Pump
20 + 6
1
Hollow Bolt
M14x1.5
Pipe, Fuel Filter inlet NRV
20 + 6
Fuel Filter
20 + 6
79
Operation and Maintenance Manual
Assy, Fuel Injector and Valve Cover
Qty.
Descriptio
n
Size
Application
Torque(N m)
SC/CC
1
Screw
M6
Special Step Bolt Fuel injection
Clamp
4± 1
SC
2
Bolt
M6 x 60
Valve Cover
8.5 ± 1
Descri
Qty.
ption
1
Size
Screw
M6
Application
Screw - Fastening
Bridge Fuel
Injector
Torque
(Nm)
1+0.5
Relieve Torque
to (Nm) (Nm)
0
Torque
1 (°)
4 ±1
90
Torqu Torqu
e
e
2 (°)
3 (°)
90
30
Torqu
e
Rang
e
SC/CC
7+6
Intake Manifold
Qty.
Description
8
8
1
80
Size
Application
Torque(N m)
Bolt
M8x35
Intake Manifold to
Cylinder Head
24 ± 2
Bolt
M8x80
Intake Manifold to
Cylinder Head
24 ± 2
Hollow Bolt
M12X1.5
Tube -Intake Manifold to FIP
20 + 6
SC/CC
Operation and Maintenance Manual
Exhaust Manifold
Qty.
Description
Size
8
Stud
M10x45
8
Stover Nut
M10
Application
Exhaust Manifold to
Cylinder Head
Exhaust Manifold to stud
Cylinder Head
Torque(N m)
SC/CC
6±2
70 ± 10
Exhaust Elbow
Qty.
Description
Size
3
Stud
M8
3
Stover Nut
M8
Application
Exhaust Elbow to
Turbocharger
Exhaust Elbow to
Turbocharger
Torque(N m)
SC/CC
6 ± 2
35 ± 4
81
Operation and Maintenance Manual
Crankshaft Pulley
Qty.
Description
Size
Application
Torque (Nm)
4
Cylindrical Bolt
M16x6
5
Crankshaft Pulley to
Crankshaft
9
Bolt
M8
Damper to Crankshaft Pulley
35 ± 5
1 st
2 nd
100 ± 10
275 ± 15
SC/CC
CC
Oil Suction Pipe
Qty.
Description
Size
Application
Torque(N m)
2
Bolt
M8x20
Oil Suction Pipe to Block
25 ± 4
SC/CC
Water Inlet Manifold
Qty.
Description
Size
Application
Torque(N m)
3
Bolt
M8x25
Water Inlet connection
20 ± 3
82
SC/CC
Operation and Maintenance Manual
Engine Breather
Qty.
Description
Size
Application
Torque(N m)
1
Bolt
M8x35
Breather to Block
25 ± 5
1
Bolt
M8x16
Engine breather tube to
Breather housing
10 + 2
Size
Application
SC/CC
Oil Pan
Qty.
Description
Torque(N m)
25
Bolt
M8x16
Oil Pan to Block
25 + 5
1
Bolt
M8x30
25 + 5
1
Plug
M18X1.5
1
Bolt
M12x20
1
Bolt
M6x16
Oil Pan to Block
Drain Plug engine oil
sump
Bracket oil filling tube to
flywheel housing
Bracket oil filling tube to
oil filling tube
SC/CC
65 ± 10
30 ± 5
10 ± 5
83
Operation and Maintenance Manual
Flywheel
Qty.
6
Description
Cylindrical
Bolt
Size
M16x35
Application
Flywheel to
Crankshaft
Torque (Nm)
1 st
2 nd
100 ± 10
275 ± 15
SC/CC
CC
Flywheel Housing
Qty.
Description
Size
Application
Torque(N m)
13
Bolt
M12x30
Flywheel Housing to Block
100 ± 5
SC/CC
Lubricating Oil Flilter Head andOil Cooler
Qty.
Description
10
Screw
1
Hollow Bolt
Size
M8x 40
M14X1.5
Application
Torque(N m)
oil cooler to block
25 ± 3
Adapter
25 + 5
SC/CC
Oil Pump
Qty.
Description
Size
Application
Torque(N m)
SC/CC
2
Bolt
M8x20
Oil Pump to Block
20 ± 5
SC
84
Operation and Maintenance Manual
Turbocharger
Qty.
4
Description
Bolt
Size
M8x30
Qty.
Description
Size
1
Hollow Bolt
M12x1.5
1
Hollow Bolt
M14x1.5
2
Bolt
M6x16
2
2
SCREW, HEX
FLANGED
HEAD
SCREW, HEX
FLANGED
HEAD
Application
Turbocharger to Exhaust
Manifold
Application
Turbocharger Inlet
Lubrication Pipe to
Turbocharger
Turbocharger Inlet
Lubrication Pipe to Block
Turbocharger Lubrication
Return Pipe to Turbocharger
Torque(N m)
SC/CC
30 ± 4
Torque
(Nm)
SC/CC
30 ± 4
37 ± 3
10 + 3
M8 x 20
Turbocharger Lubrication
Return Pipe to Turbocharger
20+3
M8 x 20
Turbocharger Lubrication
Return Pipe to Turbocharger
20+3
85
Operation and Maintenance Manual
Intake Curve
Qty.
3
Description
Screw, Hex.
Flanged head
Size
M8x35
1
Stud
M8x48
4
Screw, Hex.
Flanged head
M8x25
1
Nut, Hex.
M8x8
2
Plug, Allen
Tapered
M22 X 1.5 X 5.8
Application
Intake curve to intake
manifold
Intake curve to intake
manifold
Intake curve to intake
manifold
Intake curve to intake
manifold
Torque(N m)
For Plugging Heater Holes
30 ± 5
Application
Torque
(Nm)
SC/CC
20 ± 3
6±2
20 ± 3
20 ± 3
Air Cleaner Assembly
Qty.
Description
Size
1
Clamp SAE J1 508
Type SLTB
SAE No.124
4
Screw, Hex.
M10x20
1
2
86
Clamp SAE J1 508
Type SLTB
Screw, Serrated Hex.
flanged head
SAE No.- 42
M10x20
Clamping Hose ,Air cleaner Turbocharger to Air Cleaner
Assembly
Air Cleaner Assembly to
Air cleaner Mounting Bracket
Clamping Hose ,Air cleaner Turbocharger to Turbocharger
Air cleaner Mounting Bracket to
Cylinder Block
7.3 ± 1.3
25 ± 4
7.3 ± 1.3
50 ± 8
SC/CC
Operation and Maintenance Manual
Fan Assembly
Qty.
6
6
Description
Screw, Hex. Flanged
head
Screw, Serrated Hex.
Flanged head
Size
Application
Torque(N m)
SC/CC
M8x20
Fan Hub to Fan(28 inch)
25 ± 4
SC
M10X70
Fan pulley to Fan Hub and Fan
50 ± 8
SC
1
Bolt, Hex. Flanged head
M10x50
Fan Bracket to Timing case
50 ± 8
4
Bolt, Hex. Flanged head
M10x30
Housing Fan Bearing to Fan
Bracket
50 ± 8
M10X70
Auto Tensioner to Fan bracket
50 ± 8
M8X80
Fan Bracket to Timing case
25 ± 4
1
2
Screw, Serrated Hex.
Flanged head
Screw, Hex. Flanged
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
Operation and Maintenance Manual
Fuel Filter Assembly
Qty.
Description
Size
Application
Torque(N m)
1
Banjo bolt
M12X1.5X8.8
Fuel Pump end to NRV pipe
23 ± 3
Application
Elbow, turbocharger Mounting
bracket to turbocharger
Turbocharger Mounting bracket
to Elbow, turbocharger
Torque(N m)
SC/CC
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
SC/CC
25 + 5
25 + 5
Gear Case Assembly
Qty.
Description
Size
Application
Torque(N m)
3
Screw, Hex.
Flanged
M10X30X8.8
Air compressor closing plate to
Gear Case
45± 5
88
SC/CC
Operation and Maintenance Manual
Intake Manifold Assembly
Qty.
Description
Size
Application
Torque(N m)
1
Plug, Allen
Tapered
M12 X 1.5 X 5.8
For Pluging Intake manifold Hole
10± 2
Application
Feed Pump mounting to Gear
case
Feed Pump mounting to Gear
case
Feed Pump Inlet/Outlet
Feed Pump adapter to Timing
case
Torque(N m)
SC/CC
Feed Pump Assembly
Qty.
Description
Size
3
Allen bolt
M6X16X8.8
2
Screw, Hex.
Flanged
Banjo bolt
M8 X 25X 1.25 X
8.8
M14X1.5X8.8
1
Adapter
M14X1.5X8.8
2
SC/CC
10 ± 1.5
25 ± 4
23± 3
30 ± 4
89
Operation and Maintenance Manual
Radiator & Intercooler
Qty
.
Description
Size
Application
2
Clamp SAE J1 508 Type
SLTB
SAE
No.- 76
2
Clamp SAE J1 508 Type
SLTB
SAE
No.- 76
2
Clamp SAE J1 508 Type
SLTB
2
Clamp SAE J1 508 Type SLTB
1
Clamp SAE J1 508 Type SLTB
1
Clamp SAE J1 508 Type SLTB
2
Clamp SAE J1 508 Type SLTB
1
Clamp SAE J1 508 Type SLTB
1
Clamp SAE J1 508 Type SLTB
Hose clamp for intake curve to
intercooler
Hose clamp for Elbow
Turbocharger to Tube,
turbocharger -intercooler
Hose Clamp for Tube, turbocharger intercooler 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
Hose clamp on Engine Water inlet
pipe
Hose clamp on small end of reducer
hose at radiator outlet
Hose Clamp on reducer hose at
radiator outlet
1
Clamp SAE J1 508 Type SLTB
SAE
No.- 76
SAE No.42
SAE No.42
SAE No.34
SAE No.42
SAE No.42
SAE No.48
SAE No.- HOSE, TURBOCHARGER 72
INTERCOOLER
SAE No.HOSE, AIR CLEANER54
TURBOCHARGER
1 CLAMP SAE J1 508 TYPE SLTB 2
Mounted on the water inlet
connection tube
90
M8X12
Engine water inlet tube connection
Torque(N m)
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
7.3 ± 1.3
7.3 ± 1.3
7.3 ± 1.3
7.3 ± 1.3
10± 2
SC/CC
Operation and Maintenance Manual
Engine Mounting Foot
Qty.
8
Engine
Screw, Serrated
Hex. Flanged head
Size
M12x3
0
Application
Torque(N m)
Engine Mounting Foot to Cylinder Block
70 ± 10
SC/CC
Cylinder Block
Qty.
Description
Size
Application
Torque(N m)
1
Plug, Allen Tapered
M14 X 1.5
X 5.8
Plugging Compressor inlet
Hole in Cylinder block
10+5
SC/CC
Starter Motor Assembly
Qty.
Description
Size
Application
Torque(N m)
3
Screw, Hex. Flanged
M10 X 30 X
8.8
Starter Motor (24V) Mounting
45± 5
SC/CC
91
Operation and Maintenance Manual
Lubricating Oil Filter Head and Oil cooler
Qty.
Description
Size
Application
Torque
(Nm)
1
Oil Pressure sensor
cum switch
M12x12
Oil Pressure sensor cum switch
mounted at Oil Filter Head
Max. 50
SC/CC
Alternator 24 V Assembly– Electronic Genset
Qty.
2
1
1
92
Description
Screw, Hex. Flanged
head
Screw, Hex. Flanged
head
Screw, Hex. Flanged
head
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(N m)
20 ± 3
70 ± 10
40 ± 6
SC/CC
Operation and Maintenance Manual
Alternator Bracket- 12V
Qty.
Description
Size
1
Bolt
M8x80
1
Bolt
M8x20
Application
Alternator Bracket to
Alternator Bush
Alternator bracket to casting
bracket
Torque(N m)
SC/CC
30 ± 5
20 ± 3
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)
8.8
6±1
10 ± 1.5
25 ± 4
50 ± 8
86 ± 13
135 ± 20
207 ± 31
298 ± 45
418 ± 63
569 ± 85
10.9
9±1
15 ± 2
37 ± 6
73 ± 11
124 ± 19
198 ± 30
304 ± 46
424 ± 64
595 ± 89
810 ± 122
12.9
10 ± 1.5
18 ± 3
43 ± 7
84 ± 13
145 ± 22
231± 35
325 ± 49
497 ± 75
696 ± 104
948 ± 142
SC/CC
93
Operation and Maintenance Manual
NOTES
94
Operation and Maintenance Manual
NOTES
95
Operation and Maintenance Manual
NOTES
96
Delivery date
Month
Day
Operation
and Maintenance Manual
For Genset Application
OEM Name
Model (From Serial No. Plate)
Year
Serial No. (From serial No. plate)
NAVISTAR COPY
Commissioning Date
Month
Day
Year
Owner Surname or Company Name
First Name
Telephone (Area Code / Number)
Voltage
Phase
Genset No For Off High Way application only
Street / P. O BOX (2)
Zip Code / Post Code
Kva
Title
Street / P. O BOX (1)
City
Alternator
Model (From Serial No. Plate)
Serial No. (From serial No. plate)
Equipment No.
Chassis No.
State / Province
Country
Mobile phone No.
Email address
Transmission No.
Dealer Name
Commissioning Certified by:
Address
City
State/Prov.
Name
ZIP / Post Code
Sign
Telephone No. (Area code/Phone No.)
Dealer Name
E-Mail Address
95
Operation and Maintenance Manual
74
Delivery date
Month
Day
Operation
and Maintenance Manual
For Genset Application
OEM Name
Model (From Serial No. Plate)
Year
Serial No. (From serial No. plate)
Commissioning Date
Month
Day
Year
OEM COPY
Owner Surname or Company Name
First Name
Telephone (Area Code / Number)
Voltage
Phase
Genset No For Off High Way application only
Street / P. O BOX (2)
Zip Code / Post Code
Kva
Title
Street / P. O BOX (1)
City
Alternator
Model (From Serial No. Plate)
Serial No. (From serial No. plate)
Equipment No.
Chassis No.
State / Province
Country
Mobile phone No.
Email address
Transmission No.
Dealer Name
Commissioning Certified by:
Address
City
State/Prov.
Name
ZIP / Post Code
Sign
Telephone No. (Area code/Phone No.)
Dealer Name
E-Mail Address
Operation and Maintenance Manual
76
Delivery date
Month
Day
Operation
and Maintenance Manual
For Genset Application
OEM Name
Model (From Serial No. Plate)
Year
Serial No. (From serial No. plate)
OWNER'S COPY
Commissioning Date
Month
Day
Year
Owner Surname or Company Name
First Name
Telephone (Area Code / Number)
Voltage
Phase
Genset No For Off High Way application only
Street / P. O BOX (2)
Zip Code / Post Code
Kva
Title
Street / P. O BOX (1)
City
Alternator
Model (From Serial No. Plate)
Serial No. (From serial No. plate)
Equipment No.
Chassis No.
State / Province
Country
Mobile phone No.
Email address
Transmission No.
Dealer Name
Commissioning Certified by:
Address
City
State/Prov.
Name
ZIP / Post Code
Sign
Telephone No. (Area code/Phone No.)
Dealer Name
E-Mail Address