OPERATION AND MAINTENANCE MANUAL

MaxxForce 4.8IMaxxForce 4.8PMaxxForce 7.2IMaxxForce 7.2P

Operation and Maintenance Manual Operation and Maintenance Manual

Operation and Maintenance Manual

Av. das Nações Unidas, 22.002ZIP CODE - 04795-915São Paulo - SP - Brazil

Part No : 972P00602101Rev Date : 01-2014

MAXXFORCE 4.8 & 7.2

Operation and Maintenance Manual Operation and Maintenance Manual

3

General Information

INDEX

INDEX Introduction 5

Important Safety Remarks 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

Operation and Maintenance Manual Operation and Maintenance Manual

3

General Information

INDEX

INDEX Introduction 5

Important Safety Remarks 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

Operation and Maintenance Manual Operation and Maintenance Manual

Introduction

54

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.

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

Operation and Maintenance Manual Operation and Maintenance Manual

Introduction

54

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.

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

Operation and Maintenance Manual 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

76

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.

Operation and Maintenance Manual 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

76

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.

Operation and Maintenance Manual 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.

98

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 .

Operation and Maintenance Manual 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.

98

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 .

Operation and Maintenance Manual 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.

1110

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 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

Operation and Maintenance Manual 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.

1110

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 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

Operation and Maintenance Manual 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

1312

Engine Identification

4. 12 TC A

No of Cylinders

Series

Turbo Charged

After cooler

Operation and Maintenance Manual 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

1312

Engine Identification

4. 12 TC A

No of Cylinders

Series

Turbo Charged

After cooler

Operation and Maintenance Manual Operation and Maintenance Manual

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

FIRST CYLINDER

Engine Identification

6. 12 TC A

No of Cylinders

Series

Turbo Charged

After cooler

1514

Operation and Maintenance Manual Operation and Maintenance Manual

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

FIRST CYLINDER

Engine Identification

6. 12 TC A

No of Cylinders

Series

Turbo Charged

After cooler

1514

Operation and Maintenance Manual 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.

1716

Operation and Maintenance Manual

17

Operation and Maintenance Manual Operation and Maintenance Manual

1918

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 BOLTTUBE LINE16 VALVE SPRING 46 BEARING CAP 76 TENSIONER PULLEY BOLT 163 INTAKE ROCKER ARM

105 TURBO ELBOW BRACKET 133 PLUG17 SPRING RETAINER - UPPER 47 BEARING CAP BOLT 77 ALTERNATOR BOLT 164 NIPPLEBOLT 134 PLUG18 VALVE LOCK 48 CRANKSHAFT GEAR 78 ALTERNATOR 165 CYLINDER HEAD

106 TURBO OIL RETURN TUBE 135 OIL FILTER HEAD LUBRICATION BOLT19 VALVE SEAL 49 MAIN BEARING - LOWER 79 ALTERNATOR._BRACKET107 T-BOLT CLAMP 136 OIL FILTER HEAD BOLT 166 SEALING WAHSER20 ROCKER SHAFT 50 CRANKSHAFT BUSHING - 80 CLOSING PLATE108 TURBOCHARGERFRONT 137 OIL MAIN LINE BRACKET 167 TEE CONNECTION VALVE21 EXHAUST ROCKER ARM 81 CLOSING PLATE GASKET109 EXHAUST COVER NUT51 DEFLECTOR 138 OIL TUBE- MAIN LINE TO 168 TURBO OIL RETURN TUBE 22 INJECTOR HOLDER 82 AIR COMPRESSOR ASSY.110 EXHAUST ELBOW CYLINDER HEAD CONNECTION52 LUBRICANT OIL EJECTOR23 SPL. SCREW INJECTOR 83 HOSE-WATER OUTLET TUBE 111 TURBO BRACKET 139 IDLER SHAFT 169 EXHAUST COVER STUDHOLDER 53 CAM SHAFT TO COMPRESSOR112 EXHAUST MANIFOLD TURBO 140 BANJO BOLT 170 BANJO UNION24 A/C COMPRESSOR BRACKET 54 CAMSHAFT BUSHING 84 BREATHER HOSE CLIP & BOLT

STUDBOLT 141 SEALING WASHER 171 SEALING WASHER55 WATER PUMP GEAR 85 SEALING WASHER113 TURBO ELBOW BRACKET25 INTERMEDIATE ROCKER ARM 142 HIGH PRESSURE TUBE 172 BANJO BOLT56 WATER PUMP 86 WATER TEMPERATURE 114 EXHAUST MANIFOLD TURBO 26 FASTNING BRIDGE BOLT SENSOR 143 INTAKE MANIFOLD 173 HOSE-COMPRESSOR TO 57 GEAR CASE NUT WATER OUTLET TUBE27 PUSH ROD 87 WATER OUTLET CON PIPE 144 INTAKE COVER GASKET58 FIP GEAR 115 FUEL PUMP 174 TIMING CASE CONNECTION28 VALVE SETTING SCREW 88 BANJO UNION 145 INTAKE COVER59 GEAR CASE LUBRICATION 116 FIP GASKET 175 CLAMP IN BUSH, MAIN 29 TAPPET PIPE 89 SPRING CLAMP THEMOSTAT 146 INTAKE MANIFOLD BOLT117 FIP BRACKET BEARINGCONNECTION HOSE30 VALVE COVER GASKET 60 TENSIONER PULLEY 147 INTAKE MANIFOLD GASKET

Operation and Maintenance Manual Operation and Maintenance Manual

1918

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 BOLTTUBE LINE16 VALVE SPRING 46 BEARING CAP 76 TENSIONER PULLEY BOLT 163 INTAKE ROCKER ARM

105 TURBO ELBOW BRACKET 133 PLUG17 SPRING RETAINER - UPPER 47 BEARING CAP BOLT 77 ALTERNATOR BOLT 164 NIPPLEBOLT 134 PLUG18 VALVE LOCK 48 CRANKSHAFT GEAR 78 ALTERNATOR 165 CYLINDER HEAD

106 TURBO OIL RETURN TUBE 135 OIL FILTER HEAD LUBRICATION BOLT19 VALVE SEAL 49 MAIN BEARING - LOWER 79 ALTERNATOR._BRACKET107 T-BOLT CLAMP 136 OIL FILTER HEAD BOLT 166 SEALING WAHSER20 ROCKER SHAFT 50 CRANKSHAFT BUSHING - 80 CLOSING PLATE108 TURBOCHARGERFRONT 137 OIL MAIN LINE BRACKET 167 TEE CONNECTION VALVE21 EXHAUST ROCKER ARM 81 CLOSING PLATE GASKET109 EXHAUST COVER NUT51 DEFLECTOR 138 OIL TUBE- MAIN LINE TO 168 TURBO OIL RETURN TUBE 22 INJECTOR HOLDER 82 AIR COMPRESSOR ASSY.110 EXHAUST ELBOW CYLINDER HEAD CONNECTION52 LUBRICANT OIL EJECTOR23 SPL. SCREW INJECTOR 83 HOSE-WATER OUTLET TUBE 111 TURBO BRACKET 139 IDLER SHAFT 169 EXHAUST COVER STUDHOLDER 53 CAM SHAFT TO COMPRESSOR112 EXHAUST MANIFOLD TURBO 140 BANJO BOLT 170 BANJO UNION24 A/C COMPRESSOR BRACKET 54 CAMSHAFT BUSHING 84 BREATHER HOSE CLIP & BOLT

STUDBOLT 141 SEALING WASHER 171 SEALING WASHER55 WATER PUMP GEAR 85 SEALING WASHER113 TURBO ELBOW BRACKET25 INTERMEDIATE ROCKER ARM 142 HIGH PRESSURE TUBE 172 BANJO BOLT56 WATER PUMP 86 WATER TEMPERATURE 114 EXHAUST MANIFOLD TURBO 26 FASTNING BRIDGE BOLT SENSOR 143 INTAKE MANIFOLD 173 HOSE-COMPRESSOR TO 57 GEAR CASE NUT WATER OUTLET TUBE27 PUSH ROD 87 WATER OUTLET CON PIPE 144 INTAKE COVER GASKET58 FIP GEAR 115 FUEL PUMP 174 TIMING CASE CONNECTION28 VALVE SETTING SCREW 88 BANJO UNION 145 INTAKE COVER59 GEAR CASE LUBRICATION 116 FIP GASKET 175 CLAMP IN BUSH, MAIN 29 TAPPET PIPE 89 SPRING CLAMP THEMOSTAT 146 INTAKE MANIFOLD BOLT117 FIP BRACKET BEARINGCONNECTION HOSE30 VALVE COVER GASKET 60 TENSIONER PULLEY 147 INTAKE MANIFOLD GASKET

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Specifications

21

Engine make / model no. No MF 4.8

Prime rating KVA 62.5 / 82.5 / 100

No. of cylinder No 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

20

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

BRACKET182 TENSIONER LEVER BOLT 197 BREATHER HOUSING RING 226 CAMSHAFT BOLT 240 IDLER SHAFT BUSH

212 TURBO INLET OIL TUBE183 FIP INTERMEDIATE GEAR 198 BREATHER HOUSING 227 VALVE CAP 241 GEAR CASE BOLT

213 CONNECTION, FUEL RETURN184 FIP NUT 199 BREATHER HOUSING BOLT 228 A/C COMPRESSOR BOLT 242 TURBO HOSE PIPE CLAMP

214 BANJO UNION185 IDLER GEAR 200 FLYWHEEL HOUSING CAP 229 CRANK SHAFT PULLEY 243 OIL PUMP

215 OIL FILTER BOLT DOWEL PIN186 ALTENATOR BRACKET BOLT 201 HIGH PRESSURE NUT, BIG 244 OIL PUMP BOLT

216 PIVOT PIN 230 IDLER SHAFT WASHER187 ALTERNATOR BUSH 202 OIL PIPE BOLT 245 THERMOSTAT

217 HIGH PRESSURE PIPE NUT 231 IDLER SHAFT BOLT188 ALTERNATOR PULLEY 203 TURBOCHARGER BOLT 246 THEROMOSTAT O'RING

218 TURBO OIL RETURN BOLT 232 IDLER SHAFT DOWEL PIN189 O'RING 204 OIL FILTER HEAD PLUG 247 O'RING

219 TURBO BRACKET BOLT 233 GEAR CASE PLUG190 EXHUAST MANIFOLD 205 OIL FILTER HEAD PLUG 248 INJECTOR WASHER

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Specifications

21

Engine make / model no. No MF 4.8

Prime rating KVA 62.5 / 82.5 / 100

No. of cylinder No 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

20

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

BRACKET182 TENSIONER LEVER BOLT 197 BREATHER HOUSING RING 226 CAMSHAFT BOLT 240 IDLER SHAFT BUSH

212 TURBO INLET OIL TUBE183 FIP INTERMEDIATE GEAR 198 BREATHER HOUSING 227 VALVE CAP 241 GEAR CASE BOLT

213 CONNECTION, FUEL RETURN184 FIP NUT 199 BREATHER HOUSING BOLT 228 A/C COMPRESSOR BOLT 242 TURBO HOSE PIPE CLAMP

214 BANJO UNION185 IDLER GEAR 200 FLYWHEEL HOUSING CAP 229 CRANK SHAFT PULLEY 243 OIL PUMP

215 OIL FILTER BOLT DOWEL PIN186 ALTENATOR BRACKET BOLT 201 HIGH PRESSURE NUT, BIG 244 OIL PUMP BOLT

216 PIVOT PIN 230 IDLER SHAFT WASHER187 ALTERNATOR BUSH 202 OIL PIPE BOLT 245 THERMOSTAT

217 HIGH PRESSURE PIPE NUT 231 IDLER SHAFT BOLT188 ALTERNATOR PULLEY 203 TURBOCHARGER BOLT 246 THEROMOSTAT O'RING

218 TURBO OIL RETURN BOLT 232 IDLER SHAFT DOWEL PIN189 O'RING 204 OIL FILTER HEAD PLUG 247 O'RING

219 TURBO BRACKET BOLT 233 GEAR CASE PLUG190 EXHUAST MANIFOLD 205 OIL FILTER HEAD PLUG 248 INJECTOR WASHER

Operation and Maintenance Manual Operation and Maintenance Manual

●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

Engine Specifications

23

MF 4.8

Engine Specifications

22

Firing Order 1-3-4-2

● COOLING SYSTEM Method of Jacket cooling RadiatorHeat Removal By WaterQty of coolant(Engine + Radiator) Ltr 12 / 18Fan Power KW 2.0 / 3.0 / 5.0

● FUEL SYSTEM OF ENGINEFuel oil High speed Diesel(HSD IS 1460:2005)Fuel Filter type Spin-on type with paper elementFiltration capacity Micron 5Filter Change period hrs 500

1) FUEL INJECTION PUMP Make STANADYNE MAKEType Rotary2) GOVERNER DATA Type MECHANICAL (3- 5%)

Response time As per IS10002Recovery time

MF 4.8

Operation and Maintenance Manual Operation and Maintenance Manual

●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

Engine Specifications

23

MF 4.8

Engine Specifications

22

Firing Order 1-3-4-2

● COOLING SYSTEM Method of Jacket cooling RadiatorHeat Removal By WaterQty of coolant(Engine + Radiator) Ltr 12 / 18Fan Power KW 2.0 / 3.0 / 5.0

● FUEL SYSTEM OF ENGINEFuel oil High speed Diesel(HSD IS 1460:2005)Fuel Filter type Spin-on type with paper elementFiltration capacity Micron 5Filter Change period hrs 500

1) FUEL INJECTION PUMP Make STANADYNE MAKEType Rotary2) GOVERNER DATA Type MECHANICAL (3- 5%)

Response time As per IS10002Recovery time

MF 4.8

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Specifications Engine make / model no. No MF 7.2Prime rating KVA 125 / 140 / 160No. of cylinder No 6Type of construction Inline / V type InlineDisplacement Ltrs 7.12Bore mm 105Stroke mm 137Rated output kW 114.8 / 128.1 / 146.5

hp 156 / 174 / 199Standby output kW 125.6 / 139.9 / 160.0

hp 170.6 / 190.1 / 217.5Tolerance on rated output power % ±5Rated speed rpm 1500Method of Starting of engine 24V ELECAspiration NA/TC/TCA Turbocharged AftercoolerCompression Ratio 16.8:1Brake Mean Effective Pressure (bmep) Bar 1)Rated 12.9 / 14.4 / 16.4 2)Maximum 14.1 / 15.7 / 18Firing Order 1-5-3-6-2-4

25

Engine Specifications

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

Filtration capacity Microns 20

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 354flywheel housing

Weight to power ratio Kg/Kw 6.00 / 4.59 / 3.77

24

MF 4.8

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Specifications Engine make / model no. No MF 7.2Prime rating KVA 125 / 140 / 160No. of cylinder No 6Type of construction Inline / V type InlineDisplacement Ltrs 7.12Bore mm 105Stroke mm 137Rated output kW 114.8 / 128.1 / 146.5

hp 156 / 174 / 199Standby output kW 125.6 / 139.9 / 160.0

hp 170.6 / 190.1 / 217.5Tolerance on rated output power % ±5Rated speed rpm 1500Method of Starting of engine 24V ELECAspiration NA/TC/TCA Turbocharged AftercoolerCompression Ratio 16.8:1Brake Mean Effective Pressure (bmep) Bar 1)Rated 12.9 / 14.4 / 16.4 2)Maximum 14.1 / 15.7 / 18Firing Order 1-5-3-6-2-4

25

Engine Specifications

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

Filtration capacity Microns 20

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 354flywheel housing

Weight to power ratio Kg/Kw 6.00 / 4.59 / 3.77

24

MF 4.8

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Specifications

Recovery time

●LUBE OIL SYSTEMLube Oil Consumption at 100% Load Lit/hr 0.014 / 0.015 / 0.017Recommended lube oil 15W40 API CH4/ CI4Lub oil filter type Full flow: Spin on cartridge type with Paper elementFiltration capacity Microns 15Lube oil change period hours 500Maximum lube oil temperatorure Deg C Min:-10 & Max:125Lube 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 TypeExhaust noise level (with Silencer) @ 3M dB Complies with CPCB normsMax. Permissible back pressure in Exhaust mm of Hg 75Exhaust gas flow kg/hr 558 / 603 / 664Exhaust gas temperature (Max ) Deg C 600

●HEAT REJECTION DETAILS Heat Rejection to coolant kW 59.73 / 62.22 / 70.98

27

MF 7.2

Engine Specifications

●COOLING SYSTEM Method of Jacket cooling RadiatorHeat Removal By WaterDimensions of radiator (L X H X W ) mm 831x390.5x1135Qty of coolant(Engine + Radiator) Ltr 25Air Flow at Radiator Outlet CFM 10000 / 11800 / 11800Fan Power KW 6 / 7 / 7

●FUEL SYSTEM OF ENGINEFuel oil High speed Diesel(HSD IS 1460:2005)Fuel Filter type Spin-on type with paper elementFiltration capacity Micron 5Filter Change period hrs 5001)FUEL INJECTION PUMP Make STANADYNE MAKEType Rotary2)GOVERNER DATA Type MECHANICAL (3- 5%)Response time As per IS10002

26

MF 7.2

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Specifications

Recovery time

●LUBE OIL SYSTEMLube Oil Consumption at 100% Load Lit/hr 0.014 / 0.015 / 0.017Recommended lube oil 15W40 API CH4/ CI4Lub oil filter type Full flow: Spin on cartridge type with Paper elementFiltration capacity Microns 15Lube oil change period hours 500Maximum lube oil temperatorure Deg C Min:-10 & Max:125Lube 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 TypeExhaust noise level (with Silencer) @ 3M dB Complies with CPCB normsMax. Permissible back pressure in Exhaust mm of Hg 75Exhaust gas flow kg/hr 558 / 603 / 664Exhaust gas temperature (Max ) Deg C 600

●HEAT REJECTION DETAILS Heat Rejection to coolant kW 59.73 / 62.22 / 70.98

27

MF 7.2

Engine Specifications

●COOLING SYSTEM Method of Jacket cooling RadiatorHeat Removal By WaterDimensions of radiator (L X H X W ) mm 831x390.5x1135Qty of coolant(Engine + Radiator) Ltr 25Air Flow at Radiator Outlet CFM 10000 / 11800 / 11800Fan Power KW 6 / 7 / 7

●FUEL SYSTEM OF ENGINEFuel oil High speed Diesel(HSD IS 1460:2005)Fuel Filter type Spin-on type with paper elementFiltration capacity Micron 5Filter Change period hrs 5001)FUEL INJECTION PUMP Make STANADYNE MAKEType Rotary2)GOVERNER DATA Type MECHANICAL (3- 5%)Response time As per IS10002

26

MF 7.2

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Specifications

29

Maximum longitudinal working inclination (Angle):Reference values. For specific installations consult the factory.

O 4 Cylinder engines-20

O 6 Cylinder engines-20

Engine Specifications

Heat Rejection to CAC kW 14.74 / 19.33 / 22.49Heat Rejection to exhaust kW 82.39 / 101.19 / 110.58Heat Rejection from engine surface kW 12.1 / 12.89 / 14.38

●AIR INTAKE SYSTEM Intake filter type Dry type Air cleanerAir intake restriction - with clean element mm of H2O 230Air intake restriction - with dirty element mm of H20 600Filtration capacity Microns 20Maximum Intake manifold temperature Deg C 55Combustion 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 1727X932X1274.4Dry engine weight-with flywheel & kg 598.6flywheel housingWeight to power ratio Kg/Kw 5.21 / 4.67 / 4.09

28

MF 7.2

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Specifications

29

Maximum longitudinal working inclination (Angle):Reference values. For specific installations consult the factory.

O 4 Cylinder engines-20

O 6 Cylinder engines-20

Engine Specifications

Heat Rejection to CAC kW 14.74 / 19.33 / 22.49Heat Rejection to exhaust kW 82.39 / 101.19 / 110.58Heat Rejection from engine surface kW 12.1 / 12.89 / 14.38

●AIR INTAKE SYSTEM Intake filter type Dry type Air cleanerAir intake restriction - with clean element mm of H2O 230Air intake restriction - with dirty element mm of H20 600Filtration capacity Microns 20Maximum Intake manifold temperature Deg C 55Combustion 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 1727X932X1274.4Dry engine weight-with flywheel & kg 598.6flywheel housingWeight to power ratio Kg/Kw 5.21 / 4.67 / 4.09

28

MF 7.2

Operation and Maintenance Manual Operation and Maintenance Manual

Engine FeaturesMAXXFORCE 4.8 Liter is in-line four cylinder engines with 4.8 Liter displacement and 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.

MAXXFORCE

Engine Specifications

3130

Maximum transversal working inclination (Angle):Reference values only. For specific installations consult the factory.

O• 4 & 6 Cylinder engines-30

Maximum transversal installation inclination (Angle):Reference values only. For specific installations consult the factory.

O• 4 & 6 Cylinder engines-15

Operation and Maintenance Manual Operation and Maintenance Manual

Engine FeaturesMAXXFORCE 4.8 Liter is in-line four cylinder engines with 4.8 Liter displacement and 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.

MAXXFORCE

Engine Specifications

3130

Maximum transversal working inclination (Angle):Reference values only. For specific installations consult the factory.

O• 4 & 6 Cylinder engines-30

Maximum transversal installation inclination (Angle):Reference values only. For specific installations consult the factory.

O• 4 & 6 Cylinder engines-15

Operation and Maintenance Manual 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.

3332

• Viscous damper is used for the 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

MAXXFORCE

Operation and Maintenance Manual 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.

3332

• Viscous damper is used for the 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

MAXXFORCE

Operation and Maintenance Manual 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

Engine Front View

1. Fan

2. Alternator

3. Tensioner Pulley

4. Vibration damper

5. Front cover

3534

Operation and Maintenance Manual 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

Engine Front View

1. Fan

2. Alternator

3. Tensioner Pulley

4. Vibration damper

5. Front cover

3534

Operation and Maintenance Manual Operation and Maintenance Manual

1 Flywheel2 Lube Oil sump3 Air Filter

Engine Rear ViewRight View (Hot Side)

1 Oil dipstick2 Turbo inlet3 Turbo outlet4 Exhaust manifold5 Turbo exhaust curve6 Flywheel housing7 Cylinder block8 Water outlet tube

3736

Operation and Maintenance Manual Operation and Maintenance Manual

1 Flywheel2 Lube Oil sump3 Air Filter

Engine Rear ViewRight View (Hot Side)

1 Oil dipstick2 Turbo inlet3 Turbo outlet4 Exhaust manifold5 Turbo exhaust curve6 Flywheel housing7 Cylinder block8 Water outlet tube

3736

Operation and Maintenance Manual 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.

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.

3938

Operation and Maintenance Manual 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.

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.

3938

Operation and Maintenance Manual Operation and Maintenance Manual

Fuel Specifications - HSD IS 1460:2005

• 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)

S. No Characteristic BSII BSIII BSIV

1 Density Kg/m3

15 0C 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 - -

(a) Reco. Min. At 350 0C 95 - -

(b) Reco. Min. At 370 0C - 360 360

(c) 95%Vol Reco at 0 C max

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.

4140

0

Operation and Maintenance Manual Operation and Maintenance Manual

Fuel Specifications - HSD IS 1460:2005

• 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)

S. No Characteristic BSII BSIII BSIV

1 Density Kg/m3

15 0C 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 - -

(a) Reco. Min. At 350 0C 95 - -

(b) Reco. Min. At 370 0C - 360 360

(c) 95%Vol Reco at 0 C max

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.

4140

0

Operation and Maintenance Manual 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.

Lubricating Oil Circuit

4342

Operation and Maintenance Manual 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.

Lubricating Oil Circuit

4342

Operation and Maintenance Manual 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.

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.

4544

Attention: Do not mix different oil brand / grade.

Operation and Maintenance Manual 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.

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.

4544

Attention: Do not mix different oil brand / grade.

Operation and Maintenance Manual 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

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.

4746

Operation and Maintenance Manual 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

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.

4746

Operation and Maintenance Manual 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

4948

Engine Oil Filter Element Removal

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.

(For specific 4 cyl engines only)

Operation and Maintenance Manual 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

4948

Engine Oil Filter Element Removal

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.

(For specific 4 cyl engines only)

Operation and Maintenance Manual Operation and Maintenance Manual

Cooling Fluid and Coolant :

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.

5150

Attention:

Coolant System

Operation and Maintenance Manual Operation and Maintenance Manual

Cooling Fluid and Coolant :

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.

5150

Attention:

Coolant System

Operation and Maintenance Manual Operation and Maintenance Manual

52

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.

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 Operation and Maintenance Manual

52

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.

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 Operation and Maintenance Manual

55

Mai

nte

nan

ce P

lan

: M

AX

XFO

RC

E 4

.8 &

7

.2 G

en

set

Engi

ne

s

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

Operation and Maintenance Manual Operation and Maintenance Manual

55

Mai

nte

nan

ce P

lan

: M

AX

XFO

RC

E 4

.8 &

7

.2 G

en

set

Engi

ne

s

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

Operation and Maintenance Manual Operation and Maintenance ManualM

ain

ten

ance

Pla

n:

MA

XX

FOR

CE

4.8

&

7.2

Ind

ust

rial

En

gin

es

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.

5756

Operation and Maintenance Manual Operation and Maintenance Manual

Mai

nte

nan

ce P

lan

: M

AX

XFO

RC

E 4

.8 &

7.2

Ind

ust

rial

En

gin

es

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.

5756

Operation and Maintenance Manual Operation and Maintenance Manual

5958

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.

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.

Operation and Maintenance Manual Operation and Maintenance Manual

5958

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.

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.

Operation and Maintenance Manual Operation and Maintenance Manual

6160

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

Engine Starting Preparation

Clean Engine

To avoid serious personal injury, possible death, or damage to the engine or Genset, read all safety

instructions in the “Safety Information” section of this manual.

1. Cap all turbocharger and manifold openings to prevent water and degreased agents from entering any engine

components internally.

2. Use an appropriate detergent mixed in the correct ratio of water and applies to engine using a warm water and

moderate pressure washer or similar cleaning equipment.

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.

Warning:

NOTE

NOTE

Operation and Maintenance Manual Operation and Maintenance Manual

6160

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

Engine Starting Preparation

Clean Engine

To avoid serious personal injury, possible death, or damage to the engine or Genset, read all safety

instructions in the “Safety Information” section of this manual.

1. Cap all turbocharger and manifold openings to prevent water and degreased agents from entering any engine

components internally.

2. Use an appropriate detergent mixed in the correct ratio of water and applies to engine using a warm water and

moderate pressure washer or similar cleaning equipment.

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.

Warning:

NOTE

NOTE

Operation and Maintenance Manual Operation and Maintenance Manual

Trouble/Concern List

6362

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

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

Operation and Maintenance Manual Operation and Maintenance Manual

Trouble/Concern List

6362

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

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

Operation and Maintenance Manual Operation and Maintenance Manual

6564

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

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

Operation and Maintenance Manual Operation and Maintenance Manual

6564

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

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

Operation and Maintenance Manual Operation and Maintenance Manual

6766

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

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

Operation and Maintenance Manual Operation and Maintenance Manual

6766

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

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

Operation and Maintenance Manual Operation and Maintenance Manual

6968

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

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

Operation and Maintenance Manual Operation and Maintenance Manual

6968

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

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

Operation and Maintenance Manual Operation and Maintenance Manual

7170

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 Replace gasketsleaking through the gaskets

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 Correctthrough 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

Operation and Maintenance Manual Operation and Maintenance Manual

7170

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 Replace gasketsleaking through the gaskets

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 Correctthrough 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

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Block

Qty. Description Size Application Torque (Nm) SC/CC

2 Bolt M14 Bearing Cap to Block

1st 2nd Torq. Range

CC50 - 5 155 °± 5°

170 to 282

Qty. Description Size Application Torque(N m)Required

SealingSC/CC

1 Plug 3/8”Water Drain Plug to

Block10 + 5

Loctite 567

1 Hollow Bolt M8x1 Oil Ejector to Block 10 ± 1.5 **

1 Plug 1/2”Water Drain Plug to

Block15 + 5

Loctite 567

1Plug, Allen Straight

M22x1.5

To plug TC oil return 40 ± 5

Connecting Rod

Qty. Description Size Application Torque (Nm) SC/CC

2 BoltMJ

12x58Connecting Rod to

Crankshaft

1st 2nd Torq. Range

CC40 ± 5 80 °± 2°

130 to 160

Camshaft

Qty. Description Size Application Torque (Nm) SC/CC

4 Bolt M8x25 Gear to Camshaft1st 2nd Torq. Range

SC15 ± 1 30 °± 2° 35 to 65

2 Bolt M8x16 Camshaft Lock to Block 25 ± 4

Water Pump

Qty.Descriptio

n Size Application Torque(N m) SC/CC

2 Bolt M8x20 Water Pump to Block 20 ± 5

7372

Operation and Maintenance Manual Operation and Maintenance Manual

Engine Block

Qty. Description Size Application Torque (Nm) SC/CC

2 Bolt M14 Bearing Cap to Block

1st 2nd Torq. Range

CC50 - 5 155 °± 5°

170 to 282

Qty. Description Size Application Torque(N m)Required

SealingSC/CC

1 Plug 3/8”Water Drain Plug to

Block10 + 5

Loctite 567

1 Hollow Bolt M8x1 Oil Ejector to Block 10 ± 1.5 **

1 Plug 1/2”Water Drain Plug to

Block15 + 5

Loctite 567

1Plug, Allen Straight

M22x1.5

To plug TC oil return 40 ± 5

Connecting Rod

Qty. Description Size Application Torque (Nm) SC/CC

2 BoltMJ

12x58Connecting Rod to

Crankshaft

1st 2nd Torq. Range

CC40 ± 5 80 °± 2°

130 to 160

Camshaft

Qty. Description Size Application Torque (Nm) SC/CC

4 Bolt M8x25 Gear to Camshaft1st 2nd Torq. Range

SC15 ± 1 30 °± 2° 35 to 65

2 Bolt M8x16 Camshaft Lock to Block 25 ± 4

Water Pump

Qty.Descriptio

n Size Application Torque(N m) SC/CC

2 Bolt M8x20 Water Pump to Block 20 ± 5

7372

Operation and Maintenance Manual Operation and Maintenance Manual

Gear Housing

Qty. Description Size ApplicationTorque(N

m)SC/CC

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

Qty. Description Size ApplicationTorque(N

m)SC/CC

5 Hollow Bolt M10x1 Valve Lubrication pipe to Cylinder Head 10 + 5

Front Cover

Qty. Description Size ApplicationTorque(N

m)SC/CC

16 Bolt M8x16 Front Cover to Gear Housing 30 ± 3

9 Bolt M8x55 Front Cover to Gear Housing to Block 30 ± 3

1Inspection

CoverS65 X 4 Inspection cover to front cover 20 ± 3

Alternator Bracket

Qty. Description Size ApplicationTorque(N

m)SC/CC

3 Bolt M10x35Alternator Bracket to

Gear Housing40 ± 6

1 Bolt M10x20 Pulley to Alternator Bracket 40 ± 6

Water Flow Tube Assembly

Qty. Description Size ApplicationTorque

(Nm)SC/CC

1Temparature sensor cum

Switch

M14 X 1.5 X 11

Sensor fitted in water flow tube Max. 20

7574

Operation and Maintenance Manual Operation and Maintenance Manual

Gear Housing

Qty. Description Size ApplicationTorque(N

m)SC/CC

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

Qty. Description Size ApplicationTorque(N

m)SC/CC

5 Hollow Bolt M10x1 Valve Lubrication pipe to Cylinder Head 10 + 5

Front Cover

Qty. Description Size ApplicationTorque(N

m)SC/CC

16 Bolt M8x16 Front Cover to Gear Housing 30 ± 3

9 Bolt M8x55 Front Cover to Gear Housing to Block 30 ± 3

1Inspection

CoverS65 X 4 Inspection cover to front cover 20 ± 3

Alternator Bracket

Qty. Description Size ApplicationTorque(N

m)SC/CC

3 Bolt M10x35Alternator Bracket to

Gear Housing40 ± 6

1 Bolt M10x20 Pulley to Alternator Bracket 40 ± 6

Water Flow Tube Assembly

Qty. Description Size ApplicationTorque

(Nm)SC/CC

1Temparature sensor cum

Switch

M14 X 1.5 X 11

Sensor fitted in water flow tube Max. 20

7574

Operation and Maintenance Manual Operation and Maintenance Manual

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

1 Hollow Bolt M12Water outlet tube to degassing tank

20 ± 3

1 Nipple M22Nipple Bypass

connection for AC application

40 ± 5

1 Plug M22X1.5Plug, Connection

Bypass for Non-AC application

25 + 5

Water Outlet Pipe

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

8 Bolt M8x55Water Outlet Pipe to Cylinder Head

25 ± 4

2 Bolt M8x30Connection water

outlet25 ± 3

2 Bolt M8x30 Connection by pass 25 ± 3

Cylinder Head

Qty. Description SizeApplicatio

n

Pre-Torque

(Nm)

Torque

(Nm)

Torque

1 (°)

Torque2 (°)

Torque

3 (°)

TorqueRange

SC/CC

14 Bolt M14x152Cylinder

Head to Block40+5

60+ 10

60± 3 60± 3 90± 3120 To

260CC

2 Bolt M14Cylinder

Head to Block40+5

60+ 10

60± 3 60± 3 90± 3120 To

260CC

2Engine lifting

hookM12

Cylinder Head

mounting bolt

-80 ±10

- - - -

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

2Socket head

cap screwM5x10

Lubrication pipe to Cylinder head

5 ± 1

1 Nut M22 High pressure connector nut 50 + 5

1 Nut M8x10Nut – Valve clearance

adjustment20 + 5

7776

Operation and Maintenance Manual Operation and Maintenance Manual

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

1 Hollow Bolt M12Water outlet tube to degassing tank

20 ± 3

1 Nipple M22Nipple Bypass

connection for AC application

40 ± 5

1 Plug M22X1.5Plug, Connection

Bypass for Non-AC application

25 + 5

Water Outlet Pipe

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

8 Bolt M8x55Water Outlet Pipe to Cylinder Head

25 ± 4

2 Bolt M8x30Connection water

outlet25 ± 3

2 Bolt M8x30 Connection by pass 25 ± 3

Cylinder Head

Qty. Description SizeApplicatio

n

Pre-Torque

(Nm)

Torque

(Nm)

Torque

1 (°)

Torque2 (°)

Torque

3 (°)

TorqueRange

SC/CC

14 Bolt M14x152Cylinder

Head to Block40+5

60+ 10

60± 3 60± 3 90± 3120 To

260CC

2 Bolt M14Cylinder

Head to Block40+5

60+ 10

60± 3 60± 3 90± 3120 To

260CC

2Engine lifting

hookM12

Cylinder Head

mounting bolt

-80 ±10

- - - -

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

2Socket head

cap screwM5x10

Lubrication pipe to Cylinder head

5 ± 1

1 Nut M22 High pressure connector nut 50 + 5

1 Nut M8x10Nut – Valve clearance

adjustment20 + 5

7776

Operation and Maintenance Manual Operation and Maintenance Manual

High Pressure Pump

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

3 Stud M8 X 30High Pressure Pump adaptor

to Gear Housing8 ± 1

3 Nut M8High Pressure Pump to Gear

Housing38 ± 3 SC

1 Nut M14x1.5 Gear to High Pressure Pump 180 ± 5 SC

1 Hollow Screw M12High Pressure Pump –Tube ,Fuel

Return22.5 ± 2.5

1 Connector M8 Connector for Boost pressure 10 + 5

1 Box Nut M10x1Tube, Injection Pump to Intake

manifold12.5 ± 2.5

Low Pressure Pipe

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

6 Connection M8x1Pipe, Fuel Return to Cylinder

Head8 ± 1

High Pressure Pipe

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

6 Nut M12Nut high pressure tube to

fuel injection pump15 + 5 SC

6 Nut M14Nut high pressure tube to

Connector high pressure tube25 + 5 SC

Fuel Filter

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

2 Bolt M10x30 Fuel Filter to Block 35 ± 4

2 Connection M14x1.5 Fuel inlet to Filter Head 20 + 6

1 Hollow Bolt M12x1.5Pipe, Fuel Filter outlet to VE

Pump20 + 6

1 Hollow Bolt M14x1.5Pipe, Fuel Filter inlet for mechanical feed Pump

20 + 6

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

7978

Operation and Maintenance Manual Operation and Maintenance Manual

High Pressure Pump

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

3 Stud M8 X 30High Pressure Pump adaptor

to Gear Housing8 ± 1

3 Nut M8High Pressure Pump to Gear

Housing38 ± 3 SC

1 Nut M14x1.5 Gear to High Pressure Pump 180 ± 5 SC

1 Hollow Screw M12High Pressure Pump –Tube ,Fuel

Return22.5 ± 2.5

1 Connector M8 Connector for Boost pressure 10 + 5

1 Box Nut M10x1Tube, Injection Pump to Intake

manifold12.5 ± 2.5

Low Pressure Pipe

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

6 Connection M8x1Pipe, Fuel Return to Cylinder

Head8 ± 1

High Pressure Pipe

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

6 Nut M12Nut high pressure tube to

fuel injection pump15 + 5 SC

6 Nut M14Nut high pressure tube to

Connector high pressure tube25 + 5 SC

Fuel Filter

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

2 Bolt M10x30 Fuel Filter to Block 35 ± 4

2 Connection M14x1.5 Fuel inlet to Filter Head 20 + 6

1 Hollow Bolt M12x1.5Pipe, Fuel Filter outlet to VE

Pump20 + 6

1 Hollow Bolt M14x1.5Pipe, Fuel Filter inlet for mechanical feed Pump

20 + 6

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

7978

Operation and Maintenance Manual Operation and Maintenance Manual

Assy, Fuel Injector and Valve Cover

Qty.Descriptio

n Size Application Torque(N m) SC/CC

1 Screw M6Special Step Bolt Fuel injection

Clamp4± 1 SC

2 Bolt M6 x 60 Valve Cover 8.5 ± 1

Qty.Description

Size ApplicationTorque

(Nm)Relieve to (Nm)

Torque(Nm)

Torque1 (°)

Torque

2 (°)

Torque

3 (°)

Torque

Range

SC/CC

1 Screw M6Screw- Fastening

Bridge Fuel Injector

1+0.5 0 4 ± 1 90 90 30 7+6

Intake Manifold

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

8 Bolt M8x35Intake Manifold to

Cylinder Head24 ± 2

8 Bolt M8x80Intake Manifold to

Cylinder Head24 ± 2

1 Hollow Bolt M12X1.5 Tube-Intake Manifold to FIP 20 + 6

Exhaust Manifold

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

8 Stud M10x45Exhaust Manifold to

Cylinder Head6 ± 2

8 Stover Nut M10Exhaust Manifold to stud

Cylinder Head70 ± 10

Exhaust Elbow

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

3 Stud M8Exhaust Elbow to

Turbocharger6 ± 2

3 Stover Nut M8Exhaust Elbow to

Turbocharger35 ± 4

8180

Operation and Maintenance Manual Operation and Maintenance Manual

Assy, Fuel Injector and Valve Cover

Qty.Descriptio

n Size Application Torque(N m) SC/CC

1 Screw M6Special Step Bolt Fuel injection

Clamp4± 1 SC

2 Bolt M6 x 60 Valve Cover 8.5 ± 1

Qty.Description

Size ApplicationTorque

(Nm)Relieve to (Nm)

Torque(Nm)

Torque1 (°)

Torque

2 (°)

Torque

3 (°)

Torque

Range

SC/CC

1 Screw M6Screw- Fastening

Bridge Fuel Injector

1+0.5 0 4 ± 1 90 90 30 7+6

Intake Manifold

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

8 Bolt M8x35Intake Manifold to

Cylinder Head24 ± 2

8 Bolt M8x80Intake Manifold to

Cylinder Head24 ± 2

1 Hollow Bolt M12X1.5 Tube-Intake Manifold to FIP 20 + 6

Exhaust Manifold

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

8 Stud M10x45Exhaust Manifold to

Cylinder Head6 ± 2

8 Stover Nut M10Exhaust Manifold to stud

Cylinder Head70 ± 10

Exhaust Elbow

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

3 Stud M8Exhaust Elbow to

Turbocharger6 ± 2

3 Stover Nut M8Exhaust Elbow to

Turbocharger35 ± 4

8180

Operation and Maintenance Manual Operation and Maintenance Manual

Crankshaft Pulley

Qty. Description Size Application Torque (Nm) SC/CC

4 Cylindrical BoltM16x6

5Crankshaft Pulley to

Crankshaft

1st 2nd

CC100 ± 10 275 ± 15

9 Bolt M8 Damper to Crankshaft Pulley 35 ± 5

Oil Suction Pipe

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

3 Bolt M8x25 Water Inlet connection 20 ± 3

Engine Breather

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

1 Bolt M8x35 Breather to Block 25 ± 5

1 Bolt M8x16Engine breather tube to

Breather housing10 + 2

Oil Pan

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

25 Bolt M8x16 Oil Pan to Block 25 + 5

1 Bolt M8x30 Oil Pan to Block 25 + 5

1 Plug M18X1.5Drain Plug engine oil sump

65 ± 10

1 Bolt M12x20Bracket oil filling tube to flywheel housing

30 ± 5

1 Bolt M6x16Bracket oil filling tube to oil filling tube

10 ± 5

8382

Operation and Maintenance Manual Operation and Maintenance Manual

Crankshaft Pulley

Qty. Description Size Application Torque (Nm) SC/CC

4 Cylindrical BoltM16x6

5Crankshaft Pulley to

Crankshaft

1st 2nd

CC100 ± 10 275 ± 15

9 Bolt M8 Damper to Crankshaft Pulley 35 ± 5

Oil Suction Pipe

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

3 Bolt M8x25 Water Inlet connection 20 ± 3

Engine Breather

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

1 Bolt M8x35 Breather to Block 25 ± 5

1 Bolt M8x16Engine breather tube to

Breather housing10 + 2

Oil Pan

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

25 Bolt M8x16 Oil Pan to Block 25 + 5

1 Bolt M8x30 Oil Pan to Block 25 + 5

1 Plug M18X1.5Drain Plug engine oil sump

65 ± 10

1 Bolt M12x20Bracket oil filling tube to flywheel housing

30 ± 5

1 Bolt M6x16Bracket oil filling tube to oil filling tube

10 ± 5

8382

Operation and Maintenance Manual Operation and Maintenance Manual

Flywheel

Qty. Description Size Application Torque (Nm) SC/CC

6Cylindrical

BoltM16x35

Flywheel to Crankshaft

1st 2nd

CC100 ± 10 275 ± 15

Flywheel Housing

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

13 Bolt M12x30 Flywheel Housing to Block 100 ± 5

Lubricating Oil Flilter Head andOil Cooler

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

10 Screw M8x 40 oil cooler to block 25 ± 3

1 Hollow Bolt M14X1.5 Adapter 25 + 5

Oil Pump

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

2 Bolt M8x20 Oil Pump to Block 20 ± 5 SC

Turbocharger

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

4 Bolt M8x30Turbocharger to Exhaust Manifold

30 ± 4

Qty. Description Size ApplicationTorque(Nm)

SC/CC

1 Hollow Bolt M12x1.5Turbocharger InletLubrication Pipe to Turbocharger

30 ± 4

1 Hollow Bolt M14x1.5Turbocharger InletLubrication Pipe to Block

37 ± 3

2 Bolt M6x16Turbocharger Lubrication Return Pipe to Turbocharger

10 + 3

2SCREW, HEX FLANGED HEAD

M8 x 20 Turbocharger Lubrication Return Pipe to Turbocharger

20+3

2SCREW, HEX FLANGED HEAD

M8 x 20 Turbocharger Lubrication Return Pipe to Turbocharger

20+3

8584

Operation and Maintenance Manual Operation and Maintenance Manual

Flywheel

Qty. Description Size Application Torque (Nm) SC/CC

6Cylindrical

BoltM16x35

Flywheel to Crankshaft

1st 2nd

CC100 ± 10 275 ± 15

Flywheel Housing

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

13 Bolt M12x30 Flywheel Housing to Block 100 ± 5

Lubricating Oil Flilter Head andOil Cooler

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

10 Screw M8x 40 oil cooler to block 25 ± 3

1 Hollow Bolt M14X1.5 Adapter 25 + 5

Oil Pump

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

2 Bolt M8x20 Oil Pump to Block 20 ± 5 SC

Turbocharger

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

4 Bolt M8x30Turbocharger to Exhaust Manifold

30 ± 4

Qty. Description Size ApplicationTorque(Nm)

SC/CC

1 Hollow Bolt M12x1.5Turbocharger InletLubrication Pipe to Turbocharger

30 ± 4

1 Hollow Bolt M14x1.5Turbocharger InletLubrication Pipe to Block

37 ± 3

2 Bolt M6x16Turbocharger Lubrication Return Pipe to Turbocharger

10 + 3

2SCREW, HEX FLANGED HEAD

M8 x 20 Turbocharger Lubrication Return Pipe to Turbocharger

20+3

2SCREW, HEX FLANGED HEAD

M8 x 20 Turbocharger Lubrication Return Pipe to Turbocharger

20+3

8584

Operation and Maintenance Manual Operation and Maintenance Manual

Intake Curve

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

3Screw, Hex.

Flanged headM8x35

Intake curve to intake manifold

20 ± 3

1 Stud M8x48Intake curve to intake

manifold6 ± 2

4Screw, Hex.

Flanged headM8x25

Intake curve to intake manifold

20 ± 3

1 Nut, Hex. M8x8Intake curve to intake

manifold20 ± 3

2Plug, Allen

TaperedM22 X 1.5 X 5.8 For Plugging Heater Holes 30 ± 5

Air Cleaner Assembly

Qty. Description Size ApplicationTorque

(Nm)SC/CC

1Clamp SAE J1 508

Type SLTB SAE No.-

124

Clamping Hose ,Air cleaner -Turbocharger to Air Cleaner

Assembly7.3 ± 1.3

4 Screw, Hex. M10x20Air Cleaner Assembly to

Air cleaner Mounting Bracket25 ± 4

1Clamp SAE J1 508

Type SLTB SAE No.- 42

Clamping Hose ,Air cleaner -Turbocharger to Turbocharger

7.3 ± 1.3

2Screw, Serrated Hex.

flanged headM10x20

Air cleaner Mounting Bracket to Cylinder Block

50 ± 8

Fan Assembly

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

6Screw, Hex. Flanged

head M8x20 Fan Hub to Fan(28 inch) 25 ± 4 SC

6Screw, Serrated Hex.

Flanged headM10X70 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 M10x30Housing Fan Bearing to Fan

Bracket50 ± 8

1Screw, Serrated Hex.

Flanged headM10X70 Auto Tensioner to Fan bracket 50 ± 8

2Screw, Hex. Flanged

headM8X80 Fan Bracket to Timing case 25 ± 4

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

8786

Operation and Maintenance Manual Operation and Maintenance Manual

Intake Curve

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

3Screw, Hex.

Flanged headM8x35

Intake curve to intake manifold

20 ± 3

1 Stud M8x48Intake curve to intake

manifold6 ± 2

4Screw, Hex.

Flanged headM8x25

Intake curve to intake manifold

20 ± 3

1 Nut, Hex. M8x8Intake curve to intake

manifold20 ± 3

2Plug, Allen

TaperedM22 X 1.5 X 5.8 For Plugging Heater Holes 30 ± 5

Air Cleaner Assembly

Qty. Description Size ApplicationTorque

(Nm)SC/CC

1Clamp SAE J1 508

Type SLTB SAE No.-

124

Clamping Hose ,Air cleaner -Turbocharger to Air Cleaner

Assembly7.3 ± 1.3

4 Screw, Hex. M10x20Air Cleaner Assembly to

Air cleaner Mounting Bracket25 ± 4

1Clamp SAE J1 508

Type SLTB SAE No.- 42

Clamping Hose ,Air cleaner -Turbocharger to Turbocharger

7.3 ± 1.3

2Screw, Serrated Hex.

flanged headM10x20

Air cleaner Mounting Bracket to Cylinder Block

50 ± 8

Fan Assembly

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

6Screw, Hex. Flanged

head M8x20 Fan Hub to Fan(28 inch) 25 ± 4 SC

6Screw, Serrated Hex.

Flanged headM10X70 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 M10x30Housing Fan Bearing to Fan

Bracket50 ± 8

1Screw, Serrated Hex.

Flanged headM10X70 Auto Tensioner to Fan bracket 50 ± 8

2Screw, Hex. Flanged

headM8X80 Fan Bracket to Timing case 25 ± 4

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

8786

Operation and Maintenance Manual Operation and Maintenance Manual

Turbocharger Bracket Assembly

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

1Screw, Hex. Flanged

HeadM8 x 30 X

1.25 X 10.9Elbow, turbocharger Mounting

bracket to turbocharger25 + 5

1Screw, Hex.

Flanged HeadM8 x 25 X 1.25 X 8.8

Turbocharger Mounting bracket to Elbow, turbocharger

25 + 5

Fuel Filter Assembly

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

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

Gear Case Assembly

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

3Screw, Hex.

Flanged M10X30X8.8

Air compressor closing plate to Gear Case

45± 5

Feed Pump Assembly

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

3 Allen bolt M6X16X8.8Feed Pump mounting to Gear

case10 ± 1.5

2Screw, Hex.

Flanged M8 X 25X 1.25 X

8.8 Feed Pump mounting to Gear

case25 ± 4

2 Banjo bolt M14X1.5X8.8 Feed Pump Inlet/Outlet 23± 3

1 Adapter M14X1.5X8.8Feed Pump adapter to Timing

case30 ± 4

Intake Manifold Assembly

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

1Plug, Allen

TaperedM12 X 1.5 X 5.8 For Pluging Intake manifold Hole 10± 2

8988

Operation and Maintenance Manual Operation and Maintenance Manual

Turbocharger Bracket Assembly

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

1Screw, Hex. Flanged

HeadM8 x 30 X

1.25 X 10.9Elbow, turbocharger Mounting

bracket to turbocharger25 + 5

1Screw, Hex.

Flanged HeadM8 x 25 X 1.25 X 8.8

Turbocharger Mounting bracket to Elbow, turbocharger

25 + 5

Fuel Filter Assembly

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

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

Gear Case Assembly

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

3Screw, Hex.

Flanged M10X30X8.8

Air compressor closing plate to Gear Case

45± 5

Feed Pump Assembly

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

3 Allen bolt M6X16X8.8Feed Pump mounting to Gear

case10 ± 1.5

2Screw, Hex.

Flanged M8 X 25X 1.25 X

8.8 Feed Pump mounting to Gear

case25 ± 4

2 Banjo bolt M14X1.5X8.8 Feed Pump Inlet/Outlet 23± 3

1 Adapter M14X1.5X8.8Feed Pump adapter to Timing

case30 ± 4

Intake Manifold Assembly

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

1Plug, Allen

TaperedM12 X 1.5 X 5.8 For Pluging Intake manifold Hole 10± 2

8988

Operation and Maintenance Manual Operation and Maintenance Manual

Radiator & IntercoolerQty

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

2Clamp SAE J1 508 Type

SLTB SAE

No.- 76Hose clamp for intake curve to

intercooler7.3 ± 1.3

2Clamp SAE J1 508 Type

SLTB SAE

No.- 76

Hose clamp for Elbow Turbocharger to Tube,

turbocharger -intercooler7.3 ± 1.3

2Clamp SAE J1 508 Type

SLTB SAE

No.- 76Hose Clamp for Tube, turbocharger -

intercooler to Intercooler inlet7.3 ± 1.3

2 Clamp SAE J1 508 Type SLTB SAE No.-

42Hose Clamp for Engine Water

Outlet pipe 7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

42Hose clamp for Engine Water outlet

pipe to Hose, Radiator side7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

34Hose clamp for Engine Water

outlet pipe to hose at Radiator inlet7.3 ± 1.3

2 Clamp SAE J1 508 Type SLTB SAE No.-

42Hose clamp on Engine Water inlet

pipe7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

42Hose clamp on small end of reducer

hose at radiator outlet7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

48Hose Clamp on reducer hose at

radiator outlet7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

72HOSE, TURBOCHARGER -

INTERCOOLER

7.3 ± 1.3

1 CLAMP SAE J1 508 TYPE SLTB -SAE No.-

54HOSE, AIR CLEANER-

TURBOCHARGER7.3 ± 1.3

2Mounted on the water inlet

connection tubeM8X12 Engine water inlet tube connection 10± 2

Engine Mounting Foot

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

8Screw, Serrated

Hex. Flanged headM12x3

0Engine Mounting Foot to Cylinder Block 70 ± 10

Cylinder Block

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

1 Plug, Allen TaperedM14 X 1.5

X 5.8Plugging Compressor inlet

Hole in Cylinder block10+5

Starter Motor Assembly

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

3 Screw, Hex. FlangedM10 X 30 X

8.8Starter Motor (24V) Mounting 45± 5

9190

Operation and Maintenance Manual Operation and Maintenance Manual

Radiator & IntercoolerQty

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

2Clamp SAE J1 508 Type

SLTB SAE

No.- 76Hose clamp for intake curve to

intercooler7.3 ± 1.3

2Clamp SAE J1 508 Type

SLTB SAE

No.- 76

Hose clamp for Elbow Turbocharger to Tube,

turbocharger -intercooler7.3 ± 1.3

2Clamp SAE J1 508 Type

SLTB SAE

No.- 76Hose Clamp for Tube, turbocharger -

intercooler to Intercooler inlet7.3 ± 1.3

2 Clamp SAE J1 508 Type SLTB SAE No.-

42Hose Clamp for Engine Water

Outlet pipe 7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

42Hose clamp for Engine Water outlet

pipe to Hose, Radiator side7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

34Hose clamp for Engine Water

outlet pipe to hose at Radiator inlet7.3 ± 1.3

2 Clamp SAE J1 508 Type SLTB SAE No.-

42Hose clamp on Engine Water inlet

pipe7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

42Hose clamp on small end of reducer

hose at radiator outlet7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

48Hose Clamp on reducer hose at

radiator outlet7.3 ± 1.3

1 Clamp SAE J1 508 Type SLTB SAE No.-

72HOSE, TURBOCHARGER -

INTERCOOLER

7.3 ± 1.3

1 CLAMP SAE J1 508 TYPE SLTB -SAE No.-

54HOSE, AIR CLEANER-

TURBOCHARGER7.3 ± 1.3

2Mounted on the water inlet

connection tubeM8X12 Engine water inlet tube connection 10± 2

Engine Mounting Foot

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

8Screw, Serrated

Hex. Flanged headM12x3

0Engine Mounting Foot to Cylinder Block 70 ± 10

Cylinder Block

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

1 Plug, Allen TaperedM14 X 1.5

X 5.8Plugging Compressor inlet

Hole in Cylinder block10+5

Starter Motor Assembly

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

3 Screw, Hex. FlangedM10 X 30 X

8.8Starter Motor (24V) Mounting 45± 5

9190

Operation and Maintenance Manual Operation and Maintenance Manual

Lubricating Oil Filter Head and Oil cooler

Qty. Description Size ApplicationTorque

(Nm)SC/CC

1Oil Pressure sensor

cum switchM12x12

Oil Pressure sensor cum switch mounted at Oil Filter Head

Max. 50

Alternator 24 V Assembly – Electronic Genset

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

2Screw, Hex. Flanged

headM8 x 20

Pull rod, Alternator Bracket to Main Alternator Bracket

20 ± 3

1Screw, Hex. Flanged

headM12 x 35

Pull rod, Alternator Bracket to Alternator (Charging)

70 ± 10

1Screw, Hex. Flanged

headM10 x 110

Main Alternator Bracket to Alternator (Charging)

40 ± 6

Alternator Bracket- 12V

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

1 Bolt M8x80Alternator Bracket to Alternator Bush

30 ± 5

1 Bolt M8x20Alternator bracket to castingbracket

20 ± 3

Standard Torque Table for Normal Steel Bolts(According to DIN 2230)

Nominal SizeBolt Class ( Nm)

SC/CC8.8 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

9392

Operation and Maintenance Manual Operation and Maintenance Manual

Lubricating Oil Filter Head and Oil cooler

Qty. Description Size ApplicationTorque

(Nm)SC/CC

1Oil Pressure sensor

cum switchM12x12

Oil Pressure sensor cum switch mounted at Oil Filter Head

Max. 50

Alternator 24 V Assembly – Electronic Genset

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

2Screw, Hex. Flanged

headM8 x 20

Pull rod, Alternator Bracket to Main Alternator Bracket

20 ± 3

1Screw, Hex. Flanged

headM12 x 35

Pull rod, Alternator Bracket to Alternator (Charging)

70 ± 10

1Screw, Hex. Flanged

headM10 x 110

Main Alternator Bracket to Alternator (Charging)

40 ± 6

Alternator Bracket- 12V

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

1 Bolt M8x80Alternator Bracket to Alternator Bush

30 ± 5

1 Bolt M8x20Alternator bracket to castingbracket

20 ± 3

Standard Torque Table for Normal Steel Bolts(According to DIN 2230)

Nominal SizeBolt Class ( Nm)

SC/CC8.8 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

9392

Operation and Maintenance Manual Operation and Maintenance Manual

NOTESNOTES

9594

Operation and Maintenance Manual Operation and Maintenance Manual

NOTESNOTES

9594

Operation and Maintenance Manual Operation and Maintenance Manual

9596

Delivery date

Commissioning Date

OEM Name For Genset Application

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Alternator

Voltage

Kva

Phase

Dealer Name

Address

City

State/Prov.

Telephone No. (Area code/Phone No.)

ZIP / Post Code

E-Mail Address

Owner Surname or Company Name

First Name Title

Street / P. O BOX (1)

Street / P. O BOX (2)

City

Zip Code / Post Code Country

State / Province

Telephone (Area Code / Number)

Email address

Mobile phone No.

Genset No For Off High Way application only

Equipment No.

Transmission No.

Chassis No.

Commissioning Certified by:

Name

Sign

Dealer Name

NAVIS

TAR

CO

PY

NOTESMonth Day Year

Month Day Year

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Operation and Maintenance Manual Operation and Maintenance Manual

9596

Delivery date

Commissioning Date

OEM Name For Genset Application

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Alternator

Voltage

Kva

Phase

Dealer Name

Address

City

State/Prov.

Telephone No. (Area code/Phone No.)

ZIP / Post Code

E-Mail Address

Owner Surname or Company Name

First Name Title

Street / P. O BOX (1)

Street / P. O BOX (2)

City

Zip Code / Post Code Country

State / Province

Telephone (Area Code / Number)

Email address

Mobile phone No.

Genset No For Off High Way application only

Equipment No.

Transmission No.

Chassis No.

Commissioning Certified by:

Name

Sign

Dealer Name

NAVIS

TAR

CO

PY

NOTESMonth Day Year

Month Day Year

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Operation and Maintenance Manual Operation and Maintenance Manual

74

OEM

CO

PY

Delivery date

Commissioning Date

OEM Name For Genset Application

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Alternator

Voltage

Kva

Phase

Dealer Name

Address

City

State/Prov.

Telephone No. (Area code/Phone No.)

ZIP / Post Code

E-Mail Address

Owner Surname or Company Name

First Name Title

Street / P. O BOX (1)

Street / P. O BOX (2)

City

Zip Code / Post Code Country

State / Province

Telephone (Area Code / Number)

Email address

Mobile phone No.

Genset No For Off High Way application only

Equipment No.

Transmission No.

Chassis No.

Commissioning Certified by:

Name

Sign

Dealer Name

Month Day Year

Month Day Year

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Operation and Maintenance Manual Operation and Maintenance Manual

74

OEM

CO

PY

Delivery date

Commissioning Date

OEM Name For Genset Application

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Alternator

Voltage

Kva

Phase

Dealer Name

Address

City

State/Prov.

Telephone No. (Area code/Phone No.)

ZIP / Post Code

E-Mail Address

Owner Surname or Company Name

First Name Title

Street / P. O BOX (1)

Street / P. O BOX (2)

City

Zip Code / Post Code Country

State / Province

Telephone (Area Code / Number)

Email address

Mobile phone No.

Genset No For Off High Way application only

Equipment No.

Transmission No.

Chassis No.

Commissioning Certified by:

Name

Sign

Dealer Name

Month Day Year

Month Day Year

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Operation and Maintenance Manual Operation and Maintenance Manual

76

OW

NER

'S C

OPY

Delivery date

Commissioning Date

OEM Name For Genset Application

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Alternator

Voltage

Kva

Phase

Dealer Name

Address

City

State/Prov.

Telephone No. (Area code/Phone No.)

ZIP / Post Code

E-Mail Address

Owner Surname or Company Name

First Name Title

Street / P. O BOX (1)

Street / P. O BOX (2)

City

Zip Code / Post Code Country

State / Province

Telephone (Area Code / Number)

Email address

Mobile phone No.

Genset No For Off High Way application only

Equipment No.

Transmission No.

Chassis No.

Commissioning Certified by:

Name

Sign

Dealer Name

Month Day Year

Month Day Year

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Operation and Maintenance Manual Operation and Maintenance Manual

76

OW

NER

'S C

OPY

Delivery date

Commissioning Date

OEM Name For Genset Application

Model (From Serial No. Plate) Serial No. (From serial No. plate)

Alternator

Voltage

Kva

Phase

Dealer Name

Address

City

State/Prov.

Telephone No. (Area code/Phone No.)

ZIP / Post Code

E-Mail Address

Owner Surname or Company Name

First Name Title

Street / P. O BOX (1)

Street / P. O BOX (2)

City

Zip Code / Post Code Country

State / Province

Telephone (Area Code / Number)

Email address

Mobile phone No.

Genset No For Off High Way application only

Equipment No.

Transmission No.

Chassis No.

Commissioning Certified by:

Name

Sign

Dealer Name

Month Day Year

Month Day Year

Model (From Serial No. Plate) Serial No. (From serial No. plate)