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VM Motori R754EU5 Instruction Manual

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R750EU5 - IE3 - TE4 - IE4 - ISE4
Engine instructions manual
GB
VM p/n - 42432055F
Ed. 8 / 10 - 2012
English

Ed.8 / 0-202

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Summary of Contents for VM Motori R754EU5

  • Page 1 R750EU5 - IE3 - TE4 - IE4 - ISE4 Engine instructions manual VM p/n - 42432055F Ed. 8 / 10 - 2012 English Ed.8 / 0-202...

  • Page 2: Table Of Contents

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 GENERAL INDEX SommARIo GENERAL INDEX ..........................2 GENERAL INFoRmATIoN ........................4 INTRODUCTION............................4 QUALITY.SYSTEM.CERTIFICATE.ISO.9001-QS.9000-ISO.14001............4 PURPOSE.OF.THE.MANUAL........................5 MANUFACTURER.AND.ENGINE.IDENTIFICATION................6 PROCEDURE.TO.REQUEST.TECHNICAL.ASSISTANCE..............7 WARRANTY.CONDITIONS........................7 ATTACHED.DOCUMENTATION......................7 TECHNICAL INFoRmATIoN ........................8 ENGINE.GENERAL.DESCRIPTION...................... 8 TECHNICAL DATA ..........................2 TECHNICAL.DATA.(R754.EU5-R756.EU5).
  • Page 3 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 mAINTENANCE INFoRmATIoN ......................36 RECOMMENDATIONS.FOR.MAINTENANCE..................36 ENGINE.MAINTENANCE........................36 .50. )..................37 AINTENANCE DURING RUNNING FIRST HOURS )....................38 OUTINE MAINTENANCE AFTER RUNNING Periodic maintenance operation record sheet ..............40 MAINTENANCE.WHEN.THE.ENGINE.IS.LEFT.IDLE................

  • Page 4: General Information

    If engines designed and built by VM MO- QUALITY SYSTEm CERTIFICATE ISo 900-QS 9000-ISo 400 ciation under the QS-9000 Quality System VM MOTORI S.PA. has obtained the cer- Standard for the manufacture of Diesel tification of its quality assurance regime in engines.

  • Page 5: Purpose.of.the.manual

    MOTORI S.P.A.. employees. environmental management systems and while respecting the environment and the VM MOTORI S.P.A. considers quality as a population. dynamic process of continuous improve- ment in all activities to achieve the goals. Customer satisfaction, efficiency and...

  • Page 6: Manufacturer.and.engine.identification

    P) Engine serial number (punched on the crankcase) q) Engine code r) Consecutive number The table helps you to identify the model through the engine code. Engine code Engine model R754EU5 R756EU5 R754IE3 R756IE3 R754TE4 R754IE4 R754ISE4 English Ed.8 / 0-202...

  • Page 7: Procedure.to.request.technical.assistance

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 PRoCEDURE To REQUEST TECHNICAL ASSISTANCE Please state the data contained in the manufacturer’s Technical Assistance identification plate, the serial number, Service or to an authorised workshop (see approximate hours of operation and the attached documentation “Address booklet type of defect detected in every request of of assistance and spare part centres”)

  • Page 8: Technical Information

    L) Suction manifold: conveys the combu- stion air into the combustion chamber. Y) Debimeter R754EU5, R756EU5: it de- tects the air mass that feeds the engine. m) Water pump: feeds the cooling circuit Z) Rail: stores pressurised fuel and distri- N) Driving belt (type Poly-V): it starts butes it to the injectors.
  • Page 9 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 English Ed.8 / 0-202...
  • Page 10 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 main components R754TE4 - IE4 - ISE4 A) Cooler: cools the engine oil by heat W) Antiparticulate filter: this is installed in exchange with the coolant fluid. the engine exhaust pipe conduit. It serves to retain the particulate so as to reduce B) Turbo device: Made up of a turbine the emissions from diesel engines, which...
  • Page 11 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Air Filter (X) DPF Filter (W) Debimeter Turbo (B) Intake Manifold Fuel Filter (F) Exhaust Manifold “waste-gate” Starter Motor (R) valve (D) EGR Valve (C) Injector (V) Thermostatic valve (E) Common RAIL Alternator (Q)

  • Page 12: Technical Data

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 TECHNICAL DATA These technical data and specifications refer exclusively to standard VM MOTORI S.P.A. engines. TECHNICAL DATA (R754 EU5-R756 EU5) Unit of measure- R754EU5 R756EU5 ment Dimensions Unit of...
  • Page 13 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Unit of measure- ment R754EU5 R756EU5 Cooler water/oil Anticlockwise (observing the engine from the handwhe Crankshaft rotation el side) Combustion sequence 1-3-4-2 1-5-3-6-2-4 Pushrods and rocker arms With hydraulic tappets and camshaft...
  • Page 14 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Unit of measure- ment R754EU5 R756EU5 Fuel supply Gear pump Injector supply High pressure injection pump Lubrication circuit Type of lubrication Forced lubrication Circuit fuel supply Rotor pump 13,8 (12) ÷...

  • Page 15: Technical.data.(R754.Ie3-R756.Ie3)

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 TECHNICAL DATA (R754 IE3-R756 IE3) These technical data and specifications refer exclusively to standard VM MOTORI S.P.A. engines. Table 2: Technical data of the engine Unit of measure-...
  • Page 16 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Unit of measure- ment R754IE3 R756IE3 Cooler water/oil Anticlockwise (observing the engine from the handwhe Crankshaft rotation el side) Combustion sequence 1-3-4-2 1-5-3-6-2-4 Pushrods and rocker arms With hydraulic tappets and camshaft Timing Gear cascade control and camshaft fitted on the crankbase...
  • Page 17 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Unit of measure- ment R754IE3 R756IE3 Fuel supply Gear pump Injector supply High pressure injection pump Lubrication circuit Type of lubrication Forced lubrication Circuit fuel supply Rotor pump Oil change including filter (standard sump) liters (kg)

  • Page 18: Technical.data.(R754.Te4-R754.Ie4.-.R754Ise4)

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 TECHNICAL DATA (R754 TE4-R754 IE4 - R754ISE4) These technical data and specifications refer exclusively to standard VM MOTORI S.P.A. engines. Unit of measure- R754TE4 R754IE4 R754ISE4 ment Dimensions...
  • Page 19 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Unit of measure- ment R754TE4 R754IE4 R754ISE4 Cooler water/oil Crankshaft rotation Anticlockwise (observing the engine from the handwhe el side) Combustion sequence 1-3-4-2 1-3-4-2 1-3-4-2 Pushrods and rocker arms With hydraulic tappets and camshaft Timing Gear cascade control and camshaft fitted on the...
  • Page 20 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Unit of measure- ment R754TE4 R754IE4 R754ISE4 Lubrication circuit Type of lubrication Forced lubrication Circuit fuel supply Rotor pump Oil change including filter (standard sump) liters (kg) 11 (9.57) Oil quantity at minimum level (standard sump) liters (kg)

  • Page 21: Safety Information

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 SAFETY INFoRmATIoN GENERAL SAFETY WARNINGS –All the installation phases should have –During the design and construction been taken into account since the deve- phases, the Manufacturer paid special lopment of the initial project.

  • Page 22: Safety.warnings.for.the.environmental.impact

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 –If appropriate, before using the engine ments laid down in the applicable legisla- for the first time, after gathering all the tion regarding safety at the workplace. necessary information, simulate a few –Keep the equipment as much efficient trial manoeuvres to identify the controls as possible and carry out the scheduled...

  • Page 23: Safety.warnings.for.the.electrical.equipment

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 –All packaging components should be di- according to the composition of the diffe- sposed of in accordance with the legisla- rent materials and in compliance with the tion in force in the country where disposal legislation in force.

  • Page 24: Handling And Installation Information

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 HANDLING AND INSTALLATIoN INFoRmATIoN RECommENDATIoNS FoR HANDLING AND INSTALLATIoN Carry out handling and installation Those authorized to carry out these following the information provided by the operations should prepare, if necessary, manufacturer and stated directly on the a “safety plan”...

  • Page 25: Unpacking

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 In order to guarantee the perfect con- servation of all engine components, an “overseas” packaging should be used in case of maritime transport. The packaging contains all the informa- tion needed to carry out the loading and unloading operations.

  • Page 26: Handling.and.lifting

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 HANDLING AND LIFTING Secure the engine with a lifting device (lifting beam) of appropriate capacity. 0° The angle formed by the lifting device chains must not exceed 5°, as shown in the figure.

  • Page 27: Engine.storage

    “FL mECA FLUID / ages to people’s safety and health. P8V” anticorrosion oil. Vm motori recommends that this pro- RUBBER ComPoNENTS: unpainted tection procedure is only carried out manifolds and pipes must be protected by Vm-authorised personnel.
  • Page 28 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 BATTERY: Disconnect the battery. • Check the coolant level (for water- When it is fully charged, store it in a cooled engines only). The coolant safe place. Before doing this, protect mixture must be 50% demineralised the terminals against corrosion by ap- or distilled water and 50% Petronas...
  • Page 29 3) SToRAGE CoNDITIoNS Engines on pallets Vm motori, however, recommends the use of diesel without Biodiesel. After applying the anticorrosion protection, the engine must be placed in a dry, well-ventilated environment The use of any other fuel is forbidden.
  • Page 30 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Check the level of the fluids: engine oil START-UP and coolant. Top up if necessary. Engines on pallets Remove the covers and protective Nothing needs to be done to remove the elements applied to the engine open- internal protection (either for engines on ings (for instance, air suction ducts...

  • Page 31: Installation.design

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 INSTALLATIoN DESIGN In order to ensure the highest performan- ce while protecting people, the product itself and the environment, a full project During the design and installation has to be developed before carrying out phases, it is advisable to consult the the installation.

  • Page 32: Operating Information

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 oPERATING INFoRmATIoN RECommENDATIoNS FoR USE AND oPERATIoN Tampering with any device to achieve a The engine has been designed and different performance from the intended manufactured to satisfy all the operating one can entail risks for people’s safety conditions indicated by the manufacturer.
  • Page 33 Do not attempt to disconnect the mIL indicator light sensor in order to clear the signal. Vm motori does not assume any liability for economic damages or risks to personal safety. For more information, refer to the documentation...

  • Page 34: Operating.the.engine.under.specific.conditions

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 oPERATING THE ENGINE UNDER SPECIFIC CoNDITIoNS The engine performance is affected by When using the engine at high altitudes fuel temperature, the temperature and and high air and fuel temperatures, the relative humidity of incoming air and output is reduced.

  • Page 35: Refuelling

    5%, with fuel available on the European market (according to regulation EN 590). Do not use fuels with specifications other than those indicated. – For engines model R754EU5 - R756EU5 - R754TE4,IE4,ISE4, use fuel with a low sulphur content. The percentage sulphur must never exceed 0-50 ppm (parts per million).

  • Page 36: Maintenance Information

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 mAINTENANCE INFoRmATIoN RECommENDATIoNS FoR mAINTENANCE Keep the equipment as much efficient interventions should follow all the as possible and carry out the scheduled precautions needed to guarantee maintenance operations established by the safety of the people involved, in the manufacturer.

  • Page 37: Running - In .( First .50. Hours )

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 mAINTENANCE DURING RUNNING-IN (FIRST 50 HoURS) For each maintenance operation, fill in the “Periodic maintenance operation record sheet” provided, so as to keep a trace of the operations performed and therefore establish the most suitable methods for future operations.

  • Page 38: Outine Maintenance After Running In )

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 RoUTINE mAINTENANCE (AFTER RUNNING-IN) For each maintenance operation, fill in the “Periodic maintenance operation record sheet” provided, so as to keep a trace of the operations performed and therefore establish the most suitable methods for future operations.
  • Page 39 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Type of inter- Intervention Frequency () Component Reference vention procedures See “Changing Drive belt (type Replace t belt (type Poly-V) (5) Poly-V)” Clean the fuel Every 900 hours tank and check fuel tank the efficiency of...

  • Page 40: Periodic Maintenance Operation Record Sheet

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 PERIoDIC mAINTENANCE oPERATIoN RECoRD SHEET For each maintenance operation, fill in the sheet, so as to keep a trace of the operations performed and therefore establish the most suitable methods for future operations. Date Hours Type of maintenance performed...
  • Page 41 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Date Hours Type of maintenance performed Signature and stamp of workshop 1) Indicate the total number of working hours.. English Ed.8 / 0-202...
  • Page 42 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Date Hours Type of maintenance performed Signature and stamp of workshop 1) Indicate the total number of working hours.. English Ed.8 / 0-202...
  • Page 43 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Date Hours Type of maintenance performed Signature and stamp of workshop 1) Indicate the total number of working hours.. English Ed.8 / 0-202...
  • Page 44 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Date Hours Type of maintenance performed Signature and stamp of workshop 1) Indicate the total number of working hours.. English Ed.8 / 0-202...

  • Page 45: Maintenance.when.the.engine.is.left.idle

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 mAINTENANCE WHEN THE ENGINE IS LEFT IDLE If the vehicle/equipment to which the engine is fitted remains inactive, certain maintenance operations must be carried It is advisable to start the engine out to ensure the engine remains in full bringing it to the operating temperatu- working order.

  • Page 46: Maintenance.in.case.of.engine.inactivity

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 mAINTENANCE IN CASE oF ENGINE INACTIVITY – Replace the air filter according to the After a period of inactivity, it is necessary established intervals (See “Routine main- to carry out a few maintenance interven- tenance (after running-in)”) tions before starting the engine again to ensure its maximum efficiency conditions.

  • Page 47: Checks.and.controls

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 CHECKS AND CoNTRoLS –Coolant replacement The list indicates some of the maintenan- ce, testing and control operations to be –Oil filter cartridge replacement carried out on the engine during normal operation.

  • Page 48: Engine.oil.level.control

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 3- Prepare a container of appropriate capacity. Be careful to ensure that the fuel in the 4- Loosen the screw (E). filter does not drain completely out. If it does, remove it (see “Fuel filter replacement.”), fill it manually and then Do not loosen high-pressure pipe repeat the bleeding operation.

  • Page 49: Engine.coolant.level.check

    Tech Library http://engine.od.ua R750EU5 - R750IE3 R750EU5 - IE3 - TE4 - IE4 - ISE4 ENGINE CooLANT LEVEL CHECK Follow the procedure below. Filler cap (P) 1- Start the engine and bring it to the ope- rating temperature (70÷80 °C). 2- Turn off the engine and remove the ignition key.

  • Page 50: Cleaning.and.replacement.of.the.air.filter

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 CLEANING AND REPLACEmENT oF THE AIR FILTER The air filter is equipped with the indicator 7- Remove the cartridge (G), and then (A) that displays the relevant clogging le- clean both the cartridge and the inside of vel.

  • Page 51: Engine.oil.change

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 ENGINE oIL CHANGE Follow the procedure below. Filler cap (M) • Start the engine and bring it to the operating temperature (70÷80 °C) • Turn off the engine and remove the ignition key.

  • Page 52: Engine.oil.dilution

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 ENGINE oIL DILUTIoN Reset the ECU parameters (carry out this operation after completing the engine oil Do not throw the oil in the environment change). but carry out its disposal in com- pliance with legislation in force in the country where it is used.

  • Page 53: Coolant.replacement

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 CooLANT REPLACEmENT Follow the procedure below. Filler Cap (P) 1- Start the engine and run it at minimum speed for a few minutes. The cooling circuit reaches the operating pressure. 2- Turn off the engine and remove the ignition key.

  • Page 54: Oil.filter.cartridge.replacement

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 oIL FILTER CARTRIDGE REPLACEmENT Follow the procedure below. 1- Turn off the engine and remove the ignition key. 2- Let the engine cool down adequately to avoid being burnt. Gasket (V) 3- Prepare a container to collect any leak.

  • Page 55: Fuel.filter.replacement

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 FUEL FILTER REPLACEmENT Follow the procedure below. 1- Turn off the engine and remove the Fuel Filter (Z) ignition key. 2- Let the engine cool down adequately to avoid being burnt.

  • Page 56: Recommended.lubricants

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 RECommENDED LUBRICANTS The lubricant recommended by VM –Viscosity grade: SAE 10W-40 MOTORI S.P.A. is: Q8 T 905 10W-40 for –Specifications: ACEA E6 operating temperatures from - 20°C to +50°C.

  • Page 57: Information About Failures

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 INFoRmATIoN ABoUT FAILURES TRoUBLESHooTING The information below are provided to facilitate the identification and solution Activation of a visual and/or acoustic of possible anomalies and failures which may occur during operation. Some of signal indicates some form of malfun- ction.
  • Page 58 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Problem Cause Remedy Flat battery Recharge or replace battery Interrupted electric connection Check the electric connections The starter motor is not running Replace the worn brushes Worn brushes Apply to an authorised workshop Presence of air in the fuel supply Carry out bleeding (See “Fuel...
  • Page 59 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Problem Cause Remedy oil level too high Adjust the oil level Check compression Light emission of white smoke Worn segments from the exhaust pipe Apply to an authorised workshop Check wear Worn valve guideways Apply to an authorised workshop...
  • Page 60 Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 Problem Cause Remedy The coolant temperature warning Replace the belt (See “Changing Broken or worn belt light comes on the belt (type Poly-V)”) Replace filter (See “Fuel filter Clogged fuel filter replacement.”) Presence of air in the fuel supply...

  • Page 61: Information About Component Replacement

    In particular, place When requesting spare parts, always proper signs in the nearby areas and keep contact your nearest VM MOTORI S.P.A. away all devices which, once activated, spare parts centre (See “documentation may represent a source of unexpected enclosed”: Spare parts and service centre...

  • Page 62: Belt Tensioner

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 CHANGING THE BELT (TYPE PoLY-V) WITH AUTomATIC BELT TENSIoNER 4- Remove the belt (D) and replace it. Follow the procedure below. 1- Turn off the engine and remove the ignition key.

  • Page 63: Tensioner

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 CHANGING THE BELT (TYPE PoLY-V) WITH AUTomATIC BELT TENSIoNER Photo 1 Special equipment must be used to replace the belt with linear turnbuckle. This operation must be performed by an authorised repair shop.

  • Page 64: Changing.the.belt.(Type.poly-V). Engine.disposal

    Tech Library http://engine.od.ua R750EU5 - IE3 - TE4 - IE4 - ISE4 ENGINE DISPoSAL This operation should be carried out by experienced operators, in compliance with the legislation in force concerning safety at the workplace. Do not throw away non biodegradable products and non ferrous components (rubber, PVC, resins, etc.).

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