VM Motori MR704LX, MR704LS, MR706LX, MR706LH, MR706LS Instruction Manual

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MR 700

Ed. 3 - 2012_11

English

Engine instrucons manual

MR 700

Ed. 3 - 2012_11

English

GENERAL INDEX

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

STANDARD COMPONENTS ........................................................................................................ 11

SPECIFICATIONS .........................................................................................................................11

SAFETY INFORMATION ..............................................................................................................15

SAFETY RULES ............................................................................................................................ 15

SAFETY RULES FOR THE ENVIRONMENTAL IMPACT .............................................................17

RESIDUAL RISKS .........................................................................................................................17

HANDLING AND INSTALLATION INFORMATION ......................................................................18

RECOMMENDATIONS FOR HANDLING AND INSTALLATION ................................................... 18

PACKAGING AND TRANSPORT ..................................................................................................18

UNPACKING .................................................................................................................................19

HANDLING AND LIFTING ............................................................................................................. 20

ENGINE STORAGE ......................................................................................................................21

INSTALLATION DESIGN ...............................................................................................................25

OPERATING INFORMATION ....................................................................................................... 26

RECOMMENDATIONS FOR USE AND OPERATION .................................................................. 26

CONTROL BOARD DESCRIPTION .............................................................................................. 26

RECOMMENDATIONS FOR USE ................................................................................................27

OPERATING THE ENGINE UNDER SPECIFIC CONDITIONS ....................................................27

ENGINE IGNITION AND TURNING OFF ......................................................................................28

REFUELLING ................................................................................................................................29

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MAINTENANCE INFORMATION ..................................................................................................29

RECOMMENDATIONS FOR MAINTENANCE ..............................................................................29

ENGINE MAINTENANCE .............................................................................................................. 30

Maintenance during running-in table (rst 50 hours) .....................................................................

Routine maintenance table (after running-in) ................................................................................30

Periodic maintenance operation record sheet ...............................................................................

MAINTENANCE WHEN THE ENGINE IS LEFT IDLE ..................................................................37

MAINTENANCE IN CASE OF ENGINE INACTIVITY ...................................................................38

CHECKS AND CONTROLS ..........................................................................................................39

FUEL SUPPLY CIRCUIT BLEEDING ............................................................................................39

CONTROL SCREW TIGHTENING AND UNION SEALING ..........................................................39

ENGINE OIL LEVEL CONTROL....................................................................................................40

ENGINE COOLANT LEVEL CHECK ............................................................................................. 40

METHOD FOR TIGHTENING OR LOOSENING THE BELT ......................................................... 41

ENGINE OIL CHANGE .................................................................................................................. 42

COOLANT REPLACEMENT .........................................................................................................43

SEAWATER CIRCUIT EMPTYING ................................................................................................44

OIL FILTER CARTRIDGE REPLACEMENT .................................................................................. 45

FUEL FILTER REPLACEMENT ....................................................................................................46

RECOMMENDED LUBRICANTS .................................................................................................. 46

INFORMATION ABOUT FAILURES ............................................................................................. 47

TROUBLESHOOTING ..................................................................................................................47

RESET FUSES .............................................................................................................................. 50

DIAGNOSIS OF FAILURES ..........................................................................................................51

READING ERROR CODES ..........................................................................................................51

ERROR CODES LIST ...................................................................................................................52

INFORMATION ABOUT COMPONENT REPLACEMENT ...........................................................58

RECOMMENDATIONS FOR PART REPLACEMENT ...................................................................58

BELT REPLACEMENT ..................................................................................................................58

INLET AIR FILTER REPLACEMENT.............................................................................................59

ELECTROLYTIC ZINC REPLACEMENT ......................................................................................60

ENGINE DISPOSAL ......................................................................................................................60

ELECTRICAL SYSTEM ................................................................................................................61

ENGINE ELECTRICAL DIAGRAM - MR704 .................................................................................61

ENGINE ELECTRICAL DIAGRAM - MR706 .................................................................................62

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GENERAL INFORMATION

INTRODUCTION

QUALITY SYSTEM CERTIFICATE ISO 9001 -QS 9000-ISO 14001

Dear Client, we wish to thank you for purchasing an engine manufactured by

VM MOTORI S.P.A.

Our Technical Assistance and Spare Part department has recently been strengthened to ensure even better service to all our Clients.

Only by using original spare parts and by relying on our specialised staff you can ensure the best performance to your

engine.

Let us advise you to rely EXCLUSIVELY on our Technical Assistance and Spare Part Service for the maintenance of engines manufactured by VM MOTORI S.P.A.

If an engine manufactured by VM MOTORI S.P.A. is serviced by unauthorised technicians, or if NON ORIGINAL spare parts are used, you will immediately lose any right in terms of warranty and technical assistance by VM MOTORI S.P.A.

We are condent that you will understand the technical importance of this recommendation, which is mainly aimed at protecting our Clients from any unpleasant situation.

Please get in touch with us for any requirements.

Best regards.

VM MOTORI S.PA. has obtained the certication of its quality assurance regime in compliance with UNI EN ISO 9001 standards and with the even stricter prescriptions established by Ford, Chrysler and General Motors car manufacturer association under the QS-9000 Quality System Standard for the manufacture of

Diesel engines. Moreover, its environmental management system has been certied against the ISO 14001 standard.

This is the result of a working plan which involves all company levels.

The quality and environmental policy, with a special focus on the continuous improvement principle, is an essential part of VM MOTORI S.P.A top management ‘s strategy and it is being implemented in all company departments in accordance with internationally accepted quality and environmental management systems and while respecting the environment and the population.

Customer satisfaction, efciency and personnel motivation, intended as a set of services rendered inside and outside the

company, are the most important elements of the quality concept.

All VM MOTORI S.P.A. employees are committed to the achievement of quality and environmental policy goals.

Regular training ensures a suitable and constantly updated knowledge to VM MOTORI S.P.A. employees.

VM MOTORI S.P.A. considers quality as a dynamic process of continuous improvement in all activities to achieve the goals.

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PURPOSE OF THE MANUAL

This manual is an essential part of the engine and it has been written by the manufacturer to provide all the information necessary to those who are authorized to interact with it throughout its expected life:

handlers, carriers, installers and users. Besides adopting a good operation

technique, the recipients of the information should carefully read it and apply it rigorously.

Spend some of your time reading this information to avoid any risk for people’s health and safety as well as economic damage.

Keep this manual throughout the life of the engine in a place within easy reach, so that it is always at hand and you can consult it at all times.

Besides the actual installation of the engine, this manual may contain additional information which, however, will not

hinder the general understanding. The manufacturer reserves the right to

make changes without any prior notice. The relevance of certain parts of the ma-

nual and of some specications is pointed out by a few symbols whose meaning is described below.

Danger - Attention

It indicates very dangerous situations which can seriously endanger people’s health and safety if they are neglected.

Warning - Caution

It indicates that a correct behaviour should be adopted to avoid any risk for people’s health and safety as well as any economic damage.

Important

It indicates some very important pieces of technical information which should not be neglected.

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65 C MR704LX

68 C MR704LH

69 C MR704LS

71 C MR706LX

72 C MR706LH

74 C MR706LS

C D E

G L

English

MANUFACTURER AND ENGINE IDENTIFICATION

The identication plate shown is applied directly on the engine.

It contains all the references and indications needed for a safe operation.

A) Manufacturer identication B) Serial number C) Weight D) Type E) Family F) Model G) Version H) Maximum power (kW) L) Maximum number of revolutions M) Homologation number N) Lubricating oil features 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

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PROCEDURE TO REQUEST TECHNICAL ASSISTANCE

Please state the data contained in the identication plate, the serial number, approximate hours of operation and the type of defect detected in every request of technical assistance for the engine.

In case of need, please apply to the manufacturer’s Technical Assistance Service

or to an authorised workshop (see attached documentation “Address booklet of assistance and spare part centres”)

Further information are available in the website: www.vmmotori.it, in the “Contacts – Request Info” section.

WARRANTY CONDITIONS

ATTACHED DOCUMENTATION

The warranty conditions are stated in the attached documentation (see “Warranty

sheet”)

The stated documentation is supplied to the client along with this manual.

– Wiring diagrams – Address booklet of assistance and spare part centres – Warranty sheet

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TECHNICAL INFORMATION

ENGINE GENERAL DESCRIPTION

Engines of model MR704-MR706 have been designed and built to be installed in vessels as inboard engines.

The engines are used to equip offshore vessels for professional and/or civil use.

The engines differ from each other in terms of power and performance (see “Specications”).

A few accessories are supplied with the engine (see “Standard components”).

Main components

A) Cooler: It cools down the coolant

and the reversing gear oil through a heat exchange with seawater.

B) Cooler: It cools down the fuel through a heat exchange with seawater.

C) Cooler: It cools down the engine oil through a heat exchange with seawater.

D) Turbo device: Made up of a turbine which exploits a part of the exhaust gas energy to carry out the engine turbochar-

ging.

E) Intercooler: It cools down the air needed for engine turbocharging through a heat exchange with seawater.

F) “waste-gate” valve: It controls the turbo device activation, depending on the pressure of the exhaust gases.

G) Wet exhaust gas sleeve: It cools down the exhaust gases through a heat exchange with seawater.

H) Air intake lter: It traps any impurity J) Heat expansion valve: It adjusts the

water temperature according to the engine working temperature

K) Electrolytic zinc: It absorbs the galvanic currents

L) Fuel lter: It traps any impurity L1) Oil lter: It traps any impurity

M) Oil sump: It contains the engine lubrication oil

N) Electronic control unit: It controls the engine functions

P) Water pump: It feeds the freshwater cooling circuit

___________________________________

Q) Water pump: It feeds the seawater cooling circuit

R) High pressure injection pump: It feeds the injectors with fuel under pressure

S) Injector: injects fuel under pressure into the combustion chamber.

S1) Rail: stores pressurised fuel and distributes it to the injectors.

T) Transmission belt: It drives the service parts

T1) Belt tensioner: It keeps the belt constantly tensioned

U) Expansion chamber: It contains the freshwater circuit coolant

U1) Expansion chamber plug: It is used to rell the coolant. It is tted with an overpressure valve set to 1 bars to drain any residual pressure.

V) Alternating current generator:

produces and regulates the electric system voltage

V1) Starter: It is used to start the engine W) Fusebox: the engine is equipped with

(resettable) safety fuses, which cut out in the event of overload or shortcircuit currents, to prevent damage to the electrical components.

X) Boiler connection: It is used to connect the boat’s rooms to the heating system.

Y) Seawater inlet: It collects seawater to cool down the engine

Z) Exhaust manifold: It is used to expel the combustion gases

Z1) Water manifold: It is used to collect the coolant from the heads

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Electrolytic zinc (K)

Wet exhaust gas sleeve (G)

Air lter (H)

Turbocharger (D)

Coolant manifold (Z1)

Boiler connection (X)

Exhaust manifold (Z)

Fluid Cooler (A)

Electrolytic zinc (K)

Waste gate valve (F)

Thermostatic valve (J)

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Fusebox (W)

Fuel Filter (L)

Starter (V1)

Oil lter (L1)

Cooler (B)

Alternator (V)

Injector (S)

Electronic control unit (N)

Rail (S1)

Fuel Filter (L)

Starter (V1)

Cooler (C)

Oil lter (L1)

Oil sump (M)

Intercooler (E)

Coolant ller plug (U1)

Coolant expansion tank (U)

Fresh water pump (P)

High pressure injection pump (R)

Alternator belt (T)

Alternator belt tensioner (T1)

Seawater pump (Q)

Seawater pump inlet (Y)

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STANDARD COMPONENTS

SPECIFICATIONS

The following accessories are supplied with the engine

1) Oil change pump

2) Control board

3) Extension cable connecting control board/engine wiring

These technical data and specications refer exclusively to standard VM MOTORI S.P.A. engines.

MR704 MR706

DIMENSIONS

A mm 705 929 B mm 758 758 C mm 786 788

GENERAL DATA

Cycle

Four stroke Diesel

Total displacement litres

2,776 4,164

No. of cylinders n. 4 6

Bore and stroke mm 94x100 94x100

Compression ratio

17,5:1 17,5:1

Induction type

Turbocharged and inter-cooled circuit - (Dry) air lter

Cooling

Water circuit

Cooler water/water

Crankshaft rotation

Anticlockwise (observing the engine from the hand-

wheel side)

Combustion sequence

1-3-4-2 1-5-3-6-2-4

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MR704 MR706

Timing

Pushrods and rocker arms with hydraulic tappets

and camshaft

Gear cascade control and camshaft tted on the

crankbase

Minimum idling speed (standard engine)

rpm

700 700

Dry shipping weight of

engine

Kg 360 460

Maximum permanent lengthwise inclination (with handwheel up)

Degrees 20° 20°

Maximum permanent lengthwise inclination (with handwheel down)

Degrees 15° 15°

Maximum permanent crosswise inclination

Degrees 25° 25°

POWER AND TORQUE

Maximum operating speed (rpm)

3800 3800

Maximum power

kW (CV)

@ rpm

LX - 169.1 kW=230.0 CV

@ 3800 rpm

LX - 257.3 kW=350.0 CV

@ 3800 rpm

kW (CV)

@ rpm

LH - 154.4 kW=210.0 CV

@ 3800 rpm

LH - 235.3 kW=320.0 CV

@ 3800 rpm

kW (CV)

@ rpm

LS - 125.0 kW=170.0 CV

@ 3800 rpm

LS - 198.6 kW=270.0 CV

@ 3800 rpm

Maximum torque

Nm (kgm)

@ rpm

LX - 480 Nm @ 2600 rpm LX - 700 Nm @ 2600 rpm

Nm (kgm)

@ rpm

LH - 480 Nm @ 2600

rpm

LH - 700 Nm @ 2600

rpm

Nm (kgm)

@ rpm

LS - 450 Nm @ 2200 rpm LS - 670 Nm @ 2400 rpm

CONSUMPTION AT MAXIMUM POWER

Specic oil consumption g/CVh / /

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FUEL SUPPLY CIRCUIT

MR704 MR706

Type of injection Common Rail direct injection

Type of fuel

The engine has been designed to be powered by

standard fuels available on the European market

(according to specications DIN EN 590). If it is to be

tions UNI EN14214), it can be mixed, up to 5%, with fuel available on the European market (according to

regulation DIN EN 590).

Important

Do not use fuels with specications other

than those indicated.

Fuel supply

Gear pump integrated in high pressure injection

pump

Injector supply High pressure injection pump

LUBRICATION CIRCUIT

Type of lubrication

Forced lubrication

Circuit fuel supply

Rotor pump

Oil change including lter (standard sump)

litres (kg) 9 (8) 13,8 (12,3)

Oil quantity at minimum level (standard sump)

litres (kg) 5,6 (5) 9 (8)

Oil quantity at maximum level (standard sump)

litres (kg) 7,3 (6,5) 12,3 (11)

Oil pressure at minimum speed (with started engine)

bar 1 -4 1 - 4

Alarm for oil pressure too low

bar 0,4 0,4

Oil cooling Oil/water cooler

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FRESHWATER COOLING CIRCUIT

MR704 MR706

Capacità totale circuito di raffredda-mento

litres 13 18

Pressione taratura tappo vaso espansione

bar 1 1

Liquido di raffreddamento

50% demineralised or distilled water and 50%

petronas Parau Up (protective radiator uid with

monoethylene glycol and organic inhibitor formula-

tion complying with ASTM D 3306 type 1 Standards)

(Colour of uid: RED)

ELECTRIC SYSTEM

Total capacity of the cooling circuit

V 12 12

Setting pressure of the expansion tank

V 14 14

Alternating current gene-

rator (nominal current)

A 110 110

Starter motor output kW 2,3 2,3

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– During the design and construction phases, the Manufacturer paid special attention to the aspects which are liable to cause any risk for the safety and health of people interacting with the engine. Besides complying with the relevant legislation in force, he followed all the “rules for a good construction technique”. The purpose of this information is making users aware of the need to pay the utmost attention to prevent any risk. Caution is however imperative. Safety also depends on all the operators who interact with the

engine.

– Read carefully the instructions contained in the manual supplied and those applied on the engine, in particular follow those concerning safety. Spend some of your time reading the instructions to avoid unpleasant accidents.

– Pay attention to the meaning of the symbols in the applied plates; their shape and colour have a specic meaning related to safety. Keep them visible and follow the stated information.

– Use the engine only for the tasks authorised by the manufacturer and do not tamper with any device to achieve a different performance from the intended one.

– The staff carrying out any type of intervention throughout the life of the engine should have precise technical skills, specic abilities and experiences acquired and acknowledged in this sector. The lack of these requirements may cause damages to people’s safety and health.

– All the installation phases should have been taken into account since the development of the initial project. The designer has to observe with the engine xing points and the general indications provided by the manufacturer.

– Carry out the handling of the engine in compliance with the information stated directly on the engine, on the packaging and in the operating instructions supplied by the manufacturer.

– When lifting or transporting unpacked engines use means of appropriate load capacity which must be properly ancho-

red.

– When lifting and transporting packaged engines, means of appropriate load capacity as stated on the packaging itself.

– Before carrying out other transfers, create the conditions required to guarantee stability and to prevent any engine part from being damaged.

– Before starting the installation, the installer has to implement a “safety plan” and to follow the designer’s indications. Do not make changes to the engine components for any reason.

– It is necessary to make sure that the installation area is tted with all intake, fuel supply and exhaust connections.

– The manufacturer cannot be held responsible for any damage resulting from the misuse of the engine, from the failure to follow the indications contained in this manual and from any tampering with or change made without the manufacturer’s authorization.

– If appropriate, before using the engine for the rst time, after gathering all the necessary information, simulate a few trial manoeuvres to identify the controls and their main functions, especially those related with starting and stop operations.

SAFETY INFORMATION

SAFETY RULES

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– Do not operate the engine in a closed and insufciently ventilated environment; the exhaust fumes are harmful and can have serious consequences on people’s health.

– Do not keep using the engine if anomalies are detected and in particular if suspect vibrations occur.

– In case of anomaly, stop immediately the engine or reduce the speed as much as possible and reach the closest assistance centre.

– Start again the engine only when the normal operating conditions have been restored.

– Unless otherwise stated, all interventions should be carried out when the engine has been stopped, cooled down and the ignition key has been removed. Those authorized to carry out these interventions should follow all the precautions needed to guarantee the safety of the people involved, in compliance with the requirements laid down in the applicable legislation regarding safety at the workplace.

– Keep the equipment as much efcient as possible and carry out the scheduled maintenance operations established by the manufacturer. A good maintenance will ensure the highest performance, a longer working lifetime and a constant compliance with safety requirements.

– Replace any worn part with original spare parts. Use the oils and greases recommended by the manufacturer. All this will ensure the engine good operation and the prescribed safety level.

– Do not throw away any polluting material in the environment. Carry out their disposal in compliance with the relevant legislation in force.

– During all maintenance operations always use the individual protection clothing and/or devices indicated in the operating instructions supplied by the manufacturer and those provided by the applicable legislation concerning safety at the workplace.

– All maintenance operations should be carried out by using suitable and efcient equipment and tools.

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SAFETY RULES FOR THE ENVIRONMENTAL IMPACT

Each organization is responsible for implementing procedures aimed at identifying, evaluating and controlling the environmental impact of its own activities (products, services, etc.).

The procedures to be followed to identify any signicant environmental impact should take into account the following factors:

– Emissions in the atmosphere – Discharged liquids – Waste disposal – Soil contamination – Use of raw materials and natural re-

sources – Local problems related to the environ-

mental impact. In order to reduce the environmental impact, the manufacturer provides below a few indications to be taken into account by all those who will interact with the engine throughout its expected life.

– All packaging components should be disposed of in accordance with the legislation in force in the country where disposal takes place.

– When installing the engine, ensure a suitable air renewal in the environment to protect the operators from a high concentration of harmful substances.

– During operation and maintenance, do not throw away polluting products (oils, greases, etc) in the environment and carry out the differentiated waste disposal according to the composition of the different materials and in compliance with the legislation in force. Electric and electronic components should be carried out as special waste.

– Keep the exhaust pipelines efcient to limit the noise level of the engine and to reduce atmospheric pollution.

– While decommissioning the engine, divide all the components depending on their chemical composition and dispose of them accordingly.

RESIDUAL RISKS

During the design and construction phases, the Manufacturer paid special attention to the aspects which are liable to cause any risk for the safety and health of people interacting with the engine.

Despite this, some potential and hidden risks still exist.

Danger of injuring your

arms

Do not put your hands inside any moving part.

Danger of being burnt

Pay attention to hot surfaces

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Means of transport

Lifting means

packaging with wooden case

packaging with cardboard box

packaging with cellophane

HANDLING AND INSTALLATION INFORMATION

RECOMMENDATIONS FOR HANDLING AND INSTALLATION

PACKAGING AND TRANSPORT

Eseguire la movimentazione e l’installazione nel rispetto delle informazioni fornite dal costruttore e riportate direttamente sull’imballo e nelle istruzioni per l’uso.

Chi è autorizzato ad eseguire queste operazioni dovrà, se necessario, organizzare un “piano di sicurezza” per salvaguardare l’incolumità delle persone direttamente coinvolte.

The packaging is also made according to the type of transport chosen to keep sizes as small as possible.

– By road – By railway – By sea – By air

The engine can be transported with different types of packaging according to the destination, the transport system and preset technical-commercial specications.

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In order to guarantee the perfect conservation of all engine components, an “overseas” packaging should be used in case of maritime transport.

The packaging contains all the information needed to carry out the loading and unloading operations.

During transport, make sure the load is properly secured to the means of transport to avoid unexpected displacements.

When transporting the uncovered engine by road, use the lifting points provided to secure it steadily and prevent components from being damaged.

UNPACKING

Follow the procedure below. 1 -Remove the cover of the packaging. The packaging includes a bag with all

the relevant technical documentation and standard components.

2 -While unpacking, make sure the components are intact and their quantity is correct.

3 -Place the lifting device as shown in the gure.

4 -Loosen the screws (A) and disassemble the side supports (B).

5 -Move the engine to the installation

area.

If necessary, keep the material in case you need to pack the engine in the future.

Important

In case of any damage or missing part, contact the manufacturer’s Assistance Service to establish the procedure to be adopted. The packaging material should be suitably eliminated in compliance with the applicable legislation.

Screw (A)

Support (B)

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HANDLING AND LIFTING

Secure the engine with a lifting device (lifting beam) of appropriate capacity.

Warning - Caution

The angle formed by the lifting device chains must not exceed 5°, as shown

in the gure.

Hook the lifting device to the xing points as shown in the gure.

Before carrying out the lifting, identify the barycentre position of the load.

Warning - Caution

The brackets of the xing points have

been designed to lift the engine only without any additional weight. Do not lift the engine using a different procedure from the prescribed one; otherwise, the warranty for damages will be invalidated.

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ENGINE STORAGE

If the engine is left idle for prolonged periods, check the possible conditions of conservation in relation to the storage area and the type of packaging.

Avoid any environment exposed to dampness or to the inclemency of weather.

The manufacturer supplies the engine with a protection treatment which is valid for 6 months from the delivery date.

The staff carrying out any type of intervention throughout the life of the engine should have precise technical skills, specic abilities and experiences acquired and acknowledged in this sector. The lack of these requirements may cause damages to people’s safety and health.

VM Motori recommends that this protection procedure is only carried out by VM-authorised personnel.

– All packaging components should be disposed of in accordance with the legislation in force in the country where disposal takes place.

The protection procedure is only considered complete when all the following tasks have been performed:

1) protection against external corrosion

2) protection against internal corrosion

3) packaging and storage

This procedure is valid for the following engine situations:

• on a vehicle

• on a pallet

For engines on pallets, it is necessary to install the following accessories for engine start-up:

• battery

• fuel tank

• cooling radiator (for liquid-cooled engines only)

• command belt for the alternating current generator

• command belt for the water pump (for liquid-cooled engines only)

1) EXTERNAL PROTECTION

UNPAINTED SURFACES: the unpainted metal components and surfaces (for instance the engine handwheel) must be protected with “FL MECA FLUID / P118V” anticorrosion oil.

RUBBER COMPONENTS: unpainted manifolds and pipes must be protected with talcum powder. Check the

tightening of the relative xing clips.

DRIVE BELTS: after applying the internal protection, remove the belts and put them into storage. Protect the surfaces of the metal pulleys with “FL MECA FLUID / P118V” spray.

ENGINE OPENINGS: Seal all the engine openings, including the exhaust. Use cardboard, plywood or metal covers, making sure they do not leave behind any fragments of material. All the engine openings (e.g. air suction ducts or turbocharger air inlet) must be protected with covers or guards to prevent the entry of solids, liquids or dusts that delay the evaporation of the anticorro-

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sion agents. Apply plugs to the fuel inlet and outlet pipes of the injection system.

BATTERY: Disconnect the battery. When it is fully charged, store it in a safe place. Before doing this, protect the terminals against corrosion by applying an anti-rust spray.

2) INTERNAL PROTECTION

COMBUSTION CHAMBER: Remove the heating glowplugs from the head, check the piston is in its lowest stroke position (lower standstill point), then spray with Petronas PROT 30 M protective oil. Repeat the operation for the other cylinders, then reinstall the glowplugs.

TURBOCHARGER: Remove the inlet plug from the pipe that delivers oil

to the turbocharger, and ll with

Petronas PROT 30 M protective oil. Replace the inlet plug, applying the correct tightening torque.

ELECTRIC COMPONENTS: Apply anticorrosion spray to the electric contacts and connectors.

AIR SUCTION SYSTEM: check the

air lter is in good condition, and no

foreign bodies/liquids are present:

If the air lter is damaged, replace it

If there are any foreign bodies, remove them

•

LUBRICATION SYSTEM: this procedure must be carried out together with the injection system protection procedure.

• Using the oil dipstick and check whether there is engine oil in the sump.

• Drain the oil from the sump.

• Fill the engine with Petronas PROT 30 M protective oil.

• Check the coolant level (for watercooled engines only). The coolant mixture must be 50% demineralised or distilled water and 50% Petronas

Parau Up (protective radiator uid

with monoethylene glycol and organic inhibitor formulation complying with ASTM D 3306 type 1 Standards).

• Start up the engine and run it until it reaches the right temperature for water-cooled engines (about 70°- 80°C); for air-cooled engines, run the engine for about 20 (twenty) minutes.

• With the engine up to temperature, carry on for about 5 minutes so that the system components are lubricated.

• Switch off the engine and wait for it to cool down.

• Drain the oil from the sump.

• Drain off the coolant.

• Check for any uid leakage (and

make any necessary repairs).

• Disconnect the engine from all the components used for the test.

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INJECTION SYSTEM: this procedure must be carried out together with the lubrication system protection procedure.

• Make sure there are no deposits or sediments in the fuel tank.

• Prepare a mixture of diesel fuel complying with the DIN EN 590

specications, and Petronas DIESEL

TMF PLUS additive. The ratio must be at least 1:400 (1 litre of additive to 400 litres of fuel). If you use Biodiesel (complying with the UNI EN 14214

specications), it must be mixed with

diesel fuel up to 5%;

VM Motori, however, recommends the use of diesel without Biodiesel.

The use of any other fuel is forbidden.

• Fill the tank with this fuel mixture.

• Where relevant, check there is no interference between the radiator fan blades and the relative air duct.

Start up the engine and run it until it reaches the right temperature for water-cooled engines (about 70°- 80°C); for air-cooled engines, run the engine for about 20 (twenty) minutes.

• Drain the fuel tank.

• Check for any uid leakage (and

make any necessary repairs).

• Switch off the engine and wait for it to cool down.

SEAWATER SYSTEM (for marine engines and on-board auxiliary units only): this procedure must be carried out together with the injection system protection procedure.

• Connect the seawater intake of the seawater pump to an auxiliary tank containing a mixture of 40% fresh-

water and 60% Petronas Parau Up (protective radiator uid with mono-

ethylene glycol and organic inhibitor formulation complying with ASTM D 3306 type 1 Standards), making sure it seeps out from the drainage point.

• Check for any uid leakage (and

make any necessary repairs).

• Switch off the engine and wait for it to cool down.

• Disconnect the engine from all the components used for the test

3) STORAGE CONDITIONS

- Engines on pallets

After applying the anticorrosion protection, the engine must be placed in a dry, well-ventilated environment and adequately covered. The covering must be applied in such a way that air can circulate around the engine, preventing the formation of condensation.

- Engines on vehicles

The vehicle must be stored so as to minimise exposure to atmospheric agents

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START-UP

- Engines on pallets

Remove the covers and protective elements applied to the engine openings (for instance, air suction ducts or turbocharger air inlet, exhaust gas ducts or turbocharger guard).

Check there is no damage to the external engine components; make any necessary repairs.

Clean the throats of the metal belt pulleys, using a suitable solvent. Install the service belts

Check the rubber tubes and manifolds are in good condition, and check the tightening of the relative

xing clips; if they are damaged,

replace them.

All surfaces and components protected with “FL MECAFLUID / P118 V” protective oil can be cleaned with a suitable solvent.

Check the level of the uids: engine

oil and coolant. Top up if necessary.

- Engines on vehicles Check there is no damage to the ex-

ternal engine components; make any necessary repairs.

Clean the throats of the metal belt pulleys, using a suitable solvent. Install the service belts.

Check the rubber tubes and manifolds are in good condition, and check the tightening of the relative

xing clips; if they are damaged,

replace them.

All surfaces and components protected with “FL MECAFLUID / P118 V” protective oil can be cleaned with a suitable solvent.

Check the level of the uids: engine

oil and coolant. Top up if necessary.

Nothing needs to be done to remove the internal protection (either for engines on pallets or on vehicles).

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INSTALLATION DESIGN

In order to ensure the highest performance while protecting people, the product itself and the environment, a full project has to be developed before carrying out the installation.

The design phase should take into account the technical data of the engine (see”Technical data”) and all the risks which may occur during its expected lifetime, from installation to disposal.

During the design and installation phase, it is a good idea to consult the installation manual drawn up by VM MOTORI S.P.A. as this contains the installation guidelines.

Further information are available in the website: www.vmmotori.it, in the “Contacts – Request Info” section.

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rev counter- hour counter (G)

OPERATING INFORMATION

RECOMMENDATIONS FOR USE AND OPERATION

CONTROL BOARD DESCRIPTION

The engine has been designed and manufactured to satisfy all the operating conditions indicated by the manufacturer.

Tampering with any device to achieve a different performance from the intended one can entail risks for people’s safety and health as well as economic damages.

A) Pressure gauge: It indicates the engine oil pressure

B) Warning light (red): It signals that the engine oil pressure is low. When indicator lights up the beeper is triggered.

C) Voltmeter: It indicates the battery voltage

D) Warning light (red): It signals a malfunction in the alternating current generator or battery. When indicator lights up the beeper is triggered.

E) Thermometer: It indicates the temperature of the freshwater coolant

F) Warning light (red): It signals that the temperature of the freshwater coolant is too high. When indicator lights up the beeper is triggered.

G) Rev counter and hour counter:

It in-

dicates the number of engine revolutions and the actual hours of functioning

H) Digital display: in the presence of operating malfunctions, this displays the values detected by the instruments, the error identication codes and the relevant description.

L) Button: used to show the malfunctions on display in sequence.

M) Key switch: used to turn the power supply to the control panel on and off.

N) Pushbutton: It is used to start the

engine.

coolant thermometer (E)

malfunction indicator (F)

engine starter button (N)

control panel on/off key

(M)

display switching button (L)

digital display (H)

malfunction indicator (D)

battery voltmeter (C)

malfunction indicator (B)

oil pressure gauge (A)

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RECOMMENDATIONS FOR USE

The engine is delivered by the factory in the running order. However, during operation the following indications should be observed:

1 -During running-in (rst 50 working hours) and throughout the engine lifetime, carry out the maintenance in compliance with the intervals established by the manufacturer (see “Engine maintenance”

2 -If the engine is not used regularly, start it after each month of inactivity and run it at minimum speed until the operating temperature (70÷80°C) is reached.

3 -Avoid using the engine at the highest speed for prolonged periods during run-

ning- in.

4 -When starting the engine for the rst time, run it at no-load for a few minutes and make sure that the oil pressure value matches the one stated in the table (see “Specications” - “Lubrication circuit”).

5 -Properly pre-heat the engine when using it at low temperatures. When using

the engine at low temperatures (lower than -10°C), ll it with winter-type fuel.

6 -Use oils and lubricants with suitable features (viscosity grade, specications and operating temperature) (see “Recommended lubricants”).

7 -If the alarm signal, which can be acoustic and/or visible on the control panel according to the type of installation, is triggered while the engine is running, the electronic management system may switch the engine to emergency operation, with automatic restriction of performance levels..

Important

If the alarm signal is triggered, contact a VM MOTORI S.P.A. service centre.

OPERATING THE ENGINE UNDER SPECIFIC CONDITIONS

The engine performance is affected by fuel temperature, the temperature and relative humidity of incoming air and

altitude.

When using the engine at high altitudes and high air and fuel temperatures, the output is reduced.

For further information contact a VM MOTORI S.P.A. assistance centre.

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ENGINE IGNITION AND TURNING OFF

Follow the procedure below.

Starting the engine

1 -Insert the key (T) and turn it clockwise to position ON.

2 -Press button (N) to start the engine and then release the button.

3 -Run the engine at a minimum speed during the heating phase.

Important

Light-up of (red) indicator lights and/ or the sounding of a beeper indicate the presence of a fault. In these conditions, turn the engine off immediately, then identify and eliminate the cause of the fault.

Turn the engine off

4 -Run the engine at minimum idling speed for 1-2 minutes.

5 -Turn the ignition key (T) anticlockwise (pos. OFF) to turn off the engine.

All the warning lights go off. 6 -Remove the ignition key and store it

in a safe place known only to those in charge.

In the case of turbocharged engines, before switching the engine off it should be run at minimum idle speed for a few minutes in order to avoid damaging the turbocharger.

If the indicator lights are still on and/or the beeper still sounds when the engine is turned on again, turn the engine off immediately and contact one of the manufacturer’s authorised service centres.

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REFUELLING

During refuelling, make sure the fuel does not contain any residue; in this case use specic lters.

Avoid using fuel mixed with water or other substances which may damage the

engine.

The engine has been designed to be powered by standard fuels available on the European market (according to specications DIN EN 590). If it is to be powered by BIODIESEL fuels (according to specications UNI EN14214), it can be mixed, up to 5%, with fuel available on the European market (according to regulation DIN EN 590).

Important

Do not use fuels with specications

other than those indicated.

Danger - Attention

All fuels are inammable. Any fuel

leaking or dropping on hot surfaces and electric components can cause

res. Do not smoke when refuelling or nearby any lling station..

MAINTENANCE INFORMATION

RECOMMENDATIONS FOR MAINTENANCE

Keep the equipment as much efcient as possible and carry out the scheduled maintenance operations established by the manufacturer.

A good maintenance will ensure the highest performance, a longer operating lifetime and a constant compliance with safety requirements.

Warning - Caution

Unless otherwise stated, all interventions should be carried out when the engine has been stopped, cooled down and the ignition key has been removed.

Those authorized to carry out these interventions should follow all the precautions needed to guarantee the safety of the people involved, in compliance with the requirements laid down in the applicable legislation concerning safety at the workplace..

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ENGINE MAINTENANCE

The maintenance operations are subdivided into:

– Maintenance during running-in (rst 50 hours)

– Routine maintenance (after runningin) The frequency stated in the “ routine maintenance” table should be applied to engines which are used regularly.

Some lubricants or components lose their characteristics over time even if the engine is left idle for long periods; therefore, maintenance intervals should be established considering that these parts need to be replaced not only on the basis

Maintenance during running-in table (rst 50 hours)

Frequency(5) Component

Type of in-

tervention

Intervention

procedures

Reference

Every 10 hours

Engine oil Level control

Top up, if necessary

See “Engine oil level control”

Coolant Level control

Top up, if necessary

See “Engine coolant level check”

After the rst

50 hours (at the end of running- in)

Engine oil (1)

Replacement

See “Engine oil change”

Oil lter (2) Replacement

See “Oil lter cartridge replacement”

Routine maintenance table (after running-in)

Frequency(5)(5) Component Type of in-Type of in-

tervention

InterventionIntervention procedures

Reference

Every 10 hours

Engine oil (1)

Level controlLevel control Top up, if nec-

essary

See “Engine oilSee “Engine oil level control”

Coolant (3) Level controlLevel control Top up, if nec-

essary

See “Engine coolant level check”

Every 50 hours

Electrolytic zinc

Integrity control

Replace, if necessary

See “Electrolytic zinc replacement”

of their hours of operation but of ageing as well.

The approximate maximum time during which the chemical-physical characteristics of a few components or lubricants are maintained is stated below.

– 1 year – Lubricant oil – 1 year - Fuel lter cartridge – 2 years - Cartridges, air and oil lter – 2 years – Coolant – 2 years – Transmission belt (type POLY-

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Frequency(5) Component Type of in-

tervention

Intervention

procedures

Reference

Every 100 hours

Seawater pump impeller

Integrity control

Replace, if necessary

Every 300 hours

Transmission belt (2)

ReplacementReplacement See “Belt replace-

ment”

Seawater

pump impeller(1)

ReplacementReplacement Apply to an authori-

sed workshop

Engine oil (1)

Replacement See “Engine oil

change”

Oil lter (2) Replace the

cartridge

See “Oil lter cartridge replacement”

Air lter (2)

ReplacementReplacement See “Inlet air lter

replacement”

Fuel lter(1)

ReplacementReplacement See “Fuel lter

replacement”

Fuel circuit

unions

Check tighte-

ning

See “Control screw tightening and union sealing”

Electrolytic zinc

ReplacementReplacement See “Electrolytic

zinc replacement”

Every 500 hours

Heat exchangers (engine oil, fresh water) (4)

Cleaning Apply to an authori-

sed workshop

Intercooler(4)

Cleaning Apply to an authori-

sed workshop

Every 600 hours

Coolant (3) Replace See “Coolant

replacement”

(1) If the engine has not been in operation for the length of time indicated, it must still be changed at least once a year.

(2) If the engine has not been in operation for the length of time indicated, it must still be changed at least once every 24 months.

(3) If the engine has not been in operation for the length of time indicated, the uid must still be changed at least once every 24 months.

(4) If the engine has not been in operation for the length of time indicated, the heat exchangers must still be cleaned at least once every 5 years.

(5) If an hour counter is not available, the frequency of the interventions should be calculated on the basis of a calendar day: one calendar day corresponds to 12 hours of operation.

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Periodic maintenance operation record sheet

Important

For each maintenance operation, ll 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 (1) Type of maintenance performed Signature and stamp

of workshop

(1) Indicate the total number of working hours.

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Date Hours (1) Type of maintenance performed Signature and stamp

of workshop

(1) Indicate the total number of working hours.

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Date Hours (1) Type of maintenance performed Signature and stamp

of workshop

(1) Indicate the total number of working hours.

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Date Hours (1) Type of maintenance performed Signature and stamp

of workshop

(1) Indicate the total number of working hours.

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Date Hours (1) Type of maintenance performed Signature and stamp

of workshop

(1) Indicate the total number of working hours.

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MAINTENANCE WHEN THE ENGINE IS LEFT IDLE

If the boat where the engine is installed is left idle for a long time, it is necessary to carry out some maintenance work to preserve the engine’s maximum efciency conditions.

If the engine is not used for short periods of time, carry out the following interventions:

1 -Make sure the electric contacts are working properly and, if necessary, protect them with an anti-oxidant spray.

2 -Check the charge of the battery and the liquid level.

3 -If necessary, carry out the scheduled maintenance work (see “Engine maintenance”).

It is advisable to start the engine bringing it to the operating temperature (70÷80°C) at least once per month.

The engine must be started once per month if it is installed for emergency purposes.

If the engine is left idle for prolonged periods, carry out the engine protecti-

ve treatment to guarantee its efciency

for 6 months and to avoid continuous control and maintenance interventions. If the engine is not used for a further period of time, check the need to repeat the protective treatment for other 6 months (see “Engine Storage”).

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MAINTENANCE IN CASE OF ENGINE INACTIVITY

After a period of inactivity, it is necessary to carry out a few maintenance interventions before starting the engine again to ensure its maximum efciency conditions.

– Check the charge of the battery and the liquid level.

– Make sure the electric contacts are intact and properly working.

– Carry out the operation diagnosis of the engine (see “Diagnosis of failures”).

– Check the oil level, and, if necessary, top up or replace it according to the established intervals (see “Routine maintenance table (after running-in)”).

– Replace the oil lter according to the established intervals (see “Routine maintenance table (after running-in)”).

– Check the coolant level, and if necessary, top up or replace it according to the established intervals (see “Routine maintenance table (after running-in)”).

– Replace the fuel lter according to the established intervals (see “Routine maintenance table (after running-in)”).

– Replace the air lter according to the established intervals (see “Routine maintenance table (after running-in)”).

– Tension again the transmission belt (see “Method for tightening or loosening the belt”).

– Check the tightening of the hydraulic unions (see “Control screw tightening and union sealing”).

– Check the integrity of the impeller of the seawater pump (see “Routine maintenance table (after running-in)”).

– Check the integrity of the electrolytic zinc (see “Routine maintenance table (after running-in)”)

– Use a cloth soaked in a degreasing product to remove the external protective treatment.

– Start the engine and run it at minimum speed for a few minutes (see “Engine ignition and turning off”).

– If no anomalies are detected, bring the engine to its operating temperature (70÷80°C).

– Turn off the engine and check again the engine oil and coolant level.

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pump (F)

bleeding screw

(E)

7 -Tighten the screw (E). 8 -Wipe out the fuel residues before star-

ting the engine.

CONTROL SCREW TIGHTENING AND UNION SEALING

Follow the procedure below. 1 -Start the engine and run it at minimum

speed for a few minutes. 2 -Run the engine at normal speed until

the operating temperature (70÷80°C) is reached.

3 -Turn off the engine and let it cool down.

4 -Make sure the xing screws of the main parts are tightened properly.

5 -Check the union sealing on the fuel supply circuit.

6 -Check the tightening of the clamps. 7 -Check any uid leaks.

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. 3 -Prepare a container of appropriate

capacity. 4 -Loosen the screw (E). 5 -Operate the pump (F) manually to

eliminate air from the circuit. 6 -Check that a ow of clean fuel contai-

ning no air bubbles is coming out of the bleeder screw (E).

Important

When bleeding the fuel circuit, make sure that you do not drain all the fuel

contained in the lter. If you do, remove the lter , ll it with fuel, replace it

and bleed again.

FUEL SUPPLY CIRCUIT BLEEDING

CHECKS AND CONTROLS

The information needed to carry out all maintenance, check and control operations which do not require the replacement of mechanical components are provided below.

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ENGINE OIL LEVEL CONTROL

Follow the procedure below. 1 -Start the engine and bring it to the

operating temperature (70÷80 °C). 2 -Turn off the engine and remove the

ignition key. 3 -Place the engine on a perfectly level

surface.

4 -Wait a few minutes so that all the oil will ow into the sump.

5 -Remove the dipstick (L) and check the oil level.

6 -Top up, if necessary, from plug (M). As for the oil quantity, see “Specications”.

Important

The oil level should be included between the minimum and maximum marks. Do not mix oils of different brands or with different features (see “Recommended lubricants”)..

ENGINE COOLANT LEVEL CHECK

Follow the procedure below. 1 -Start the engine and bring it to the

operating temperature (70÷80 °C). 2 -Turn off the engine and remove the

ignition key. 3 -Let the engine cool down properly. 4 -Unscrew the load plug (P).

Warning - Caution

Open the plug gently to drain the pressure.

5 -Top up, if necessary, from plug (P). As for the liquid quantity and type, see “Specications”.

Important

The liquid level should be included between the minimum and maximum notches printed on the expansion chamber.

dipstick (L)

load plug (M)

load plug (P)

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tensioner (A)

METHOD FOR TIGHTENING OR LOOSENING THE BELT

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. 3 -Loosen the belt by moving the ten-

sioner (A) until the holes (B) match and block it with pin (C).

4 -Tension the belt by moving the tensioner (A), remove the pin (C) and release

it..

Warning - Caution

To tighten the belt, it must be correctly positioned in the housings on each of the pulleys (see “Belt replacement”).

hole (B)

pin (C)

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Warning - Caution

In the event of oil leaks, check the level periodically to evaluate the extent of the leak. If the amount is excessive, contact one of the manufacturer’s authorised service centres.

Important

Do not throw the oil in the environment but carry out its disposal in compliance with legislation in force in the country where it is used. Use the oils and lubricators recommended by the manufacturer (see “Recommended lubricants”).

ENGINE OIL CHANGE

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. 3 -Prepare a container of appropriate

capacity. As for the oil quantity, see “Specications”.

4 -Unscrew the load plug (M). 5 -Unscrew the plug (Q). 6 -Insert the pump (R) and screw it to

pipe. 7 -Operate manually the pump to transfer

all the oil into the container. 8 -Pour the new oil until it reaches the

correct level on the dipstick (see “Engine oil level control”)

9 -Disconnect the pump. 10 -Screw again the plug (Q).

plug (Q)

pump (R)

load plug (M)

11 -Screw again the load plug (M). 12 -Start the engine and bring it to the

operating temperature (70÷80 °C). 13 -Check for any oil leaks 14 -Turn off the engine and check the oil

level (see “Engine oil level control”).

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COOLANT REPLACEMENT

Follow the procedure below. 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.

3 -Let the engine cool down adequately to avoid being burnt.

4 -Prepare a container of appropriate capacity. As for the liquid quantity, see “Specications”.

5 -Open the cock (S). 6 -Unscrew the plug (S1). 7 -Let the liquid ow into the container. 8 -Close the cock (S). 9 -Screw again the plug (S1). 10 -Carry out the same operation on the

cock (S2) as well. 11-Unscrew the plug (P). 12-Pour in the new liquid. The liquid level

should be included between the minimum and maximum notches printed on the expansion chamber. As for the liquid quantity and type, see “Specications”.

13 -Screw again the plug (P). 14 -Turn the engine on and leave it run-

ning at minimum speed for a few minutes until it reaches working speed (70÷80°C).

15 -Turn off the engine and let it cool down properly.

16 -Check the coolant level and, if necessary, carry out topping-up (see “Engine coolant level check”).

cock (S)

cock (S2)

plug (S1)

Important

Do not throw away any polluting material in the environment. Carry out their disposal in compliance with the relevant legislation in force.

load plug (P)

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SEAWATER CIRCUIT EMPTYING

Follow the procedure below. 1 -Prepare a container of appropriate

capacity. 2 -Unscrew the plug (P1). 3 -Let water ow into the container. 4 -Screw again the plug (P1). 5 -Carry out the same operation on plug

(P2) as well.

plug (P1)

plug (P2)

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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. 3 -Prepare a container to collect any leak. 4 -Unscrew the cover (T). 5 -Replace the cartridge (U). 6 -Check the conditions of gasket (V) and,

if necessary, replace it. 7 -Screw up the cap (T).

Important

Tighten the cap to a tightening torque of 25 Nm.

8 -Turn the engine on and leave it running at minimum speed for a few minutes until it reaches working speed (70÷80°C).

9 -Check for any oil leaks

Warning - Caution

In the event of oil leaks, check the level periodically to evaluate the extent of the leak. If the amount is excessive, contact one of the manufacturer’s authorised service centres.

Important

Do not throw away any polluting material in the environment. Carry out their disposal in compliance with the relevant legislation in force.

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FUEL FILTER 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. 3 -Prepare a container to collect any leak. 4 -Disassemble lter (Z) and replace it. 5 -Fill the new lter with the fuel from the

lter being replaced. 6 -Lubricate the gasket of the new lter

before mounting it. 7 -Replace the lter and screw the sump

back on. 8 -Bleed air from the fuel supply circuit

(see “Fuel supply circuit bleeding”). 9 -Turn the engine on and check for any

fuel leaks.

Warning - Caution

In the event of fuel leaks, identify and eliminate the cause. If the problem persists, contact one of the manufacturer’s authorised service centres..

Important

Do not throw away any polluting material in the environment. Carry out their disposal in compliance with the relevant legislation in force..

RECOMMENDED LUBRICANTS

The lubricant recommended by VM MOTORI S.P.A. is: Q8 HD SPECIAL 10W-40 for operating temperatures from -20°C to

+50°C..

Oils of different brands can be used provided that they have the following features:

– Viscosity grade: SAE 10 W - 40 – Minimum specications: ACEA A3/B4

API CF

Important

It is advisable not to mix oils with different characteristics.

fuel lter (Z)

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INFORMATION ABOUT FAILURES

TROUBLESHOOTING

The information below are provided to facilitate the identication and solution of possible anomalies and failures which may occur during operation.

Some of these problems can be solved by the user, while others require specic

technical skills or abilities, therefore they should be exclusively dealt with by qualied technicians with extensive experience in the specic sector of intervention.

Problem Cause Remedy

During the ignition phase the control board and the

engine do not start.

Flat battery Recharge or replace battery

Fuse “triggered”

Reset the fuse (see “Reset

fuses”)

The electric cables are discon-

nected or they do not guarantee

continuity

Check the electric connections

Failure of engine revolution

sensor

Replace the sensor Apply to an

authorised workshop

The engine does not

start

Presence of air in the fuel supply

circuit

Carry out bleeding (see “Fuel

supply circuit bleeding”)

Dirty or faulty injectors

Clean or replace injectors Apply

to an authorised workshop

The injection pump is set incor-

rectly or is faulty

Adjust the pump or replace it Ap-

ply to an authorised workshop

Failure of the start control

Replace the start control Apply to

an authorised workshop

Fuse “triggered” Reset the fuse (see “Reset fuses”)

The starter motor runs

idle

The engine starting relay is not

connected correctly or is faulty

Replace the relay Apply to an

authorised workshop

Electromagnet failure

Check the starter motor Apply to

an authorised workshop

The starter motor is not

running

Flat battery Recharge or replace battery

Interrupted electric connection Check the electric connections

Worn brushes

Replace the worn brushes Apply

to an authorised workshop

Fuse “triggered”

Reset the fuse (see “Reset

fuses”)

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MR 700

Ed. 3 - 2012_11

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The engine stops after

ignition

Presence of air in the fuel supply

circuit

Carry out bleeding (see “Fuel

supply circuit bleeding”)

Clogged fuel lter

Replace lter (see “Inlet air lter

replace-ment”)

The injection pump is set incor-

rectly or is faulty

Adjust the pump or replace it Ap-

ply to an authorised workshop

The electric cables are discon-

nected or they do not guarantee

continuity

Check the electric connections

The engine does not

reach the operating

speed

Clogged fuel lter

Replace lter (see “Fuel lter

replacement”)

Presence of air in the fuel supply

circuit

Carry out bleeding (see “Fuel

supply circuit bleeding”)

The injection pump is set incor-

rectly or is faulty

Adjust the pump or replace it Ap-

ply to an authorised workshop

Dirty or faulty injectors

Clean or replace injectors Apply

to an authorised workshop

Clogged air lter

Clean or replace the lter (see

“Inlet air lter replacement”)

Overload Reduce the load

Emission of black

smoke from the exhaust

pipe

Dirty or faulty injectors

Clean or replace injectors Apply

to an authorised workshop

The injection pump is set incor-

rectly or is faulty

Adjust the pump or replace it Ap-

ply to an authorised workshop

Faulty turbocharging turbine

Replace the turbine Apply to an

authorised workshop

Light emission of white

smoke from the exhaust

pipe

Oil level too high Adjust the oil level

Worn segments

Check compression Apply to an

authorised workshop

Worn valve guideways

Check wear Apply to an autho-

rised workshop

Abundant emission of white smoke from the

exhaust pipe

Burnt gasket head Apply to an authorised workshop

Engine overheating. Clogged

coolers

Clean the coolers. Apply to an

authorised workshop

Clogged seawater lter Clean or replace the lter

Worn seawater pump impeller

Replace the impeller. Apply to an

authorised workshop

Broken or worn belt

Replace the belt (see “Belt

replacement”)

Failure of water temperature

sensor

Replace the sensor. Apply to an

authorised workshop

Problem Cause Remedy

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MR 700

Ed. 3 - 2012_11

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The pressure gauge-

shows a too low engineoil

pressure and the cor-

responding warning light

comes on

Failure of pressure gauge

Check or replace the pressure

gauge. Apply to an authorised

workshop

Oil level too low

Adjust the oil level (see “Engine

oil level con-trol”)

Oil pump failure

Check or replace the pump. Apply

to an authorised workshop

Faulty sensor

Check and, if appropriate, replace

the sen-sor. Apply to an autho-

rised workshop

The coolant temperature

warning light comes on

Coolant too low

Adjust the engine coolant level

(see “Engine coolant level check”)

Stucked overpressure valve of

the load plug

Replace the plug with 1 bar valve

Worn or faulty seawater pump

impeller

Replace the impeller. Apply to an

authorised workshop

Freshwater pump failure

Check the pump and, if neces-

sary, replace it. Apply to an autho-

rised workshop

Broken or worn belt

Replace the belt (see “Belt

replacement”)

Excessive noise

Dirty or faulty injectors

Clean or replace injectors. Apply

to an authorised workshop

The injection pump is set incor-

rectly or is faulty

Adjust the pump or replace it.

Apply to an authorised workshop

The injection pump timing is not

adjusted correctly

Adjust pump timing. Apply to an

authorised workshop

Output reduction

Clogged fuel lter

Replace lter (see “Fuel lter

replacement”)

Presence of air in the fuel supply

circuit

Carry out bleeding (see “Fuel

supply circuit bleeding”)

The injection pump is set incor-

rectly or is faulty

Adjust the pump or replace it.

Apply to an authorised workshop

Dirty or faulty injectors

Clean or replace injectors. Apply

to an authorised workshop

Clogged air lter

Clean or replace the lter (see

“SInlet air l-ter replacement”)

Clogged seawater pump impeller

Clean the impeller. Apply to an

authorised workshop

Insufcient accelerator stroke Adjust the accelerator stroke

The battery warning light

comes on

The alternating current generator

does not charge the battery

Check and, if appropriate, replace

the alternat-ing current generator.

Apply to an authorised workshop

The oil pressure warning

light comes on

Engine oil pressure too low Apply to an author

Problem Cause Remedy

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MR 700

Ed. 3 - 2012_11

English

RESET FUSES

The engine is equipped with safety fuses, which cut out to prevent damage to the electrical components.

In the event of malfunctions due to triggering of a fuse, the cause (overload or short circuit current) must be eliminated before the fuse is reset.

1 - To repair the protective fuse of the electrical circuit, open the fuse box/relay (A) and replace the fuse which has intervened.

Important

the new fuse must have the same electrical characteristics as the fuse replaced.

Important

If the problem persists, contact a VM MOTIRI S.P.A. service centre.

Fuse/relay box (A)

K1: Starter motor relay K2: Main relay F1: 20A F2: 10A F3: 10A F4: 15A F5: 15A F6: 5A

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MR 700

Ed. 3 - 2012_11

English

DIAGNOSIS OF FAILURES

– The engine is tted with a self-diagnosis system that allows any operating malfunctions to be identied, by means of indicators (B-D- F) and/or activation of an acoustic signal.

– In the presence of operating malfunctions, the display (H) shows the values detected by the instruments, the error identication codes and the relevant description.

– Button (L) serves to show the malfunctions on display in sequence.

Important

In the event of malfunctions, turn the engine off immediately, contact one of the manufacturer’s authorised service centres and provide them with the information shown on the display.

Button (L)

display (H)

Button (L)

Photo 2

Photo 1

READING ERROR CODES

In case of malfunction, the display (H) visualises the presence of error codes.

In the case of one or more error codes, the display shows the following caption:

DTC

Photo 1 represents the presence of 6 malfunctions that have occurred.

While holding down the button (L) you can see the rst error code “SPN”. Photo 2 represents the presence of the error code SPN 628.

By pressing the button (L) again you can see the errors later.

Refer to the table “Error Codes List” to identify the description of the error code.

Tech Library http://engine.od.ua

MR 700

Ed. 3 - 2012_11

English

ERROR CODES LIST

SPN Description

0 Immobilizer Key not Correct 0 Rail Pressure Signal Offset Control Error 0 EGR Radiator Bypass Actuator Malfunction 0 NO Description 27 Malfunctioning of EGR Exhaust Gas Recirculation Actuator 27 Malfunctioning of EGR Exhaust Gas Recirculation Actuator 27 Excessive ow of EGR Exhaust Gas Recirculation or Malfunctioning Air Inlet Sy-

stem 27 Insufcient ow of EGR Exhaust Gas Recirculation 81 DPF Particulate Filter - Low System Efciency 81 DPF Particulate Filter - Filter Disassembled or Defective 81 DPF Particulate Filter - Non Plausible Differential Pressure 81 DPF Particulate Filter - Active Engine Protection 84 Vehicle Speed Sensor Malfunction 84 NO Description 91 Synchronization Error of Accelerator Pedal Position Sensors 91 Accelerator Pedal Position Error - Sensor 1 91 Accelerator Pedal Position Error - Sensor 2 91 Position of Accelerator/Brake not plausible 91 NO Description 97 Actuator Malfunction of Water Level in Gas Oil 97 Circuit Malfunction of Water Sensor in Gas Oil 97 Detection of Water in Gas Oil 100 Alarm for Low Engine Oil Pressure 100 Alarm for Critical Engine Oil Pressure 100 Signal Error from Engine Oil Pressure Sensor 102 Overfeeding Pressure Alarm 102 Overfeeding Pressure Sensor Error 105 Intake Air Temperature Sensor Alarm 105 Intake Air Temperature Sensor Error

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MR 700

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English

SPN Description

108 DPF Particulate Filter - Non Plausible Differential Pressure 108 Atmospheric Pressure Sensor Error 110 Engine water Temperature Alarm 110 Engine Water Sensor Error 110 Engine water Sensor Malfunction 131 DPF Particulate Filter - Filter Disassembled or Defective 131 DPF Particulate Filter - Non Plausible Differential Pressure 131 DPF Particulate Filter - Active Engine Protection 131 DPF Particulate Filter - Defective Differential Pressure Sensor 132 Plausibility Error of Air Flow Signal 132 Interval Error of Battery Voltage Signal Check 132 Signal Error of Air Flow of Reference 157 Rail Pressure Error during Rail Pressure Check from Pressure Regulator 157 Error of Maximum Pressure Limiting Valve PRV Rail 164 Error of Rail Pressure Signal 168 Battery Voltage Error 172 Air Temperature Signal Duty Cycle Error 172 NO Description 173 Exhaust Gas Temperature Sensor Error - Bank 1 - Position 1 174 Gas oil Temperature Sensor Error 175 Engine Oil Temperature Alarm 175 Signal Error from Engine Oil Temperature Sensor 177 NO Description 190 Engine Overspeed Alarm 190 Crankshaft rpm Sensor Error 228 Camshaft/Crankshaft Position Sensor Error 518 NO Description 527 Cruise Control Circuit Malfunction 527 NO Description 574 NO Description 581 NO Description 597 Brake Signal Error 598 Clutch Signal Error 604 Gearbox Control unit - Neutral gearbox indicator light malfunctioning

Tech Library http://engine.od.ua

MR 700

Ed. 3 - 2012_11

English

SPN Description

624 Circuit Malfunction of System indicator light 629 Engine ECU - Performance Error of Injection Control Module A 629 Engine ECU - Performance Error of Injection Control Module B 629 Engine ECU Injector Activation Time Limit Check Error 629 Engine ECU RPM Signal Redundancy Check Error 629 Engine ECU Internal Communication Error - SPI 629 Engine ECU EEPROM Internal Memory Error 629 Engine ECU Internal Supply Voltage Error 629 Engine ECU Injector Deactivation Redundancy Test Error during Initialization 629 Engine ECU Processor Restart Abolished 629 Engine ECU Processor Restart Locked 629 Engine ECU Analogue/Digital Convertor Error 629 Verication Error of TPU Processor Activation Time 629 Internal Error of Engine ECU Controller/Processor 629 Internal Error of Communication between Processor and Control Module 630 Plausibility Error of the Dataset Variant Coding 633 Analogue/Digital Channel Error of PCV Fuel Flow Adjustment Valve Control 633 PWM Circuit Malfunction of PCV Fuel Flow Adjustment Valve Control 634 Intake Buttery Valve Actuator Error 634 Circuit Malfunction of TVA Intake Buttery Valve Actuator 639 NO Description 641 High Overfeeding Pressure Conditions 641 Low Overfeeding Pressure Conditions 641 Circuit Malfunction of Overfeeding Pressure Control Actuator Solenoid 651 Cylinder 1 - Injector Circuit Malfunction Alarm 651 Cylinder 1 - Injector Circuit Malfunction Specic Error 651 Injector Opening Time Calibration Error 652 Cylinder 2 - Injector Circuit Malfunction Alarm 652 Cylinder 2 - Injector Circuit Malfunction Specic Error 652 Injector Opening Time Calibration Error 653 Cylinder 3 - Injector Circuit Malfunction Alarm 653 Cylinder 3 - Injector Circuit Malfunction Specic Error 653 Injector Opening Time Calibration Error

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MR 700

Ed. 3 - 2012_11

English

SPN Description

654 Cylinder 4 - Injector Circuit Malfunction Alarm 654 Cylinder 4 - Injector Circuit Malfunction Specic Error 654 Injector Opening Time Calibration Error 655 Cylinder 5 - Injector Circuit Malfunction Alarm 655 Cylinder 5 - Injector Circuit Malfunction Specic Error 655 Injector Opening Time Calibration Error 656 Cylinder 6 - Injector Circuit Malfunction Alarm 656 Cylinder 6 - Injector Circuit Malfunction Specic Error 656 Injector Opening Time Calibration Error 657 Injector Circuit Malfunction Alarm 657 Injector Circuit Malfunction Specic Error Bank 1 658 Injector Circuit Malfunction Alarm 658 Injector Circuit Malfunction Specic Error Bank 2 675 Glowplugs Indicator Light Malfunction 676 Glowplugs GCU Control Unit Relay Malfunction 676 Cylinder 1 Glowplug Circuit Malfunction 676 Cylinder 2 Glowplug Circuit Malfunction 676 Cylinder 3 Glowplug Circuit Malfunction 676 Cylinder 4 Glowplug Circuit Malfunction 676 Cylinder 5 Glowplug Circuit Malfunction 676 Cylinder 6 Glowplug Circuit Malfunction 676 NO Description 676 Glowplugs Control Unit 677 Plausibility Error Terminal Signal T15 677 Plausibility Error Terminal Signal T50 677 Circuit Malfunction of Starter Motor Command Relay 679 Error of Valve Limiting Maximum Pressure PRV Rail 680 NO Description 723 Camshaft Phase Sensor Error 767 Transmission Gear Reverse Switch Error 835 Engine Oil Pressure Indicator Light Malfunction 859 Circuit Malfunction of Gas oil Filter Heater Relay 898 NO Description

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MR 700

Ed. 3 - 2012_11

English

SPN Description

970 NO Description 976 NO Description 977 Circuit Malfunction of Fan Relay 1 977 Circuit Malfunction of Fan Relay 2 977 Circuit Malfunction of Fan Relay 3 977 NO Description 979 Malfunction of PTO Switch 1079 Supply Voltage Check Error Sensors 1 1079 Supply Voltage Check Error Sensors 2 1079 Supply Voltage Check Error Sensors 3 1109 NO Description 1137 Error Checking the Plausibility of the Exhaust Gas Temperature Sensor - Position 1137 Exhaust Gas Temperature Sensor Error - Bank 1 - Position 1 1138 Error Checking the Plausibility of the Exhaust Gas Temperature Sensor,Position 2 1138 Sensor Error of Exhaust Gas Temperature - Bank 1 - Position 2 1139 NO Description 1213 Circuit Malfunction of MIL Indicator light 1213 NO Description 1347 Malfunction of Pressure Regulator Solenoid PWM Control Circuit 1347 NO Description 1351 Circuit Malfunction Air Conditioned Relay

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MR 700

Ed. 3 - 2012_11

English

SPN Description

1484 Gearbox Control unit - Solenoid Circuit Error 1484 Gearbox Control unit - Error Checking the Pressure Switch 1484 Gearbox Control unit - Relay Error 1484 Gearbox Control unit - Turbine Speed Sensor Error 1484 Gearbox Control unit - Pressure Switch Function Test Failure 1484 Gearbox Control Unit - Torque Value of Converter Out of Range 1484 Gearbox Control Unit - Switch Valve Blocked 1484 Generic Error of TCU Gearbox Control unit 1484 Internal Error of TCU Gearbox Control unit 1484 Internal Error of TCU Gearbox Control unit Gear Ratio Incorrect 1484 NO Description 1485 Relay Main Control Error 1680 Auxiliary Heater Circuit Malfunction

Tech Library http://engine.od.ua

MR 700

Ed. 3 - 2012_11

English

INFORMATION ABOUT COMPONENT REPLACEMENT

RECOMMENDATIONS FOR PART REPLACEMENT

Before carrying out any replacement, activate all safety devices and evaluate the need to inform the personnel working on the engine or nearby. In particular, place proper signs in the nearby areas and keep away all devices which, once activated, may represent a source of unexpected danger and risk for people’s safety and health. When necessary, replace the worn components, and use original spare parts only. The manufacturer cannot be

held responsible for damages to people or components resulting from the use of non original spare parts and from repairs carried out without the authorisation of the manufacturer.

When requesting spare parts, always contact your nearest VM MOTORI S.P.A. spare parts dealer (see “Enclosed documentation”: Spare parts and service centre address booklet) and indicate the engine’s serial number (see “Manufacturer and engine identication”).

BELT 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. 3 -Loosen the belt by moving the ten-

sioner (A) until the holes (B) match and block it with pin (C).

4 -Remove the belt (D) and replace it. 5 -Tension the belt by moving the tensio-

ner (A), remove the pin (C) and release it.

Warning- Attention

To tighten the belt, it must be correctly positioned in the housings on each of the pulleys.

Tech Library http://engine.od.ua

MR 700

Ed. 3 - 2012_11

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Important Before restarting the engine, make sure there are no tools or other material left near the moving parts. Do not throw away any replaced part in the environment. Carry out their disposal in compliance with the relevant legislation in force.

INLET AIR FILTER REPLACEMENT

Model MR704

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. 3 -Unscrew the nuts (A). 4 -Remove the bracket (B). 5 -Remove the protection (C) and replace

the cartridge (D). 6 -Reposition the protection (C). 7 -Reposition the bracket (B) and block it.

Model MR706

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. 3 -Loosen hose clamp (A) and remove

the lter (B). 4 -Extract sponge (C) and replace it. 5 -Replace the lter (B) and x it using the

hose clamp (A).

bracket (B)

nut (A)

cartridge (D)

housing (C)

clamp (A)

sponge (C)

lter (B)

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MR 700

Ed. 3 - 2012_11

English

ELECTROLYTIC ZINC 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. 3 -Unscrew the nut and replace the

electrolytic zinc (A).

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 bio-degradable products and non ferrous components (rubber, PVC, resins, etc.).

While decommissioning the engine, divide all the components depending on their chemical composition and dispose of them accordingly.

electrolytic zinc (A)

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MR 700

Ed. 3 - 2012_11

English

ELECTRICAL SYSTEM

ENGINE ELECTRICAL DIAGRAM - MR704

Tech Library http://engine.od.ua

MR 700

Ed. 3 - 2012_11

English

ENGINE ELECTRICAL DIAGRAM - MR706

Tech Library http://engine.od.ua

VM Motori MR704LX, MR704LS, MR706LX, MR706LH, MR706LS Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual