VM Motori R754EU5, R756EU5, R754IE3, R756IE3, R754TE4 Instruction Manual

...

Download

R750EU5 - IE3 - TE4 - IE4 - ISE4

VM p/n - 42432055F Ed. 8 / 10 - 2012

English 1 Ed.8 / 10-2012

Engine instructions manual

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 2 Ed.8 / 10-2012

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 ...............................................................................................................................12

TECHNICAL DATA (R754 EU5-R756 EU5) ...........................................................................................12

TECHNICAL DATA (R754 IE3-R756 IE3) ..............................................................................................15

TECHNICAL DATA (R754 TE4-R754 IE4 - R754ISE4) .........................................................................18

SAFETY INFORMATION ......................................................................................................................21

GENERAL SAFETY WARNINGS ..........................................................................................................21

SAFETY WARNINGS FOR THE ENVIRONMENTAL IMPACT .............................................................22

SAFETY WARNINGS FOR THE ELECTRICAL EQUIPMENT ..............................................................23

RESIDUAL RISKS .................................................................................................................................23

HANDLING AND INSTALLATION INFORMATION ..............................................................................24

RECOMMENDATIONS FOR HANDLING AND INSTALLATION ...........................................................24

PACKAGING AND TRANSPORT ..........................................................................................................24

UNPACKING .........................................................................................................................................25

HANDLING AND LIFTING ..................................................................................................................... 26

ENGINE STORAGE .............................................................................................................................. 27

INSTALLATION DESIGN .......................................................................................................................31

OPERATING INFORMATION ...............................................................................................................32

RECOMMENDATIONS FOR USE AND OPERATION ..........................................................................32

RECOMMENDATIONS FOR USE ........................................................................................................32

OPERATING THE ENGINE UNDER SPECIFIC CONDITIONS ............................................................34

REGENERATION OF THE PARTICLE FILTER ....................................................................................34

REFUELLING ........................................................................................................................................35

ENGINE IGNITION AND TURNING OFF ..............................................................................................35

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 3 Ed.8 / 10-2012

MAINTENANCE INFORMATION ..........................................................................................................36

RECOMMENDATIONS FOR MAINTENANCE ......................................................................................36

ENGINE MAINTENANCE ...................................................................................................................... 36

MAINTENANCE DURING RUNNING-IN (FIRST 50 HOURS) ...................................................................................... 37

ROUTINE MAINTENANCE (AFTER RUNNING-IN) ...................................................................................................38

Periodic maintenance operation record sheet ..................................................................... 40

MAINTENANCE WHEN THE ENGINE IS LEFT IDLE .......................................................................... 45

WASHING THE ENGINE .......................................................................................................................45

MAINTENANCE IN CASE OF ENGINE INACTIVITY ...........................................................................46

CHECKS AND CONTROLS ..................................................................................................................47

CONTROL SCREW TIGHTENING AND UNION SEALING .................................................................. 47

FUEL SUPPLY CIRCUIT BLEEDING ....................................................................................................47

ENGINE OIL LEVEL CONTROL............................................................................................................48

ENGINE COOLANT LEVEL CHECK ..................................................................................................... 49

CLEANING AND REPLACEMENT OF THE AIR FILTER ......................................................................50

ENGINE OIL CHANGE .......................................................................................................................... 51

ENGINE OIL DILUTION ........................................................................................................................ 52

COOLANT REPLACEMENT ................................................................................................................. 53

OIL FILTER CARTRIDGE REPLACEMENT ..........................................................................................54

FUEL FILTER REPLACEMENT ............................................................................................................55

RECOMMENDED LUBRICANTS ..........................................................................................................56

INFORMATION ABOUT FAILURES .....................................................................................................57

TROUBLESHOOTING ..........................................................................................................................57

INFORMATION ABOUT COMPONENT REPLACEMENT ...................................................................61

RECOMMENDATIONS FOR PART REPLACEMENT ...........................................................................61

CHANGING THE BELT (TYPE POLY-V) WITH AUTOMATIC BELT TENSIONER .................................................62

CHANGING THE BELT (TYPE POLY-V) WITH AUTOMATIC BELT TENSIONER .................................................63

ENGINE DISPOSAL ..............................................................................................................................64

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

ISO 9001 - Cert. n° 0295

ISO/TS 16949 - Cert. n° 2920

ISO 14001 - Cert. n° 0043A

English 4 Ed.8 / 10-2012

English 4

INTRODUCTION

QUALITY SYSTEM CERTIFICATE ISO 9001-QS 9000-ISO 14001

GENERAL INFORMATION

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 engines designed and built by VM MO-

TORI S.P.A. are repaired by unauthorised technicians, if the planned maintenance operations foreseen are not carried out, if NON ORIGINAL spare parts are used, if the coolants, engine oil and fuels used do not comply with the manufacturer’s specications, then any service or technical guarantee provided by VM MOTORI S.P.A. will immediately expire.

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 cer-

ti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 asso-

ciation 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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 5 Ed.8 / 10-2012

PURPOSE OF THE MANUAL

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.

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.

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

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.

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

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 6 Ed.8 / 10-2012

MANUFACTURER AND ENGINE IDENTIFICATION

Engine code Engine model

05D R754EU5 06D R756EU5 20D R754IE3 80C R756IE3 45D R754TE4 34D R754IE4 39D R754ISE4

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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 7 Ed.8 / 10-2012

PROCEDURE TO REQUEST TECHNICAL ASSISTANCE

WARRANTY CONDITIONS

ATTACHED DOCUMENTATION

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

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

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

–Address booklet of assistance and spare part centres

–Warranty sheet

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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 8 Ed.8 / 10-2012

ENGINE GENERAL DESCRIPTION

TECHNICAL INFORMATION

Engines of series R754 EU5 - R756 EU5 were designed and manufactured to

be installed on road vehicles, such as for example road-cleaning vans, lorries, etc., on condition that they have been type-approved according to EURO 5 anti-pollution directives. Model R754IE3, R756IE3, R754TE4-IE4-ISE4 engines have been

designed for off-road use, tted in agricultural machinery or load lifting machines.

The models of engine differ from each other in both power and performance (See “Technical data R754EU5,

R756EU5, R754IE3, R756IE3, R754TE4IE4-ISE4”).

Main components R754IE3, R756IE3, R754EU5, R756EU5

A) Cooler: cools the engine oil by heat

exchange with the coolant uid.

B) Turbo device: Made up of a turbine which exploits a part of the exhaust gas energy to carry out the engine turbocharging.

C) “EGR” valve: modulates the recircula-

tion of exhaust gasses before they ow

into the suction manifold.

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

E) Heat expansion valve: It adjusts the water temperature according to the engine working temperature

F) Fuel lter: It traps any impurity

G) Oil lter: It traps any impurity

H) Oil sump: It contains the engine lubri-

cation oil

L) Suction manifold: conveys the combustion air into the combustion chamber.

M) Water pump: feeds the cooling circuit

N) Driving belt (type Poly-V): it starts

service devices, the alternator (Q) and the water pump (M).

P) Automatic belt tightener: it keeps the belt constantly tightened.

Q) alternating current generator: It produces and regulates the electric system voltage

R) Starter: It is used to start the engine

S) Exhaust manifold: It is used to expel

the combustion gases

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

U) high pressure injection pump: It feeds the injectors with fuel under pressure

V) Injector: injects pressurised fuel into the combustion chamber.

W) Antiparticulate lter R754EU5, R756EU5: this is installed in the engine

exhaust pipe conduit. It serves to retain the particulate so as to reduce the emissions from diesel engines, which are responsible for atmospheric pollution.

X) Air lter: for engine intake.

The air is ltered over 3 phases: in the cyclone pre-separator , in the main lter and in the safety lter.

Y) Debimeter R754EU5, R756EU5: it detects the air mass that feeds the engine.

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

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 9 Ed.8 / 10-2012

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 10 Ed.8 / 10-2012

Main components R754TE4 - IE4 - ISE4

A) Cooler: cools the engine oil by heat

exchange with the coolant uid.

B) Turbo device: Made up of a turbine which exploits a part of the exhaust gas energy to carry out the engine turbocharging.

C) “EGR” valve: modulates the recircula-

tion of exhaust gasses before they ow

into the suction manifold.

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

(Only for

R754IE4).

E) Heat expansion valve: It adjusts the

water temperature according to the engine working temperature

F) Fuel lter: It traps any impurity

G) Oil lter: It traps any impurity

H) Oil sump: It contains the engine lubri-

cation oil

L) Suction manifold: conveys the combustion air into the combustion chamber.

M) Water pump: feeds the cooling circuit

N) Driving belt (type Poly-V): it starts

service devices, the alternator (Q) and the water pump (M).

P) Automatic belt tightener: it keeps the belt constantly tightened.

Q) alternating current generator: It produces and regulates the electric system voltage

R) Starter: It is used to start the engine

S) Exhaust manifold: It is used to expel

the combustion gases

U) high pressure injection pump: It feeds the injectors with fuel under pressure

V) Injector: injects pressurised fuel into the combustion chamber.

W) Antiparticulate lter: this is installed in

the engine exhaust pipe conduit. It serves to retain the particulate so as to reduce the emissions from diesel engines, which are responsible for atmospheric pollution.

X) Air lter: for engine intake.

The air is ltered over 3 phases: in the cyclone pre-separator , in the main lter and in the safety lter.

Y) Debimeter: it detects the air mass that feeds the engine.

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

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 11 Ed.8 / 10-2012

DPF Filter (W)

Air Filter (X)

Debimeter

(Y)

Intake

Manifold

(L)

Exhaust Manifold

(S)

Turbo (B)

“waste-gate”

valve (D)

Injector (V)

Common RAIL

(Z)

Heat Exchanger

(A)

Starter Motor (R)

Fuel Filter (F)

High Pressure

Pump (U)

Alternator Belt (N)

Belt Tensioner (P)

Coolant Pump (M)

Alternator (Q)

Thermostatic

valve (E)

EGR Valve (C)

Oil Filter (G)

Oil Pan (H)

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 12 Ed.8 / 10-2012

TECHNICAL DATA (R754 EU5-R756 EU5)

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

.A.

engines.

Unit of

measure-

ment

R754EU5 R756EU5

Dimensions

A mm 704 943 B mm 602 602 C mm 722 734

Unit of

measure-

ment

R754EU5 R756EU5

General data

Cycle Four stroke diesel Total displacement Liters 2,970 4,455 Number of cylinders nr. 4 6 Bore and stroke mm 94x107 94x107 Compression ratio 17,8 ± 0,5:1 17,8 ± 0,5:1

Intake

Turbocharged and inter-cooled circuit - (Dry) air

lter

Cooling Water circuit

TECHNICAL DATA

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 13 Ed.8 / 10-2012

Unit of

measure-

ment R754EU5 R756EU5

Cooler water/oil

Crankshaft rotation

Anticlockwise (observing the engine from the handwhe

el side)

Combustion sequence 1-3-4-2 1-5-3-6-2-4

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 800 +/-50 750 +/-50

Dry shipping weight of engine kg 260 335 Maximum permanent lengthwise

inclination (with handwheel up) degrees 30° 30° Maximum permanent lengthwise

inclination (with handwheel down) degrees 35° 35° Maximum permanent crosswise

inclination degrees 30° 30° Power and torque Maximum operating speed rpm 3000 3000

Maximum power

kW (CV) @ rpm 74 (100) @ 3000 120 (163) @ 3000

Maximum torque

Nm (kgm) @ rpm 340 (34,68) @ 1350 500 (51) @ 1350

Consumption at maximum power

Specic fuel consumption g/kWh 274 254 Specic oil consumption g/KWh 0,2 0,2

Fuel supply circuit

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 powered by

BIODIESEL fuels (according to specications UNI EN

14214), 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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 14 Ed.8 / 10-2012

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

Oil change including lter

(standard sump) liters (kg) 10 (8,7)

13,8 (12) ÷ 18.9 (16,5)

The oil quantity at maximum level ( 12÷16,5 kg) depends on the capacity of the oil sump with which the engine is equipped.

Oil quantity at minimum level (standard sump) liters (kg) 5,8 (5,1) 7,5 (6,6)

Oil quantity at maximum level (standard sump) liters (kg) 8,5 (7,4) 10,9 (9,5)

Oil pressure at minimum speed (with started engine) bar 1,4 - 1,8

Oil cooling Oil/water cooler Cooling circuit Total capacity of cooling circuit

(excluding radiator and relevant pipes) liters 5 7,5

Setting pressure of the expansion tank plug bar 1,1 1,1

Coolant

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)

Coolant maximum temperature alarm °C 107 107

Electric system Nominal voltage V 12 12 Alternating current generator

(nominal voltage) V 14 14 Alternating current generator

(nominal current) A 105 105 Starter motor output kW 2,5 2,5 Recommended battery capacity Ah 140 140 Battery breakaway current A 950 950 Suction circuit Maximum depression allowed with

new air lter mbar 40 40

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 15 Ed.8 / 10-2012

TECHNICAL DATA (R754 IE3-R756 IE3)

Table 2: Technical data of the engine

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

.A.

engines.

Unit of

measure-

ment

R754IE3 R756IE3

Dimensions

A mm 704 943 B mm 601 601 C mm 722 734

Unit of

measure-

ment

R754IE3 R756IE3

General data

Cycle Four stroke diesel Total displacement Liters 2,970 4,455 Number of cylinders nr. 4 6 Bore and stroke mm 94x107 94x107 Compression ratio 17,8 ± 0,5:1 17,8 ± 0,5:1

Intake

Turbocharged and inter-cooled circuit - (Dry) air

lter

Cooling Water circuit

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 16 Ed.8 / 10-2012

Unit of

measure-

ment R754IE3 R756IE3

Cooler water/oil

Crankshaft rotation

Anticlockwise (observing the engine from the handwhe

el side)

Combustion sequence 1-3-4-2 1-5-3-6-2-4

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 800 +/-50 750 +/-50

Dry shipping weight of engine kg 260 335 Maximum permanent lengthwise

inclination (with handwheel up) degrees 30° 30° Maximum permanent lengthwise

inclination (with handwheel down) degrees 35° 35° Maximum permanent crosswise

inclination degrees 30° 30° Power and torque Maximum operating speed rpm 3000 3000

Maximum power

kW (CV) @ rpm 74 (100) @ 3000 120 (163) @ 3000

Maximum torque

Nm (kgm) @ rpm 420 (42.80) @ 1000 500 (50.90) @ 1400

Consumption at maximum power

Specic fuel consumption g/kWh 254 284 Specic oil consumption g/kWh 0,2 0,2

Fuel supply circuit

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 powered by

BIODIESEL fuels (according to specications UNI EN

14214), 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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 17 Ed.8 / 10-2012

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 lter

(standard sump) liters (kg) 10 (8,7) 13,8 (12) Oil quantity at minimum level

(standard sump) liters (kg) 5,8 (5,1) 7,5 (6,6) Oil quantity at maximum level

(standard sump) liters (kg) 8,5 (7,4) 10,9 (9,5) Oil pressure at minimum speed

(with started engine) bar 1,4 - 1,8 Oil cooling Oil/water cooler Cooling circuit Total capacity of cooling circuit

(excluding radiator and relevant pipes) liters 5 7,5

Setting pressure of the expansion tank plug bar 1,1 1,1

Coolant

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)

Coolant maximum temperature alarm °C 107 107

Electric system Nominal voltage V 12 12 Alternating current generator

(nominal voltage) V 14 14 Alternating current generator

(nominal current) A 110 110 Starter motor output kW 2,5 2,5 Recommended battery capacity Ah 140 140 Battery breakaway current A 950 950 Suction circuit Maximum depression allowed with

new air lter mbar 40 40

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 18 Ed.8 / 10-2012

TECHNICAL DATA (R754 TE4-R754 IE4 - R754ISE4)

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

.A.

engines.

Unit of

measure-

ment

R754TE4 R754IE4 R754ISE4

Dimensions

A mm 704 704 704 B mm 554 554 554 C mm 766 766 766

Unit of

measure-

ment

R754TE4 R754IE4 R754ISE4

General data

Cycle Four stroke diesel Total displacement Liters 2,970 2,970 2,970 Number of cylinders nr. 4 4 4 Bore and stroke mm 94x107 94x107 94x107 Compression ratio 17.5 ± 0.5 : 1 17.5 ± 0.5 : 1 17.5 ± 0.5 : 1

Intake

R754TE4 - R754ISE4 Turbocharged circuit - R754IE4

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

Cooling Water circuit

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 19 Ed.8 / 10-2012

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

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 800 800 800

Dry shipping weight of engine kg 260 260 260 Maximum permanent lengthwise

inclination (with handwheel up) degrees 30° 30° 30° Maximum permanent lengthwise

inclination (with handwheel down) degrees 35° 35° 35° Maximum permanent crosswise

inclination degrees 30° 30° 30° Power and torque Maximum operating speed rpm 2600 2600

Maximum power

kW (CV) @ rpm

80 (108.8) @

2600

55.4 (75.3) @ 2600

Maximum torque

Nm (kgm) @ rpm

420 (42.8) @

1100

310 (31.6) @

1100

Consumption at maximum power

Specic fuel consumption g/kWh 222.5 217.7 Specic oil consumption g/kWh 0,2 0.2

Fuel supply circuit

Type of injection Common Rail direct injection with high pressune injection pump

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 powered by

BIODIESEL fuels (according to specications UNI EN

14214), 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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 20 Ed.8 / 10-2012

Unit of

measure-

ment R754TE4 R754IE4 R754ISE4

Lubrication circuit Type of lubrication Forced lubrication Circuit fuel supply Rotor pump

Oil change including lter

(standard sump) liters (kg) 11 (9.57) Oil quantity at minimum level

(standard sump) liters (kg) Oil quantity at maximum level

(standard sump) liters (kg) Oil pressure at minimum speed

(with started engine) bar 2 Oil cooling Oil/water cooler Cooling circuit Total capacity of cooling circuit

(excluding radiator and relevant pipes) liters 5

Setting pressure of the expansion tank plug bar 1,1

Coolant

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)

Coolant maximum temperature alarm °C 107

Electric system Nominal voltage V 12 Alternating current generator

(nominal voltage) V 14 Alternating current generator

(nominal current) A 110 Starter motor output kW 2,5 Recommended battery capacity Ah 140 Battery breakaway current A 950 Suction circuit Maximum depression allowed with

new air lter mbar 30

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 21 Ed.8 / 10-2012

GENERAL SAFETY WARNINGS

SAFETY INFORMATION

–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 anchored.

–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 in-

stallation 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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 22 Ed.8 / 10-2012

–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.

–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 require-

ments 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.

SAFETY WARNINGS 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 identi-

fy 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 resources

– Local problems related to the environmental 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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 23 Ed.8 / 10-2012

SAFETY WARNINGS FOR THE ELECTRICAL EQUIPMENT

RESIDUAL RISKS

–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.

The electrical equipment was designed and manufactured according to the provisions of the standards in force on the mat-

ter. The list species some warnings to be

complied with for the correct operation of the electrical equipment.

–Do not use boosters or quick starters to start the engine.

–Do not disconnect the electrical power supply when the engine is ON.

Before disconnecting the electrical power supply, turn off the engine and wait for at least 30 sec. so that the electronic control unit can perform the “after -run” procedure.

–Before performing arc welding on the frame where the engine is installed, ALWAYS disassemble the electronic control unit and protect all electrically connected devices that are installed close to the negative pole (mass).

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 movingpart.

Danger of being burnt

Pay attention to hot surfaces

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 24 Ed.8 / 10-2012

RECOMMENDATIONS FOR HANDLING AND INSTALLATION

HANDLING AND INSTALLATION INFORMATION

PACKAGING AND TRANSPORT

PACKAGING WITH WOODENCASE

PACKAGING WITH CARDBOARD BOX

PACKAGING WITH CELLOPHANE

Carry out handling and installation following the information provided by the manufacturer and stated directly on the packaging and operating instructions.

Those authorized to carry out these operations should prepare, if necessary, a “safety plan” to protect and the safety of people directly involved.

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.

Means of transport

Lifting equipment

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 25 Ed.8 / 10-2012

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.

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)

Stay (B)

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

0°

Max 5°

English 26 Ed.8 / 10-2012

HANDLING AND LIFTING

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

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.

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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 27 Ed.8 / 10-2012

ENGINE STORAGE

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

If the engine is still not being used 6

months after delivery, then a specic

“protection procedure” must be carried out in order to extend the storage period for a further 6 months.

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 tighten-

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

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 28 Ed.8 / 10-2012

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

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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 29 Ed.8 / 10-2012

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% freshwater

and 60% Petronas Parau Up (protective radiator uid with monoethylene

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

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 30 Ed.8 / 10-2012

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).

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 31 Ed.8 / 10-2012

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 phases, it is advisable to consult the service manual supplied by VM MOTORI S.P.A..

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

INSTALLATION DESIGN

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 32 Ed.8 / 10-2012

OPERATING INFORMATION

RECOMMENDATIONS FOR USE AND OPERATION

RECOMMENDATIONS FOR USE

Sensor (A)

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

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- Avoid using the engine at the highest speed for prolonged periods during running- in.

3- If the engine is not regularly used, it is advisable to start and take it to the working temperature (70÷80°C) at least once a month.

4- DO NOT use the engine at maximum performances before it has reached the working temperature (70÷80 °C).

5- 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 “Technical data )” - “Lubrication circuit”)

6 - In the event that the ambient temperature is low during use, proceed as follow:

□ preheat the engine adequately.

□ when ambient temperatures are

lower than -10°C, contact the manufacturer of the vehicle regarding the installation of devices which facilitate start-up and prevent ice forming in the engine oil vapour recovery

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.

7 - Use oils and lubricants with suitable

features (viscosity grade, specications

and operating temperature). (See “Recommended lubricants”)

8 - If the “water in fuel” indicator lights up, proceed as follows:

– Turn off the engine and remove the ignition key.

– Let the engine cool down adequately to avoid being burnt.

– Prepare a container of appropriate capacity.

– Unscrew the water sensor (A) of the

lter and let the fuel ow until it proves to

be water-free.

– Screw the sensor (A) back.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 33 Ed.8 / 10-2012

Be careful to ensure that the fuel in the

lter does not drain completely out. If it does, remove it (see “Fuel lter replacement.”), ll it manually and then

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

9 - When an alarm signal (visual and/or acoustic) is triggered by the control panel this indicates that there is a malfunction of some kind.

In the presence of anomalies, the electronic engine management system activates protective strategies and also the limitation of the engine performances if necessary.

In these conditions it is possible to check the ignition of the indicator light (MIL) for the engines R750EU5 or of the system indicator light (SYS) for the engines R750TE3-IE3, R750TE4-IE4-ISE4.

Do not continue to use the engine with the MIL indicator light on, instead contact an authorized VM Motori assistance centre.

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 provided by the manufacturer of the vehicle/device in which the engine is installed.

To solve the problem, proceed as indicated.

– Turn off the engine.

–Consult chapter “INFORMATION ABOUT FAILURES” for the action to be taken and details of how to deal with the causes that triggered the state of emergency.

– In case of doubts, never operate directly, but contact a VM authorised workshop.

If the engine is not regularly used, it is advisable to start and take it to the working temperature (70÷80°C) at least once a month.

If the engine is installed for use in emergencies, for example in the case of generators, it must be started at least once per month.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 34 Ed.8 / 10-2012

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.

R750EU5 engines have an automatic

particulate lter regeneration system

that can only be activated while the vehicle is running. During this phase,

the lter casing reaches temperatures of

around 500°C.

During the particulate lter regeneration

phase, do not park the vehicle on sur-

faces containing ammable materials,

which may burn on contact with the exhaust system.

R750IE4 engines have an automatic par-

ticulate lter regeneration system that

can only be activated while the vehicle

is running. During this phase, the lter

casing reaches temperatures of around 500°C.

During the particulate lter regeneration

phase, do not park the vehicle on sur-

faces containing ammable materials,

which may burn on contact with the exhaust system.

R750EU5

R750IE4

REGENERATION OF THE PARTICLE FILTER

The “Regeneration of the particle lter” is

the burning operation of the particles that

periodically accumulate in the lter.

In some applications, there may be an indicator light in the instrument panel of the vehicle which indicates the clogging of

the particulate lter

In the event of activation of this indicator light, for the regeneration of the particu-

late lter it is recommended to drive the

vehicle at medium-high engine load, until the indicator light turns off.

For more information refer to the instruction book for use and maintenance of the vehicle or contact the customer service network.

In some applications a button may be available for manual regeneration of the

particulate lter: to use this button refer to

the instruction book for use and maintenance of the vehicle.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 35 Ed.8 / 10-2012

ENGINE IGNITION AND TURNING OFF

The engine is not tted with a control

panel.

For information on the commands and control devices, please see the documentation provided by the manufacturer of the vehicle/ device in which the engine is installed.

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.

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 EN 590). If it is to be powered by BIODIESEL fuels (according to specica-

tions UNI EN 14214), it can be mixed, up to 5%, with fuel available on the European market (according to regulation EN 590).

Do not use fuels with specications

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 10-50 ppm (parts per million).

If the percentage sulphur contained in the fuel exceeds the value indicated,

the antiparticulate lter will not work

properly.

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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 36 Ed.8 / 10-2012

MAINTENANCE INFORMATION

RECOMMENDATIONS FOR MAINTENANCE

ENGINE 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.

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

The maintenance operations are subdivided into:

–Maintenance during running-in (rst 50

hours)

–Routine maintenance (after running-in)

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 of their hours of operation but of ageing as well.

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.

For each maintenance operation, ll 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.

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 – Coolant

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 37 Ed.8 / 10-2012

MAINTENANCE DURING RUNNING-IN (FIRST 50 HOURS)

For each maintenance operation, ll 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.

Frequency (1)

Component

Type of intervention

Intervention procedures

Reference

Every 10 hours (Every day)

Engine oil (2) Level control

Top up, if necessary

See Engine oil level control

Coolant (4) Level control

Top up, if necessary

See Engine coolant level check

Air lter

Check it is clean

Clean with low pressure compressed air.

Check the clogging indicator that is installed

on the lter body

Clean the lter

or, if necessary, replace it with a new one.

See Cleaning and replacement

of the air lter

Coolant uid

radiator

Check it is clean

Clean with a soft brush

After the

rst 50 hours

(at the end of running-in)

Oil lter (3) Replacement

See Oil lter

cartridge replacement

(1) 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.

(2) In hard working conditions, such as dusty environments and operation with extreme loads, change the oil of the engine and the oil

lter every 150 working hours. If the engine has not worked for the specied time, it will be necessary to replace the oil and the lter all the

same once a year.

(3) If the engine has not been in operation for

the length of time indicated, the lter must still

be changed at least once every 12 months.

(4) 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.

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

Periodic maintenance operation record sheet

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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 38 Ed.8 / 10-2012

ROUTINE MAINTENANCE (AFTER RUNNING-IN)

Frequency (1)

Component

Type of intervention

Intervention procedures

Reference

Every 10 hours

Engine oil (2) Level control

Top up, if necessary

See “Engine oil level control”

Coolant (4) Level control

Top up, if necessary

See “Engine coolant level check”

Air lter

Check it is clean

Clean with low pressure compressed air.

Check the clogging indicator that is installed

on the lter body

Clean the lter

or, if necessary, replace it with a new one.

See “Cleaning and replacement

of the air lter”

Coolant uid

radiator

Check it is clean

Clean with a soft brush

Every 300 hours (6)

Engine oil (2) (6)

Replace

See “Engine oil change”

Oil lter

Replace the cartridge

See “Oil lter

cartridge replacement”

Air lter

Replace the main cartridge

See “Cleaning and replacement

of the air lter”

Check if the safety cartridge is clean

Clean with low pressure compressed air.

See “Cleaning and replacement

of the air lter”

Fuel lter Replace

See “Fuel lter

replacement.”

Air intake circuit and intercooler pipe

Check it is clean

Check of pipe sealing

Dust discharge circuit

Check it is clean

Oil separation circuit

Check of pipe sealing

Vacuum circuit

Check of pipe sealing

For each maintenance operation, ll 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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

500 ORE

500 HOURS

English 39 Ed.8 / 10-2012

Frequency (1) Component

Type of intervention

Intervention procedures

Reference

Every 900 hours

Drive belt (type Poly-V) (5)

Replace

See “Changing t belt (type Poly-V)”

fuel tank

Clean the fuel tank and check

the efciency of the ller cap.

Air lter

Replace the clogging indicator

Every 1200 hours

Coolant (4) Replace

See “Coolant replacement”

Every 4000 hours

Antiparticulate

lter

Perform the regeneration

Apply to an authorised workshop

Every 4000 hours

Engine

Performing partial overhaul

Apply to an authorised workshop

Every 8000 hours

Engine

Performing general overhaul

Apply to an authorised workshop

(1) 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.

(2) In hard working conditions, such as dusty environments and operation with extreme loads, change the

oil of the engine and the oil lter every 150 working hours. If the engine has not worked for the specied

time, it will be necessary to replace the oil and the

lter all the same once a year.

The engine oil must in any case be changed, even before the time limit indicated in the scheduled

maintenance programme, if the MIL

indicator indicator light comes on with the ECU error 252F - “Engine oil critical mass”..

(3) If the engine has not been in operation for the

length of time indicated, the lter must still be changed

at least once every 12 months.

(4) 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.

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

(6) In engine R756EU5 models with a high capacity oil sump, a special plate is applied on the cover of the engine valves to indicate that the engine oil and the oil

lter must be changed every 500 hours instead of every

300.

Periodic maintenance operation record sheet

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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 40 Ed.8 / 10-2012

PERIODIC MAINTENANCE OPERATION RECORD SHEET

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..

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 41 Ed.8 / 10-2012

Date Hours

(1)

Type of maintenance performed Signature and stamp of

workshop

1) Indicate the total number of working hours..

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 42 Ed.8 / 10-2012

Date Hours

(1)

Type of maintenance performed Signature and stamp of

workshop

1) Indicate the total number of working hours..

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 43 Ed.8 / 10-2012

Date Hours

(1)

Type of maintenance performed Signature and stamp of

workshop

1) Indicate the total number of working hours..

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 44 Ed.8 / 10-2012

Date Hours

(1)

Type of maintenance performed Signature and stamp of

workshop

1) Indicate the total number of working hours..

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 45 Ed.8 / 10-2012

MAINTENANCE WHEN THE ENGINE IS LEFT IDLE

WASHING THE ENGINE

In order to avoid irreversibly damaging the electrical and electronic components of the engine, do not spray high pressure jets of water or jets of vapour in the direction of these components.

Pay particular attention to:

□ cable connection points and engine wiring electrical connectors

□ alternator, starter motor,

□ injection pump and related fuel

supply pump,

□ electro-injectors,

□ electrical sensors installed on the

engine,

□ electronic engine management

control unit,

□ engine suction air lter and related air ow meter,

□ fuel lter,

– If you decide to wash the engine, adequately protect the above listed components before washing.

– When washing is complete, start the engine and leave it running for a few minutes until it is completely dry.

If the vehicle/equipment to which the

engine is tted remains inactive, certain

maintenance operations must be carried out to ensure the engine remains in full working order.

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.

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

– 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 needs to be used in emer-

gency conditions, refer to the specic

regulations concerning compulsory start-up: if there are no specic regulations, you are advised to start up the engine once a month.

If the engine is left idle for prolonged

periods, carry out the engine protective

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. (Vedi

“Engine storage”).

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 46 Ed.8 / 10-2012

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.

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

–Replace the oil lter according to the

established intervals (See “Routine maintenance (after running-in)”)

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

–Replace the fuel lter according to the

established intervals (See “Routine maintenance (after running-in)”)

– Replace the air lter according to the

established intervals (See “Routine maintenance (after running-in)”)

– Tension again the transmission belt

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

–Check the rubber gaskets and relevant xing clips to ensure they are undamaged.

– 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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 47 Ed.8 / 10-2012

CHECKS AND CONTROLS

CONTROL SCREW TIGHTENING AND UNION SEALING

FUEL SUPPLY CIRCUIT BLEEDING

Pump (F)

Bleed screew (E)

The list indicates some of the maintenance, testing and control operations to be carried out on the engine during normal operation.

– Fuel supply circuit bleeding

–Control screw tightening and union sealing

–Engine oil level control

–Engine coolant level check

–Procedure for loosening or tensioning the belt

–Engine oil change

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.

This operation must be carried out each time the fuel cartridge is changed

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.

–Coolant replacement

–Oil lter cartridge replacement

– Fuel lter replacement.

– Cleaning the antiparticulate lter

For each maintenance operation, ll 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.

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.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 48 Ed.8 / 10-2012

3- Prepare a container of appropriate capacity.

4- Loosen the screw (E).

Do not loosen high-pressure pipe unions of the supply circuit (COMMON RAIL system).

5- Operate the pump (F) manually to eliminate air from the circuit.

6-Check that a ow of clean fuel containing no air bubbles is coming out of the bleeder screw (E).

Be careful to ensure that the fuel in the

lter does not drain completely out. If it does, remove it (see “Fuel lter replacement.”), ll it manually and then

repeat the bleeding operation.

7- Tighten the screw (E).

8- Wipe out the fuel residues before starting the engine.

ENGINE OIL LEVEL CONTROL

Filler Cap (M)

Oil Dipstick (L)

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 “Technical data ”.

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”)

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

R750EU5 - R750IE3

English 49 Ed.8 / 10-2012

ENGINE COOLANT LEVEL CHECK

Filler cap (P)

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 lling plug (P).

Open the plug gently to drain the pressure.

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

The uid level must be up to the base

of the neck into which the radiator plug is screwed.

For further information, please consult the documentation provided by the manufacturer of the vehicle/device in which the engine is installed.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 50 Ed.8 / 10-2012

CLEANING AND REPLACEMENT OF THE AIR FILTER

The air lter is equipped with the indicator

(A) that displays the relevant clogging le-

vel. Clean the lter as described when the

indicator always keeps red coloured.

1- Unscrew the fastening screw (B) and disassemble the cyclone pre-separator

lter (C).

2-Clean the lter with compressed air or

with a water jet.

3-Remount lter (C) and x it with the

screw.

4- Open the fasteners (D) and disassemble the cover (E).

5- Remove the cartridge (F), and then clean it with an air jet directed to the exterior.

6- Check the wearing conditions of the cartridge and, if necessary, replace it.

7- Remove the cartridge (G), and then clean both the cartridge and the inside of the container with an air jet.

When cleaning the container, pay attention so that no foreign body enters the intake duct.

8- Re-assemble the cartridge (G).

After having replaced the main cartridge (F) two or three times, it is important to replace the safety cartridge (G), as well.

9- Re-assemble the cartridge (F) and the cover (E).

10-At the end of the operation, press the button of the indicator to reset its colour.

Cover (E)

Air lter Cartdridge (F)

Air Filter Cartdridge (G)

Air Filter (C)

Screw (B)

Clogging indicator (A)

Closing hock (D)

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 51 Ed.8 / 10-2012

ENGINE OIL CHANGE

Filler cap (M)

Drain plug (Q)

Follow the procedure below.

Start the engine and bring it to the operating temperature (70÷80 °C)

Turn off the engine and remove the ignition key.

Let the engine cool down adequately to avoid being burnt.

Prepare a container of appropriate capacity. (As for the oil quantity, see “Technical data”.)

Unscrew the load plug (M).

Unscrew the exhaust plug (Q) and let

all the oil ow into the container.

Replace the gasket and screw plug (Q) back into place.

•

Lock the plug to a torque of 55 Nm.

Pour the new oil until it reaches the correct level on the dipstick. (See “Engine oil level control”)

Screw again the load plug (M).

Start the engine and bring it to the operating temperature (70÷80 °C). Check for any oil leaks.

Turn off the engine and check the oil level. (See “Engine oil level control”)

•

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 52 Ed.8 / 10-2012

In R750 EURO5 engines after each oil change the “Oil dilution calculation” function must be reset. The function is reset by the diagnosis tool available from authorised workshops or vehicle dealers. If the diagnosis tool is not available, the function can be reset using the following procedure:

1. Turn the ignition key to ON with the engine off

2. Press the accelerator pedal fully down (pedal from 0% to 100%)

3. Wait for 3 seconds before releasing the pedal.

4. Release the pedal, allow it to return to the initial position (0%) and wait a further 3 seconds before pressing it again.

Repeat the procedure described in points 2, 3 and 4, 5 times. In some applications the accelerator pedal procedure is not feasible: proceed using the manual accelerator potentiometer.

VERIFICATION: if the procedure has been done correctly, the engine oil low

pressure light will ash three times

for one second each, with a pause of

0.5 seconds. In some applications the

verication is not feasible.

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 DILUTION

Reset the ECU parameters (carry out this operation after completing the engine oil change).

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 53 Ed.8 / 10-2012

COOLANT REPLACEMENT

Filler Cap (P)

Cock (S)

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 “Technical data ”.

5-Unscrew the load plug (P).

Open the plug gently to drain the pressure.

6- Open the cock (S).

If there is no coolant drainage tap, check to see if there is a drain plug. For further information, please consult the documentation provided by the manufacturer of the vehicle/device in which the engine is installed.

7- Let the liquid ow into the container.

8-Close the cock (S).

9- Pour in the new liquid.

The uid level must be up to the base

of the neck into which the radiator plug is screwed. If there is a coolant expansion tank, consult the documentation provided by the manufacturer of the vehicle/device in which the engine is installed. As for the liquid quantity and type, see “Technical data ”.

10-Screw again the plug (P).

11-Turn the engine on and keep it running at idle speed for a few minutes to bring it up to working temperature (70÷80°C).

If the uid level decreases, top it up

until it is constantly between the reference marks

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

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

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

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 54 Ed.8 / 10-2012

OIL FILTER CARTRIDGE REPLACEMENT

Gasket (V)

Oil Filter (U)

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 lter (U) and replace it.

5-Check the conditions of gasket (V) and, if necessary, replace it.

6- Lubricate the seal of the new cartridge before assembling it.

7- Install the oil lter.

Lock the screw to a torque of 25 Nm.

8- Turn the engine on and keep it running at idle speed for a few minutes to bring it up to working temperature (70÷80°C).

9- Turn off the engine and remove the ignition key.

10-Wait a few minutes so that all the oil

will ow into the sump.

11-Check that the oil in the tank is at the correct level, and top up if necessary. (See “Engine oil level control”)

12-Check for any oil leaks

If any oil leaks are found, stop the engine immediately and contact an authorised service centre.

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

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 55 Ed.8 / 10-2012

FUEL FILTER REPLACEMENT

Fuel Filter (Z)

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 fuel from the lter

you have just removed.

6- Lubricate the gasket of the new lter

before mounting it.

7-Ret the lter.

8- Bleed air from the fuel supply circuit. (See “Fuel supply circuit bleeding”)

9- Turn the engine on and check for any fuel leaks.

If any fuel leaks are found, stop the engine immediately and contact an authorised service centre.

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

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 56 Ed.8 / 10-2012

RECOMMENDED LUBRICANTS

The lubricant recommended by VM MOTORI S.P.A. is: Q8 T 905 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 10W-40

–Specications: ACEA E6

It is advisable not to mix oils with differentcharacteristics.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 57 Ed.8 / 10-2012

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.

Activation of a visual and/or acoustic signal indicates some form of malfunction. In this case, turn the engine off immediately and consult the documentation supplied by the manufacturer of the vehicle/device in which the engine is installed.

Problem Cause Remedy

During the ignition phase the control board and the engine do not start.

Flat battery Recharge or replace battery Blown fuse Replace fuse The electric cables are

disconnected 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

Replace the injectors Apply to an authorised workshop

faulty fuel pressure regulation valve

Replace the valve Apply to an authorised workshop

Failure of the start control

Replace the start control Apply to an authorised workshop

water and/or impurities in the fuel Apply to an authorised workshop

Clogged fuel lter

Replace lter (See “Fuel lter

replacement.”)

The starter motor runs idle

Electromagnet failure

Check the starter motor Apply to an authorised workshop

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 58 Ed.8 / 10-2012

Problem Cause Remedy

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

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 “Fuel lter

replacement.”)

Injection pump malfunction Apply to an authorised workshop

faulty fuel pressure regulation valve

Replace the valve Apply to an authorised workshop

Presence of air in the fuel supply circuit

Carry out bleeding (See “Fuel

supply circuit bleeding”) water and/or impurities in the fuel Apply to an authorised workshop The electric cables are

disconnected 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”) Injection pump malfunction Apply to an authorised workshop

Dirty or faulty injectors

Replace the injectors

Apply to an authorised workshop water and/or impurities in the fuel Apply to an authorised workshop

clogged air lter Clean or replace the lter Insufcient combustion air ow Apply to an authorised workshop

Engine overheating Apply to an authorised workshop Overload Reduce the load

Emission of black smoke from the exhaust pipe

Dirty or faulty injectors

Replace the injectors

Apply to an authorised workshop

Faulty turbocharging turbine

Replace the turbine

Apply to an authorised workshop

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 59 Ed.8 / 10-2012

Problem Cause Remedy

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 authorised workshop

Abundant emission of white smoke from the exhaust pipe

Burnt gasket head Apply to an authorised workshop

Water pump malfunction

Replace the pump Apply to an authorised workshop Replace the belt (See “Changing

the belt (type Poly-V)”)

Thermostat valve malfunction

Replace the valve Apply to an authorised workshop

Coolant too low

Top up, if necessary (See “Engine coolant level check”)

The pressure gauge shows a too low engine oil pressure and the corresponding warning light comes on

Failure of pressure gauge

Check or replace the pressure gaug

Apply to an authorised workshop

Oil level too low

Adjust the oil level (See “Engine oil level control”)

Oil pump failure

Check or replace the pump Apply to an authorised workshop

Faulty sensor

Check and, if appropriate, replace the sensor.

Apply to an authorised workshop

engine oil lter blocked

Replace the engine oil lter (See “Oil lter cartridge replacement”)

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

Water pump malfunction

Replace the pump Apply to an authorised workshop

Thermostat valve malfunction

Replace the valve Apply to an authorised workshop

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 60 Ed.8 / 10-2012

Problem Cause Remedy

The coolant temperature warning light comes on

Broken or worn belt

Replace the belt (See “Changing

the belt (type Poly-V)”)

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”)

Injection pump malfunction

Replace the pump

Apply to an authorised workshop

Dirty or faulty injectors

Replace the injectors

Apply to an authorised workshop

clogged air lter Clean or replace the lter

Engine overheating Apply to an authorised workshop Insufcient combustion air ow Apply to an authorised workshop

The battery warning light comes on

The alternating current generator does not charge the battery

Check and, if appropriate,

replace the alternating current

generator

Apply to an authorised workshop

The oil pressure warning light comes on

Engine oil pressure too low

Turn off the engine. Apply to an

authorised workshop

The warning light which detects water in fuel comes on

Presence of water in the fuel lter

(See chapter “OPERATING

INFORMATION”, paragraph

“

Recommendations for use

point no.9)

The warning light of the engine MIL/ SYS (*) turns on.

Engine malfunction Apply to an authorised workshop

The particular lter indicator light

turns on

Particulate lter is clogged

The particulate lter regeneration

is necessary (see chapter

““OPERATING INFORMATION””,

paragraph “Particulate Filter

Regeneration”

(*) The luminous warning light MIL (amber colour) turns on to signal the malfunction of the engine due to the surpassing of emission thresholds.

The luminous warning light SYS (red colour) turns on to signal the malfunction of the engine without the surpassing of particle emission thresholds.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 61 Ed.8 / 10-2012

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 centre (See “documentation enclosed”: Spare parts and service centre address booklet), indicating the engine serial number. (See”Manufacturer and

engine identication”)

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 62 Ed.8 / 10-2012

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

CHANGING THE BELT (TYPE POLY-V) WITH AUTOMATIC BELT TENSIONER

Pulley (C)

Belt Tensioner (A)

Trasmission Belt (D)

Trasmission Belt (B)

Trasmission Belt (D)

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- Rotate the automatic belt tensioner (A) in counter clockwise direction to loosen the belt (B), and then remove it from the pulley (C).

4- Remove the belt (D) and replace it.

Before tightening the belt, make sure that it is correctly positioned in the pulley seats.

Before restarting the engine, make sure there are no tools or other material left near the moving parts.

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 63 Ed.8 / 10-2012

CHANGING THE BELT (TYPE POLY-V) WITH AUTOMATIC BELT TENSIONER

special tool (A)

tensioner (B)

locking bracket (C)

Trasmission Belt (D)

Special equipment must be used to replace the belt with linear turnbuckle. This operation must be performed by an authorised repair shop.

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 - Rotate the special tool (A) in any anticlockwise direction so that the turnbuckle (B) becomes compressed (Photo 1).

4 - Insert the locking clamp (C) as shown in photo 2.

5 - Remove the belt (D).

6 - Install the new belt and position it as shown in photo 3.

7 - Rotate the special tool (A) in an anticlockwise direction so that the turnbuckle (B) becomes compressed, and remove the locking clamp.

Before tightening the belt, make sure that it is correctly positioned in the pulley seats.

Photo 1

Photo 2

Photo 3

Tech Library http://engine.od.ua

R750EU5 - IE3 - TE4 - IE4 - ISE4

English 64 Ed.8 / 10-2012

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.).

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

Tech Library http://engine.od.ua

VM Motori R754EU5, R756EU5, R754IE3, R756IE3, R754TE4 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual