VM Motori D700/750 E2-E3. Manuale del motore in 5 lingue (2009)

D700/750 E2-E3

Model

D754 TE3

D754 SE3

D754 IE3

DIMENSIONS

702

557

736

GENERAL DATA

Cycle

Four stroke diesel

Total displacement

liters

2,970

Number of cylinders

Bore and stroke

94x107

Compression ratio

18 ± 0,5:1

Supercharged

Turbocharged and

Natural

inter-cooled circuit

Intake

circuit

(Dry) air filter

Cooling

Water circuit

Cooler

Water/oil

Crankshaft rotation

Anticlockwise (observing the engine from the handwheel side)

Combustion sequence

1-3-4-2

Pushrods and rocker arms with hydraulic tappets and camshaft

Timing

Gear cascade control and camshaft fitted on the crankbase

Minimum idling speed (standard engine)

rpm

900 +/-50

800-850

Dry shipping weight of engine

250

Maximum permanent lengthwise inclina-

Degrees

30°

tion (with handwheel up)

Maximum permanent lengthwise inclina-

Degrees

35°

tion (with handwheel down)

Maximum permanent crosswise inclina-

Degrees

30°

tion

POWER AND TORQUE

Maximum operating speed

rpm

2600

kW (CV)

Maximum power

59,8 (81,3)

51,5 (70)

70 (95,2)

rpm

Maximum torque

(kgm)

274 (27,9) a 1800

220 (22,4) a 1400

400 (40,7) a 1000

CONSUMPTION AT MAXIMUM POWER

Specific fuel consumption

g/kWh

Specific oil consumption

g/CVh

0,5 - 1

FUEL SUPPLY CIRCUIT

Type of injection

Iniezione diretta

The engine has been designed to be powered by standard fuels available on the

European market (according to specifications DIN EN 590). If it is to be powered

by BIODIESEL fuels (according to specifications UNI EN 14214), it can be

mixed, up to 5%, with fuel available on the European market (according to regu-

lation DIN EN 590).

Type of fuel

Important

Do not use fuels with specifications other than those indicated.

Fuel supply

Diaphragm pump

Injector supply

Mechanical rotary injection pump

English

- 19 -

Technical information

D700/750 E2-E3

Model

D754 TE3

D754 SE3

D754 IE3

LUBRICATION CIRCUIT

Type of lubrication

Forced lubrication

Circuit fuel supply

Rotor pump

Oil change including filter

liters (kg)

(standard sump)

Oil quantity at minimum level

liters (kg)

(standard sump)

liters (kg)

7÷10

Oil quantity at maximum level

The oil quantity at maximum level ( 7÷10 litre) depends on the capacity of the oil

sump with which the engine is equipped.

Oil pressure at minimum speed

bar

1,2 - 1,6

(with started engine)

Alarm for oil pressure too low

bar

0,4

Oil cooling

Oil/water cooler

COOLING CIRCUIT

Total capacity of the cooling circuit

litri

(excluding radiator and relevant pipes)

setting pressure of the expansion tank

bar

plug

Demineralised cold water 50% + Antioxidant and anti-freeze fluid 50% (Inhibited

Coolant

glycol ethylene in compliance with ASTM D 3306)

Coolant maximum temperature alarm

°C

107

Opening value (start/finish) of thermostatic

°C

80 (+/-2) / 95

valve

ELECTRIC SYSTEM

Nominal voltage

Alternating current generator (nominal volt-

Alternating current generator (nominal cur-

Starter motor output

2,3

Recommended battery capacity

110

Battery breakaway current

480

880

SUCTION CIRCUIT

Maximum depression allowed with new air

mbar

filter

English

- 20 -

Technical information

D700/750 E2-E3

TECHNICAL DATA (D754 TPE2/D756 IPE2)

These technical data and specifications re-

fer exclusively to standard VM MOTORI

S.P.A. engines.

IDM-45300900600.tif

Model

D754 TPE2

D756 IPE2

DIMENSIONS

1176

1542

647

695

903

965

GENERAL DATA

Cycle

Four stroke diesel

Total displacement

liters

2,970

4,455

Number of cylinders

Bore and stroke

94x107

Compression ratio

17,8 ± 0,5:1

supercharged circuit

Intake

(Dry) air filter

Cooling

Water circuit

Cooler

water/oil

Crankshaft rotation

Anticlockwise (observing the engine from the handwheel side)

Combustion sequence

1-3-4-2

1-5-3-6-2-4

Pushrods and rocker arms With hydraulic tappets and camshaft

Timing

Gear cascade control and camshaft fitted on the crankbase

Minimum idling speed (standard engine)

rpm

1200±50

Dry shipping weight of engine

260

335

Maximum permanent lengthwise inclination (with

Degrees

30°

handwheel up)

Maximum permanent lengthwise inclination

Degrees

35°

(with handwheel down)

Maximum permanent crosswise inclination

Degrees

30°

POWER AND TORQUE

Maximum operating speed

rpm

2300

English

- 21 -

Technical information

D700/750 E2-E3

Model

D754 TPE2

D756 IPE2

kW (CV)

Maximum power

62 (84,3)

102 (138,7)

rpm

Maximum torque

(kgm)

366 (37,3) a 1200

613 (62,5) a 1200

CONSUMPTION AT MAXIMUM POWER

Specific fuel consumption

g/kWh

250

230

Specific oil consumption

g/CVh

FUEL SUPPLY CIRCUIT

Type of injection

Direct injection

The engine has been designed to be powered by standard fuels available

on the European market (according to specifications DIN EN 590). If it is to

be powered by BIODIESEL fuels (according to specifications UNI EN

14214), it can be mixed, up to 5%, with fuel available on the European

Type of fuel

market (according to regulation DIN EN 590).

Important

Do not use fuels with specifications other than those indicated.

Fuel supply

Diaphragm pump

Injector supply

Mechanical rotary injection pump

LUBRICATION CIRCUIT

Type of lubrication

Forced lubrication

Circuit fuel supply

Rotor pump

Oil change including filter (standard sump)

liters (kg)

8,8

12,3

Oil quantity at minimum level (standard sump)

liters (kg)

The oil quantity at maximum level ( litre) depends on the capacity of the oil

Oil quantity at maximum level

liters (kg)

sump with which the engine is equipped.

Oil pressure at minimum speed (with started

bar

1,5

engine)

Alarm for oil pressure too low

bar

0,3 - 0,5

Oil cooling

Oil/water cooler

COOLING CIRCUIT

Total capacity of cooling circuit (excluding radiator

liters

7,5

and relevant pipes)

Setting pressure of the expansion tank plug

bar

1,1

Demineralised cold water 50% + Antioxidant and anti-freeze fluid 50%

Coolant

(Inhibited glycol ethylene in compliance with ASTM D 3306)

Coolant maximum temperature alarm

°C

109

Opening value (start/finish) of thermostatic valve

°C

80-90

ELECTRIC SYSTEM

Nominal voltage

12 o 24

Alternating current generator (nominal voltage)

14 o 28

Alternating current generator (nominal current)

Starter motor output

2,3

Recommended battery capacity

100

Battery breakaway current

480

550

SUCTION CIRCUIT

20 a 1500 rpm

Maximum depression allowed with new air filter

mbar

25 a 1800 rpm

40 a 2300 rpm

35 a 2300 rpm

English

- 22 -

Technical information

D700/750 E2-E3

SAFETY INFORMATION

SAFETY RULES

- During the design and construction phas-

- All the installation phases should have

es, the Manufacturer paid special attention

been taken into account since the develop-

to the aspects which are liable to cause any

ment of the initial project. The designer has

risk for the safety and health of people inter-

to observe with the engine fixing points and

acting with the engine. Besides complying

the general indications provided by the

with the relevant legislation in force, he fol-

manufacturer.

lowed all the "rules for a good construction

- Carry out the handling of the engine in

technique". The purpose of this information

compliance with the information stated di-

is making users aware of the need to pay

rectly on the engine, on the packaging and

the utmost attention to prevent any risk.

in the operating instructions supplied by the

Caution is however imperative. Safety also

manufacturer.

depends on all the operators who interact

with the engine.

- When lifting or transporting unpacked en-

gines use means of appropriate load capac-

- Read carefully the instructions contained

ity which must be properly anchored.

in the manual supplied and those applied on

the engine, in particular follow those con-

- When lifting and transporting packaged

cerning safety. Spend some of your time

engines, means of appropriate load capaci-

reading the instructions to avoid unpleasant

ty as stated on the packaging itself.

accidents.

- Before carrying out other transfers, cre-

- Pay attention to the meaning of the sym-

ate the conditions required to guarantee sta-

bols in the applied plates; their shape and

bility and to prevent any engine part from

colour have a specific meaning related to

being damaged.

safety. Keep them visible and follow the

- Before starting the installation, the install-

stated information.

er has to implement a "safety plan" and to

- Use the engine only for the tasks author-

follow the designer’s indications. Do not

ised by the manufacturer and do not tamper

make changes to the engine components

with any device to achieve a different per-

for any reason.

formance from the intended one.

- It is necessary to make sure that the in-

- The staff carrying out any type of inter-

stallation area is fitted with all intake, fuel

vention throughout the life of the engine

supply and exhaust connections.

should have precise technical skills, specific

abilities and experiences acquired and ac-

knowledged in this sector. The lack of these

requirements may cause damages to peo-

ple’s safety and health.

English

- 23 -

Safety information

D700/750 E2-E3

In the state of California, diesel engine

- Start again the engine only when the nor-

exhaust gases are recognized as one of

mal operating conditions have been restored.

the main causes of cancerous tumors,

- Unless otherwise stated, all interventions

damage to reproductive organs and de-

should be carried out when the engine has

formities in unborn children.

been stopped, cooled down and the ignition

Whenever an engine enters the state of

key has been removed. Those authorized to

California, or states or countries which

carry out these interventions should follow

adopt the same legislation, adequate in-

all the precautions needed to guarantee the

formation must be provided to confirm

safety of the people involved, in compliance

the risks associated with the engine’s

with the requirements laid down in the appli-

components and the exhaust gases

cable legislation regarding safety at the

which it produces.

workplace.

- The manufacturer cannot be held re-

- Keep the equipment as much efficient as

sponsible for any damage resulting from the

possible and carry out the scheduled main-

misuse of the engine, from the failure to fol-

tenance operations established by the man-

low the indications contained in this manual

ufacturer. A good maintenance will ensure

and from any tampering with or change

the highest performance, a longer working

made without the manufacturer’s authoriza-

lifetime and a constant compliance with

tion.

safety requirements.

- If appropriate, before using the engine for

- Replace any worn part with original spare

the first time, after gathering all the neces-

parts. Use the oils and greases recom-

sary information, simulate a few trial ma-

mended by the manufacturer. All this will en-

noeuvres to identify the controls and their

sure the engine good operation and the

main functions, especially those related with

prescribed safety level.

starting and stop operations.

- Do not throw away any polluting material

- Do not operate the engine in a closed

in the environment. Carry out their disposal

and insufficiently ventilated environment;

in compliance with the relevant legislation in

the exhaust fumes are harmful and can

force.

have serious consequences on people’s

health.

- During all maintenance operations al-

ways use the individual protection clothing

- Do not keep using the engine if anoma-

and/or devices indicated in the operating in-

lies are detected and in particular if suspect

structions supplied by the manufacturer and

vibrations occur.

those provided by the applicable legislation

- In case of anomaly, stop immediately the

concerning safety at the workplace.

engine or reduce the speed as much as pos-

- All maintenance operations should be

sible and reach the closest assistance cen-

carried out by using suitable and efficient

tre.

equipment and tools.

English

- 24 -

Safety information

D700/750 E2-E3

SAFETY RULES FOR THE ENVIRONMENTAL IMPACT

Each organization is responsible for imple-

- All packaging components should be dis-

menting procedures aimed at identifying,

posed of in accordance with the legislation

evaluating and controlling the environmen-

in force in the country where disposal takes

tal impact of its own activities

(products,

place.

services, etc.).

The procedures to be followed to identify

- When installing the engine, ensure a suit-

any significant environmental impact should

able air renewal in the environment to pro-

take into account the following factors:

tect the operators from a high concentration

of harmful substances.

- Emissions in the atmosphere

- During operation and maintenance, do

- Discharged liquids

not throw away polluting products

(oils,

greases, etc) in the environment and carry

- Waste disposal

out the differentiated waste disposal accord-

- Soil contamination

ing to the composition of the different mate-

rials and in compliance with the legislation in

- Use of raw materials and natural resourc-

force. Electric and electronic components

should be carried out as special waste.

- Local problems related to the environ-

- Keep the exhaust pipelines efficient to

mental impact. In order to reduce the envi-

limit the noise level of the engine and to re-

ronmental impact, the manufacturer

duce atmospheric pollution.

provides below a few indications to be taken

into account by all those who will interact

- While decommissioning the engine, di-

with the engine throughout its expected life.

vide all the components depending on their

chemical composition and dispose of them

accordingly.

RESIDUAL RISKS

During the design and construction of the

When planning the installation of the engine

engine, the constructor has paid particular

onto the vehicle, the installation technician

attention to aspects which may present a

must conduct an analysis to evaluate the

potential risk to the health and safety of peo-

potential risks from moving components

ple who come into contact with the engine.

(danger of becoming trapped in the trans-

Despite this, some potential and hidden

mission belt) and other hazardous zones

risks still exist.

(danger of scalding).

Once the engine is installed, before starting

Danger of injuring your arms

the engine for the first time, evaluate wheth-

Do not put your hands inside any moving

er the potentially hazardous zones have

part.

been fitted with adequate safety devices.

Danger of being burnt

Pay attention to hot surfaces

English

- 25 -

Safety information

D700/750 E2-E3

HANDLING AND INSTALLATION INFORMATION

RECOMMENDATIONS FOR HANDLING AND INSTALLATION

Carry out handling and installation following

carry out these operations should prepare, if

the information provided by the manufactur-

necessary, a "safety plan" to protect and the

er and stated directly on the packaging and

safety of people directly involved.

operating instructions. Those authorized to

PACKAGING AND TRANSPORT

The packaging is also made accord-

Means of

ing to the type of transport chosen to

transport

keep sizes as small as possible.

Lifting

equipment

- By road

- By railway

- By sea

- By air

The engine can be transported with

different types of packaging accord-

ing to the destination, the transport

IDM-45300300700.tif

system and preset technical-com-

mercial specifications.

Packaging with wooden case

Packaging with cardboard box

Packaging with cellophane

IDM-45300900700.tif

English

- 26 -

Handling and installation information

D700/750 E2-E3

In order to guarantee the perfect con-

servation of all engine components,

an "overseas" packaging should be

used in case of maritime transport.

The packaging contains all the infor-

mation needed to carry out the load-

ing and unloading operations.

During transport, make sure the load

is properly secured to the means of

transport to avoid unexpected dis-

placements.

When transporting the uncovered en-

gine by road, use the lifting points pro-

vided to secure it steadily and prevent

IDM-45300900800.tif

components from being damaged.

UNPACKING

Follow the procedure below.

1- Remove the cover of the packag-

ing. The packaging includes a bag

Screw (A)

with all the relevant technical docu-

mentation and standard components.

2-While unpacking, make sure the

components are intact and their quan-

tity is correct.

3-Place the lifting device as shown

in the figure.

4-Loosen the screws (A) and disas-

semble the side supports (B).

Stay (B)

5-Move the engine to the installa-

IDM-45300900900.tif

tion area.

If necessary, keep the material in

case you need to pack the engine in

the future.

Important

In case of any damage or missing part,

contact the manufacturer’s Assistance

Service to establish the procedure to be

adopted. The packaging material should

be suitably eliminated in compliance

with the applicable legislation.

English

- 27 -

Handling and installation information

D700/750 E2-E3

HANDLING AND LIFTING

Secure the engine with a lifting device (lift-

ing beam) of appropriate capacity.

Important

Hook the lifting device to the fixing points as

The brackets of the fixing points have

shown in the figure.

been designed to lift the engine only

Before carrying out the lifting, identify the

without any additional weight. Do not lift

barycentre position of the load.

the engine using a different procedure

from the prescribed one; otherwise, the

warranty for damages will be invalidated.

IDM-45300901000.tif

ENGINE STORAGE

If the engine is left idle for prolonged peri-

The manufacturer supplies the engine with

ods, check the possible conditions of con-

a protection treatment which is valid for 6

servation in relation to the storage area and

months from the delivery date.

the type of packaging.

After the first 6 months, if the engine is not

Avoid any environment exposed to damp-

used, it is necessary to carry out a specific

ness or to the inclemency of weather.

maintenance to extend the storage period

for a further 6-month period.

The information related to the extension of

the storage period are included in the gener-

al warranty conditions.

English

- 28 -

Handling and installation information

D700/750 E2-E3

INSTALLATION DESIGN

In order to ensure the highest performance

During the design and installation phases, it

while protecting people, the product itself

is advisable to consult the service manual

and the environment, a full project has to be

supplied by VM MOTORI S.P.A..

developed before carrying out the installa-

Further information are available in the web-

tion.

site: www.vmmotori.it, in the "Contacts -

The design phase should take into account

Request Info" section.

the technical data of the engine (see"Tech-

nical data") and all the risks which may oc-

cur during its expected lifetime, from

installation to disposal.

English

- 29 -

Handling and installation information

D700/750 E2-E3

ADJUSTMENT INFORMATION

RECOMMENDATIONS FOR ADJUSTMENTS

Before carrying out any adjustment, activate

source of unexpected danger and risk for

all safety devices and evaluate the need to

people's safety and health

inform the personnel working on the engine

or nearby. In particular, place proper signs

in the nearby areas and keep away all devic-

es which, once activated, may represent a

HOW TO ADJUST THE TENSION OF THE DRIVING BELT

Follow the procedure below.

1- Turn off the engine and remove

the ignition key.

Nut (A)

2-Let the engine cool down ade-

quately to avoid being burnt.

3-Loosen nut (A).

4-Adjust alternating current gener-

ator (B) manually and at the same

Alternating current

time tighten nut (A) to regulate belt

tension.

Water pump

Important

To check belt tension, use the

method shown in figure. The re-

sulting shifting (R) must be 10

mm.

Drive shaft

Alternating current generator

IDM-45300901300.tif

English

- 30 -

Adjustment information

D700/750 E2-E3

OPERATING INFORMATION

RECOMMENDATIONS FOR USE AND OPERATION

The engine has been designed and manu-

ferent performance from the intended one

factured to satisfy all the operating condi-

can entail risks for people's safety and

tions indicated by the manufacturer.

health as well as economic damages.

Tampering with any device to achieve a dif-

CONTROL BOARD DESCRIPTION

A) Indicator (red lamp): indicates that the

D) Warning light (orange): It signals the

alternator is not charging the battery.

pre-heating of the glowplugs

When the warning light goes off, it is possi-

B) Warning light (red): It signals that the

ble to start the engine.

engine oil pressure is low

E) Ignition key switch: It is used to start

C) Warning light (red): indicates that the

the engine

coolant temperature is too high

Engine oil indicator (B)

Battery indicator (A)

Coolant indicator (C)

Glow plugs indicator (D)

Ignition key (E)

IDM-45300901900.tif

English

- 31 -

Operating information

D700/750 E2-E3

RECOMMENDATIONS FOR USE

During the running-in period (first 50 hours

- During running-in (first 50 working hours)

of operation), the engine must be used with

and throughout the engine lifetime, carry out

an absorbed load of between 50% and 70%

the maintenance in compliance with the in-

of maximum power.

tervals established by the manufacturer

(See "Engine maintenance").

- Avoid using the engine at the highest

speed for prolonged periods during running-

Important

in.

If the engine is not used regularly, start it

- During the running-in period, do not run

after each month of inactivity and run it at

the engine with an absorbed load of less than

minimum speed until the operating tem-

50% or at low idle speed for long periods.

perature (70÷80°C) is reached. If the en-

This type of run-in may be the result of exces-

gine is installed for use in emergencies,

sive oil consumption and/or leakage from the

for example in the case of generators, it

exhaust.

must be started at least once per month.

- Component service life will be extended

- Avoid using the engine for long periods at

and maintenance costs reduced even if the

constant speeds when running in.

engine is run-in for a period longer than 50

- When starting the engine for the first

hours with an absorbed load of between

time, run it at no-load for a few minutes and

50% and 70% of maximum power.

make sure that the oil pressure value

- The engine may function in ambient tem-

matches the one stated in the table (See

peratures of between -10°C and 45°C.

"Technical data" - "Lubrication circuit").

- When using the engine in ambient tem-

- Properly pre-heat the engine when using

peratures of less than -10° it is possible to

it at low temperatures.

use a preheating system equipped with a

When using the engine at low temperatures

control unit and glow plugs, or a 24V electri-

(lower than -10°C), fill it with winter-type fu-

cal system equipped with a heater for the

el.

fuel filter. This equipment is optional.

- Use oils and lubricants with suitable fea-

The engine is delivered by the factory in the

tures

(viscosity grade, specifications and

running order. However, during operation the

operating temperature) (See "Recommend-

following indications should be observed:

ed lubricants").

Only use coolants that comply with the man-

ufacturer's specifications.

As for the liquid quantity and type, see

"Technical data".

English

- 32 -

Operating information

D700/750 E2-E3

OPERATING THE ENGINE UNDER SPECIFIC CONDITIONS

The engine performance is affected by fuel

The illustrations give indicative percentage

temperature, the temperature and relative

values for reduced engine output based on

humidity of incoming air and altitude.

fuel and air characteristics.

When using the engine at high altitudes and

For further information contact a VM MO-

high air and fuel temperatures, the output is

TORI S.P.A. assistance centre.

reduced.

Diagram of engine output based on fuel

Output variation (percentage) (%)

Fuel temperature (°C)

Fuel density (kg/dm³)

IDM-45300902900.tif

Diagram of engine output based on air

Output variation (percentage) (%)

Supercharged and inter-

Supercharged and

cooled engine

intercooled engine

Aspirated engine

Air temperature (°C)

Air pressure (mbar)

IDM-45300903000.tif

English

- 33 -

Operating information

D700/750 E2-E3

ENGINE IGNITION AND TURNING OFF

Starting the engine

1- Insert the key

(E) and turn it

Battery indicator (A)

clockwise to position 1.

All the warning lights come on, ex-

Engine oil indicator (B)

cept for coolant temperature warn-

ing light (C).

Coolant indicator (C)

The warning light (D) comes on to

signal the pre-heating phase of the

glowplugs.

Glow plugs indicator (D)

2-When the warning light (D) goes

off, turn the ignition key (E) clock-

Ignition key (E)

wise (pos. 2) to start the engine and

then release it.

All the warning lights go off.

IDM-45300902000.tif

Important

Turn the engine off

If the engine does not start imme-

diately, wait for 10-15 seconds before re-

Important

starting.

In the case of turbocharged engines, be-

3-Run the engine at a minimum speed dur-

fore switching the engine off it should be

ing the heating phase.

run at minimum idle speed for a few min-

utes in order to avoid damaging the tur-

bocharger.

Important

When the engine is running, indicator

Turn the ignition key (E) anticlockwise (pos.

lights (red) might light up and/or a buzzer

0) to turn off the engine.

sound, to indicate the presence of a

All the warning lights go off.

fault. In these conditions, turn the engine

Remove the ignition key and store it in a

off immediately, then identify and elimi-

safe place known only to those in charge.

nate the cause of the fault (See "Trouble-

shooting").

English

- 34 -

Operating information

D700/750 E2-E3

REFUELLING

During refuelling, make sure the fuel does

not contain any residue; in this case use

Important

specific filters.

Do not use fuels with specifications oth-

er than those indicated.

Avoid using fuel mixed with water or other

substances which may damage the engine.

Danger - Attention

The engine has been designed to be pow-

All fuels are inflammable. Any fuel leak-

ered by standard fuels available on the Eu-

ing or dropping on hot surfaces and

ropean market (according to specifications

electric components can cause fires. Do

DIN EN 590). If it is to be powered by BI-

not smoke when refuelling or nearby any

ODIESEL fuels (according to specifications

filling station.

UNI EN 14214), it can be mixed, up to 5%,

with fuel available on the European market

(according to regulation DIN EN 590).

English

- 35 -

Operating information

D700/750 E2-E3

MAINTENANCE INFORMATION

RECOMMENDATIONS FOR MAINTENANCE

Keep the equipment as much efficient as

terventions should follow all the precau-

possible and carry out the scheduled main-

tions needed to guarantee the safety of

tenance operations established by the man-

the people involved, in compliance with

ufacturer.

the requirements laid down in the appli-

cable legislation concerning safety at the

A good maintenance will ensure the highest

workplace.

performance, a longer operating lifetime

and a constant compliance with safety re-

quirements.

Important

For each maintenance operation, fill in

Warning - Caution

the "Periodic maintenance operation

record sheet" provided, so as to keep a

Unless otherwise stated, all interven-

trace of the operations performed and

tions should be carried out when the en-

therefore establish the most suitable

gine has been stopped, cooled down and

methods for future operations.

the ignition key has been removed.

Those authorized to carry out these in-

ENGINE MAINTENANCE

The maintenance operations are subdivided

considering that these parts need to be re-

into:

placed not only on the basis of their hours of

- Maintenance during running-in (first 50

operation but of ageing as well.

hours)

The approximate maximum time during

- Routine maintenance (after running-in)

which the chemical-physical characteristics

The frequency stated in the " routine main-

of a few components or lubricants are main-

tenance" table should be applied to engines

tained is stated below.

which are used regularly.

- Lubricant oil: duration, 1 year

Some lubricants or components lose their

- Fuel filter cartridge: duration, 1 year

characteristics over time even if the engine

is left idle for long periods; therefore, main-

- Coolant: duration, 2 years

tenance intervals should be established

English

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Maintenance information

D700/750 E2-E3

Maintenance during running-in table (first 50 hours)

Important

For each maintenance operation, fill in

trace of the operations performed and

the "Periodic maintenance operation

therefore establish the most suitable

record sheet" provided, so as to keep a

methods for future operations.

Frequency(1)

Component

Type of intervention

Intervention procedures

Reference

See “Engine oil level

Engine oil⁽²⁾

Level control

Top up, if necessary

control”

See “Engine coolant

Every 10

Coolant⁽⁴⁾

Level control

Top up, if necessary

level check”

hours

Clean with low pres-

(every day)

Air filter

Check it is clean

sure compressed air

Coolant fluid radia-

Check it is clean

Clean with a soft brush

tor

See “Engine oil

Engine oil⁽²⁾

Replacement

change”

After the first

See “Oil filter cartridge

Oil filter⁽³⁾

Replacement

50 hours (at

replacement”

the end of

See “How to adjust the

Checking the ten-

running-in)

Tension belts

tension of the driving

Transmission belt⁽⁵⁾

sion

belt”

Integrity control

Replace, if necessary

See “Belt replacement”

Routine maintenance table (after running-in)

Important

For each maintenance operation, fill in

trace of the operations performed and

the "Periodic maintenance operation

therefore establish the most suitable

record sheet" provided, so as to keep a

methods for future operations.

Frequency(1)

Component

Type of intervention

Intervention procedures

Reference

See “Engine oil level

Engine oil⁽²⁾

Level control

Top up, if necessary

control”

See “Engine coolant

Coolant⁽⁴⁾

Level control

Top up, if necessary

Every 10

level check”

hours

Clean with low pressure

Air filter

Check it is clean

compressed air

Coolant fluid radia-

Check it is clean

Clean with a soft brush

tor

English

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Maintenance information

D700/750 E2-E3

Frequency(1)

Component

Type of intervention

Intervention procedures

Reference

See “How to adjust

Checking the ten-

Tension belts

the tension of the dri-

Every 150

Transmission

sion

ving belt”

hours

belt⁽⁵⁾

See “Belt replace-

Integrity control

Replace, if necessary

ment”

See “Engine oil

Engine oil⁽²⁾

Replace

change”

Replace the cartri-

See “Oil filter cartri-

Oil filter⁽³⁾

dge

dge replacement”

Every 300

See “Fuel filter repla-

hours⁽⁶⁾

Fuel filter⁽³⁾

Replace

cement”

See "Control screw

Fuel circuit unions

Check tightening

tightening and union

sealing"

See “Coolant repla-

Coolant⁽⁴⁾

Replace

cement”

Air filter

Replace

Every 500

Injector setting

Apply to an authori-

hours

Check the pressure

pressure

sed workshop

Preheating glow

Check integrity of

Apply to an authori-

plugs

components

sed workshop

Transmission

See “Belt replace-

Every 1000

Replace

belt⁽⁵⁾

ment”

hours

Fuel tank

Clean

Every 4000

Performing partial

Apply to an authorised

Engine

hours

overhaul

workshop

Every 8000

Performing general

Apply to an authorised

Engine

hours

overhaul

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 severe working conditions, such as dusty environments and operation at extreme loads, the engine oil must be

changed every 150 working hours. If the engine has not been in operation for the length of time indicated, the oil must

still be changed at least once a year.

(3) If the engine has not been in operation for the length of time indicated, the filter 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 fluid 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 D754SE3, TE3, IE3 models with a low capacity oil sump, a special plate is applied on the cover of the

engine valves to indicate that the engine oil and the oil filter must be changed every 200 hours instead of every 300.

IDM-45300903200.tif

English

- 38 -

Maintenance information

D700/750 E2-E3

Periodic maintenance operation record sheet

Important

For each maintenance operation, fill in

lish the most suitable methods for future

the sheet, so as to keep a trace of the op-

operations.

erations performed and therefore estab-

Signature and stamp of

Datt

Hours (1)

Type of maintenance performed

workshop

_____

_____________________________________

________________

_____

_____________________________________

________________

_____

_____________________________________

________________

_____

_____________________________________

________________

(1) Indicate the total number of working hours.

English

- 39 -

Maintenance information

D700/750 E2-E3

MAINTENANCE WHEN THE ENGINE IS LEFT IDLE

If the vehicle/equipment to which the engine

is fitted remains inactive, certain mainte-

Important

nance operations must be carried out to en-

It is advisable to start the engine bring-

sure the engine remains in full working

ing it to the operating temperature

order.

(70÷80°C) at least once per month. The

engine must be started once per month if

If the engine is not used for short periods of

it is installed for emergency purposes.

time, carry out the following interventions:

1- Make sure the electric contacts are

If the engine is left idle for prolonged peri-

working properly and, if necessary, protect

ods, carry out the engine protective treat-

them with an anti-oxidant spray.

ment to guarantee its efficiency for 6 months

and to avoid continuous control and mainte-

- Check the charge of the battery and the

nance interventions. If the engine is not

liquid level.

used for a further period of time, check the

need to repeat the protective treatment for

- If necessary, carry out the scheduled

other

6 months (See "Engine protective

maintenance work (See "Engine mainte-

treatment").

nance").

ENGINE PROTECTIVE TREATMENT

Follow the procedure below.

6-Turn off the engine and remove the igni-

1- Check the engine oil and coolant level.

tion key.

2-Fill the service tank with a mixture made

7-Let the engine cool down adequately to

up of 10% protective oil (Castrol Safecoat

avoid being burnt.

DW30X, Rustilo 181, Rustilo DWX31) and

8-Protect the electric contacts with an anti-

90% fuel.

oxidant spray.

Important

9-Protect the engine with waxes and/or a

This operation can be carried out using

synthetic resin anti-oxidant spray.

an additional tank fitted with couplings

10- Disconnect the terminals of the battery.

connecting it to the engine fuel supply

circuit.

11- Fill up the fuel tank.

3-Disconnect all the mechanical parts and

12- Loosen the transmission belt to guaran-

auxiliary applications from the engine as they

tee it a longer life (See "How to adjust the

could be damaged by running it at no-load.

tension of the driving belt")

4-Start the engine and run it at minimum

13- Make sure the engine is sheltered from

speed for 5 minutes.

weather agents.

5-Bring the engine to 1500÷1800 rpm for

15 minutes until the operating temperature

(70÷80°C) is reached.

English

- 43 -

Maintenance information

D700/750 E2-E3

MAINTENANCE IN CASE OF ENGINE INACTIVITY

After a period of inactivity, it is necessary to

- Replace the air filter according to the es-

carry out a few maintenance interventions

tablished intervals

(See "Routine mainte-

before starting the engine again to ensure

nance table (after running-in)").

its maximum efficiency conditions.

- Tension again the transmission belt (See

- Check the charge of the battery and the

"How to adjust the tension of the driving

liquid level.

belt").

- Make sure the electric contacts are intact

- Check the tightening of the hydraulic un-

and properly working.

ions (See "Control screw tightening and un-

ion sealing").

- Carry out the operation diagnosis of the

engine.

- Check the rubber gaskets and relevant

fixing clips to ensure they are undamaged.

- Check the oil level, and, if necessary, top

up or replace it according to the established

- Use a cloth soaked in a degreasing prod-

intervals (See "Routine maintenance table

uct to remove the external protective treat-

(after running-in)").

ment.

- Replace the oil filter according to the es-

- Start the engine and run it at minimum

tablished intervals

(See "Routine mainte-

speed for a few minutes (See "Engine igni-

nance table (after running-in)").

tion and turning off").

- Check the coolant level, and if neces-

- If no anomalies are detected, bring the

sary, top up or replace it according to the es-

engine to its operating temperature

tablished

intervals

(See

"Routine

(70÷80°C).

maintenance table (after running-in)").

- Turn off the engine and check again the

- Replace the fuel filter according to the es-

engine oil and coolant level.

tablished intervals

(See "Routine mainte-

nance table (after running-in)").

WASHING THE ENGINE

To avoid irreversible damage to the electric

When you have finished washing the en-

and electronic components of the engine,

gine, take out all the electric connectors,

do not point jets of high pressure water or

blow compressed air to eliminate any water,

jets of steam at these components. Pay par-

and apply a specific product to prevent oxi-

ticular attention to the joins of the cables, the

dation and corrosion.

electric connectors, the alternator and the

When you have finished washing, start the

starter motor, protecting them adequately if

engine and leave it running for a few min-

necessary.

utes so that it gets completely dry.

Before washing the engine, adequately pro-

tect the fuel supply pump so as not to dam-

age it with water infiltrations.

English

- 44 -

Maintenance information

D700/750 E2-E3

CHECKS AND CONTROLS

The list indicates some of the maintenance,

testing and control operations to be carried

Important

out on the engine during normal operation.

For each maintenance operation, fill in

- Fuel supply circuit bleeding

the "Periodic maintenance operation

- Control screw tightening and union sealing

record sheet" provided, so as to keep a

- Engine oil level control

trace of the operations performed and

- Engine coolant level check

therefore establish the most suitable

methods for future operations.

- Engine oil change

- Coolant replacement

- Oil filter cartridge replacement

– Fuel filter replacement.

FUEL SUPPLY CIRCUIT BLEEDING

The operation must be carried out every

time the fuel filter is changed, following one

of the listed procedures, according to the

engine model.

Warning - Caution

To avoid fire risk due to fuel leakage or

discharge, ALWAYS carry out this oper-

ation when the engine is off and cold.

Engines equipped with single injection

pump

Follow the procedure below.

1- Turn off the engine and remove

the ignition key.

2-Let the engine cool down ade-

quately to avoid being burnt.

3-Prepare a container of appropri-

Screw (A)

ate capacity.

4-Loosen the screw (A).

Membrane pump

5-Operate the pump (B) manually

(B)

to eliminate air from the circuit.

Interrupt the operation only when

all air has been discharged.

IDM-45300902100.tif

6-Tighten the screw (A).

English

- 45 -

Maintenance information

D700/750 E2-E3

7-Loosen fittings (C).

Fuel supply hoses

8-Rotate engine ignition key to po-

sition 1 to allow the opening of sole-

Connector (C)

noid of the pump.

9-Rotate and keep ignition key in

position 2 (the engine rotates idle) to

discharge the air from the pump and

from feeding pipes.

Release ignition key when the

fuel comes out of feeding pipes.

10-Tighten fittings (C).

11-Wipe out the fuel residues be-

IDM-45300902200.tif

fore starting the engine.

12-Start the engine and run it at minimum

3-Prepare a container of appropriate ca-

speed for a few minutes.

pacity.

4-Completely fill new filter with fuel (with a

Important

container).

In case the engine does not start, repeat

the described procedure and, if neces-

Important

sary, contact an Assistance Centre au-

Use clean and impurity-free fuel.

thorised by the manufacturer.

5-Install fuel filter in the special seat (See

13-Stop the motor when you finish this op-

"Fuel filter replacement.").

eration.

6-Loosen fittings (C).

Engines equipped with rotating injection

pump

7-Rotate engine ignition key 1 to position

The operation must be carried out only by

to allow the opening of solenoid of the

means of the battery-operated starter mo-

pump.

tor.

8-Rotate and keep ignition key in position

2 (the engine rotates idle) to discharge the

Important

air from the pump and from feeding pipes.

To avoid problems, before carrying out

Release ignition key (C) when the fuel

the operation, make sure that the batter-

comes out of feeding pipes.

ies have a suitable state of charge.

1- Turn off the engine and remove the igni-

9-Wipe out the fuel residues before start-

tion key.

ing the engine.

2-Let the engine cool down adequately to

10- Start the engine and run it at minimum

avoid being burnt.

speed for a few minutes.

English

- 46 -

Maintenance information

D700/750 E2-E3

cal assistance centre that is authorised

Important

by the manufacturer.

In case the engine does not start, try to

11- Stop the motor when you finish this op-

restart it without insisting too much in

eration.

order not to damage the starter motor.

If the problem persists, contact a techni-

CONTROL SCREW TIGHTENING AND UNION SEALING

Follow the procedure below.

4-Make sure the fixing screws of the main

1- Start the engine and run it at minimum

parts are tightened properly.

speed for a few minutes.

5-Check the union sealing on the fuel sup-

2-Run the engine at normal speed until the

ply circuit.

operating temperature

(70÷80°C) is

6-Check the tightening of the clamps.

reached.

7-Check any fluid leaks.

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

ENGINE OIL LEVEL CONTROL

Follow the procedure below.

1- Start the engine and bring it to the

Dipstick (L)

operating temperature (70÷80 °C).

Filler cap (M)

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 flow into the sump.

5-Remove the dipstick (L) and

check the oil level.

IDM-45300901100.tif

6-Top up, if necessary, from plug

(M). When topping up the oil, to

avoid exceeding the maximum allowed val-

ue, add the oil in small amounts (100 to 200

ml at a time) until it reaches the correct level.

Important

The oil level should be included between

the minimum and maximum marks.

Do not mix oils of different brands or

with different features

(See "Recom-

mended lubricants").

English

- 47 -

Maintenance information

D700/750 E2-E3

ENGINE COOLANT LEVEL CHECK

Follow the procedure below.

1- Start the engine and bring it to

Filler cap (P)

the

operating

temperature

(70÷80 °C).

2-Turn off the engine and remove

the ignition key.

3-Let the engine cool down prop-

erly.

4-Unscrew the plug (P).

Warning - Caution

Open the plug gently to drain the

pressure.

IDM-45300901200.tif

5-Top up, if necessary, from plug

(P). (As for the liquid quantity and type, see

"Technical data").

Important

- When topping up, only use a mixture

with the same composition as the one al-

ready contained in the engine cooling

system.

- The fluid level must be up to the base

of the neck into which the radiator plug is

screwed.

- For further information, please con-

sult the documentation provided by the

manufacturer of the vehicle/device in

which the engine is installed.

English

- 48 -

Maintenance information

D700/750 E2-E3

ENGINE OIL CHANGE

Follow the procedure below.

1- Turn off the engine and remove

Filler cap (P)

the ignition key.

2-Let the engine cool down ade-

quately to avoid being burnt.

3-Prepare a container of appro-

priate capacity.

As for the oil quantity, see "Techni-

cal data".

4-Unscrew the plug (P).

5-Unscrew the exhaust plug (Q)

and let all the oil flow into the con-

Discharge cap (Q)

tainer.

6-Replace the gasket and screw

plug (Q) back into place.

Important

IDM-45300901400.tif

Lock the plug to a torque of 55

Nm.

9-Start the engine and bring it to the oper-

ating temperature (70÷80 °C).

7-Pour the new oil through the filling plug

Check for any oil leaks

(P).

To reach the correct engine oil level, add the

Warning - Caution

minimum oil quantity depending on the en-

In the event of oil leaks, check the level

gine model (see “Technical data").

periodically to evaluate the extent of the

Then top up.

leak. If the amount is excessive, contact

When topping up the oil, to avoid exceeding

one of the manufacturer's authorised

the maximum allowed value, add the oil in

service centres.

small amounts (100 to 200 ml at a time) until

it reaches the correct level.

10- Turn off the engine and check the oil level.

Important

The oil level must be between the mini-

- Do not throw the oil in the environ-

mum and maximum marks on the dip-

ment but carry out its disposal in compli-

stick.

ance with legislation in force in the

country where it is used.

8-Screw again the plug (P).

- Use the oils and lubricators recom-

mended by the manufacturer (See "Rec-

ommended lubricants").

English

- 49 -

Maintenance information

D700/750 E2-E3

COOLANT REPLACEMENT

Follow the procedure below.

1- Start the engine and run it at

minimum speed for a few minutes.

Filler cap (P)

The cooling circuit reaches the op-

erating pressure.

2-Turn off the engine and remove

the ignition key.

3-Let the engine cool down ade-

quately to avoid being burnt.

4-Prepare a container of appro-

Tap (S)

priate capacity.

As for the liquid quantity, see

"Technical data".

5-Unscrew the load plug (P).

Warning - Caution

Open the plug gently to drain the

pressure.

IDM-45300901500.tif

6-Open the cock (S).

8-Close the cock (S).

9-Pour in the new liquid.

Important

- In the absence of a coolant discharge

Important

tap, check for the presence of a dis-

- The fluid level must be up to the base

charge plug or loosen one of the cooling

of the neck into which the radiator plug is

circuit clamps in the lower part of the

screwed.

cooler.

- If there is a coolant expansion tank,

- For further information, please con-

consult the documentation provided by

sult the documentation provided by the

the manufacturer of the vehicle/device in

manufacturer of the vehicle/device in

which the engine is installed.

- As for the liquid quantity and type, see

7-Let the liquid flow into the container.

"Technical data".

10- Screw again the plug (P).

English

- 50 -

Maintenance information

D700/750 E2-E3

11-Turn the engine on and keep it running

13- Check the coolant level and, if neces-

at idle speed for a few minutes to bring it up

sary, carry out topping-up

(See "Engine

to working temperature (70÷80°C).

coolant level check").

Important

If the coolant level drops, top up as need-

Do not throw away any polluting material

in the environment. Carry out their dis-

posal in compliance with the relevant

12-Turn off the engine and let it cool down

legislation in force.

properly.

OIL FILTER CARTRIDGE REPLACEMENT

Follow the procedure below.

1- Turn off the engine and remove

the ignition key.

2-Let the engine cool down ade-

quately to avoid being burnt.

Oil filter (U)

3-Prepare a container to collect

any leak.

Gasket (V)

4-Unscrew filter (U) and replace

it.

5-Check the conditions of gasket

(V) and, if necessary, replace it.

6-Lubricate the seal of the new

IDM-45300901600.tif

cartridge before assembling it.

9-Turn off the engine and remove the igni-

7-Install the oil filter.

tion key.

10- Wait a few minutes so that all the oil will

Important

flow into the sump.

Lock the screw to a torque of 12,7 Nm.

8-Turn the engine on and leave it running

at minimum speed for a few minutes until it

reaches working speed (70÷80°C).

English

- 51 -

Maintenance information

D700/750 E2-E3

11-Check that the oil level is correct and top

Warning - Caution

up if necessary.

In the event of oil leaks, check the level

When topping up the oil, to avoid exceeding

periodically to evaluate the extent of the

the maximum allowed value, add the oil in

leak. If the amount is excessive, contact

small amounts (100 to 200 ml at a time) until

one of the manufacturer's authorised

it reaches the correct level.

service centres.

Important

The oil level must be between the mini-

mum and maximum marks on the dipstick.

Do not throw away any polluting material

in the environment. Carry out their dis-

12-Check for any oil leaks

posal in compliance with the relevant

legislation in force.

FUEL FILTER REPLACEMENT

Follow the procedure below.

1- Turn off the engine and remove

the ignition key.

2-Let the engine cool down ade-

quately to avoid being burnt.

Fuel filter (Z)

3-Prepare a container to collect

any leak.

4-Remove the filter (Z) using the

tool provided.

5-Fill the new filter with the fuel

from the filter being replaced.

6-Lubricate the gasket of the new

IDM-45300901700.tif

filter before mounting it.

7-Fit the new filter using the tool provided.

Warning - Caution

8-Bleed air from the fuel supply circuit

In the event of fuel leaks, identify and elimi-

(See "Fuel supply circuit bleeding").

nate the cause.

9-Turn the engine on and check for any

If the problem persists, contact one of the

fuel leaks.

manufacturer's authorised service centres.

Important

Do not throw away any polluting material

in the environment. Carry out their dis-

posal in compliance with the relevant

legislation in force.

English

- 52 -

Maintenance information

D700/750 E2-E3

RECOMMENDED LUBRICANTS

Oils of different brands can be used

provided that they have the follow-

ing features:

IDM-45300302500.tif

D700E2

D700E3

Viscosity grade

SAE10W-40 (-20°C - +50°C)

ACEA A3/B4

Minimum specifications

API CG-4, CH-4, CI-4

Important

It is advisable not to mix oils with differ-

ent characteristics.

Classification SAE

Oils are classified according to their viscos-

maximum operating temperature of the en-

ity and use: winter or summer. The symbol

gine.

W (=Winter) identifies oils intended for win-

The illustration shows the minimum and

ter use. When choosing oils for winter use,

maximum operating temperature of SAE

bear in mind the minimum ambient temper-

10W-40 grade oil.

ature at which the engine must operate. In

the case of summer oils, bear in mind the

English

- 53 -

Maintenance information

D700/750 E2-E3

INFORMATION ABOUT FAILURES

TROUBLESHOOTING

The information below are provided to facil-

Warning - Caution

itate the identification and solution of possi-

ble anomalies and failures which may occur

Activation of a visual and/or acoustic

signal indicates some form of malfunc-

during operation. Some of these problems

can be solved by the user, while others re-

tion. In this case, turn the engine off im-

mediately

and

consult

the

quire specific technical skills or abilities,

therefore they should be exclusively dealt

documentation supplied by the manufac-

turer of the vehicle/device in which the

with by qualified technicians with extensive

experience in the specific sector of interven-

engine is installed.

tion.

Problem

Cause

Remedy

Flat battery

Recharge or replace battery

Blown fuse

Replace fuse

During the ignition pha-

The electric cables are disconnected or

se the control board and

Check the electric connections

they do not guarantee continuity

the engine do not start.

Replace the sensor

Failure of engine revolution sensor

Apply to an authorised workshop

Carry out bleeding (See “Fuel supply circuit

Presence of air in the fuel supply circuit

bleeding”).

Replace the injectors.

Dirty or faulty injectors

Apply to an authorised workshop

The engine does not

Replace the valve.

Faulty fuel pressure regulation valve

start

Apply to an authorised workshop.

Replace the start control.

Failure of the start control

Apply to an authorised workshop

Water and/or impurities in the fuel

Apply to an authorised workshop

Clogged fuel filter

Replace filter (See “Fuel filter replacement”)

The starter motor runs

Check the starter motor.

Electromagnet failure

idle

Apply to an authorised workshop

Flat battery

Recharge or replace battery

The starter motor is not

Interrupted electric connection

Check the electric connections

running

Replace the worn brushes.

Worn brushes

Apply to an authorised workshop

Carry out bleeding (See “Fuel supply circuit

Presence of air in the fuel supply circuit

bleeding”)

Clogged fuel filter

Replace filter (See “Fuel filter replacement”)

Injection pump malfunction

Apply to an authorised workshop

Replace the valve.

The engine stops after

Faulty fuel pressure regulation valve

Apply to an authorised workshop

ignition

Carry out bleeding (See “Fuel supply circuit

Presence of air in the fuel supply circuit

bleeding”).

Water and/or impurities in the fuel

Apply to an authorised workshop

The electric cables are disconnected or

Check the electric connections

they do not guarantee continuity

English

- 54 -

Information about failures

D700/750 E2-E3

Problem

Cause

Remedy

Clogged fuel filter

Replace filter (See “Fuel filter replacement”)

Carry out bleeding (See “Fuel supply circuit

Presence of air in the fuel supply circuit

bleeding”)

Injection pump malfunction

Apply to an authorised workshop

Replace the injectors.

The engine does not rea-

Dirty or faulty injectors

Apply to an authorised workshop

ch the operating speed

Water and/or impurities in the fuel

Apply to an authorised workshop

Clogged air filter

Clean or replace the filter

Insufficient combustion air flow

Apply to an authorised workshop

Engine overheating

Apply to an authorised workshop

Overload

Reduce the load

Replace the injectors.

Dirty or faulty injectors

Emission of black smo-

Apply to an authorised workshop

ke from the exhaust pipe

Replace the turbine.

Faulty turbocharging turbine

Apply to an authorised workshop

Oil level too high

Adjust the oil level

Light emission of white

Check compression.

Worn segments

smoke from the exhaust

Apply to an authorised workshop

pipe

Check wear.

Worn valve guideways

Apply to an authorised workshop

Burnt gasket head

Apply to an authorised workshop

Replace the pump.

Water pump malfunction

Apply to an authorised workshop

Abundant emission of

Replace the belt

See “Belt replacement”

white smoke from the

Replace the valve.

exhaust pipe

Thermostat valve malfunction

Apply to an authorised workshop

Top up, if necessary (See “Fuel supply circuit

Coolant too low

bleeding”)

Check or replace the pressure gauge.

Failure of pressure gauge

Apply to an authorised workshop

The

pressure

Adjust the oil level (See “Engine oil level con-

gauge shows a

Oil level too low

trol”)

too low engine

Check or replace the pump.

oil pressure and

Oil pump failure

Apply to an authorised workshop

the correspon-

Check and, if appropriate, replace the sensor.

ding warning li-

Faulty sensor

ght comes on

Apply to an authorised workshop

Replace the engine oil filter (See “Oil filter

Engine oil filter blocked

cartridge replacement”)

Adjust the engine coolant level (See “Engine

Coolant too low

coolant level check”)

The coolant tem-

Stucked overpressure valve of the load

perature

war-

Replace the plug

plug

ning light comes

Replace the pump.

Water pump malfunction

Apply to an authorised workshop

Replace the valve.

Thermostat valve malfunction

Apply to an authorised workshop

Broken or worn belt

Replace the belt (See “Belt replacement”)

English

- 55 -

Information about failures

D700/750 E2-E3

Problem

Cause

Remedy

Clogged fuel filter

Replace filter (See “Fuel filter replacement”)

Carry out bleeding (See “Fuel supply circuit

Presence of air in the fuel supply circuit

bleeding”)

Replace the pump.

Injection pump malfunction

Apply to an authorised workshop

Output reduction

Replace the injectors.

Dirty or faulty injectors

Apply to an authorised workshop

Clogged air filter

Clean or replace the filter

Engine overheating

Apply to an authorised workshop

Insufficient combustion air flow

Apply to an authorised workshop

The battery war-

Check and, if appropriate, replace the alter-

The alternating current generator does

ning light comes

nating current generator.

not charge the battery

Apply to an authorised workshop

The oil pressure

warning light co-

Engine oil pressure too low

Apply to an authorised workshop

mes on

English

- 56 -

Information about failures

D700/750 E2-E3

INFORMATION ABOUT COMPONENT REPLACEMENT

RECOMMENDATIONS FOR PART REPLACEMENT

Before carrying out any replacement, acti-

damages to people or components resulting

vate all safety devices and evaluate the

from the use of non original spare parts and

need to inform the personnel working on the

from repairs carried out without the authori-

engine or nearby. In particular, place proper

sation of the manufacturer.

signs in the nearby areas and keep away all

When requesting spare parts, always con-

devices which, once activated, may repre-

tact your nearest VM MOTORI S.P.A. spare

sent a source of unexpected danger and

parts dealer

(see "enclosed documenta-

risk for people's safety and health. When

tion": Spare parts and service centre ad-

necessary, replace the worn components,

dress booklet) and indicate the engine's

and use original spare parts only. The man-

serial number (See "Manufacturer and en-

ufacturer cannot be held responsible for

gine identification").

BELT REPLACEMENT

Follow the procedure below.

1- Turn off the engine and remove

the ignition key.

Nut (A)

2-Let the engine cool down ade-

quately to avoid being burnt.

3-Adjust nut

(A) to loosen the

transmission belts.

4-Remove the belt(B) and replace

it.

Belt (B)

5-Tighten the belt (See "How to

IDM-45300901800.tif

adjust the tension of the driving

belt").

Important

- Before restarting the engine, make

sure there are no tools or other material

left near the moving parts.

- Do not throw away any replaced part

in the environment. Carry out their dis-

posal in compliance with the relevant

legislation in force.

English

- 57 -

Information about component replacement

VM Motori D700/750 E2-E3. Manuale del motore in 5 lingue (2009) - 3