VM Motori MR704LH Instruction Manual Download

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MR 700

Ed. 3 - 2012_11

English

Engine instructions manual

Summary of Contents for MR704LH

Page 1: ...MR 700 Ed 3 2012_11 Ed 3 2012_11 English Engine instructions manual ...

Page 2: ...1 SPECIFICATIONS 11 SAFETY INFORMATION 15 SAFETY RULES 15 SAFETY RULES FOR THE ENVIRONMENTAL IMPACT 17 RESIDUAL RISKS 17 HANDLING AND INSTALLATION INFORMATION 18 RECOMMENDATIONS FOR HANDLING AND INSTALLATION 18 PACKAGING AND TRANSPORT 18 UNPACKING 19 HANDLING AND LIFTING 20 ENGINE STORAGE 21 INSTALLATION DESIGN 25 OPERATING INFORMATION 26 RECOMMENDATIONS FOR USE AND OPERATION 26 CONTROL BOARD DESC...

Page 3: ...NGINE COOLANT LEVEL CHECK 40 METHOD FOR TIGHTENING OR LOOSENING THE BELT 41 ENGINE OIL CHANGE 42 COOLANT REPLACEMENT 43 SEAWATER CIRCUIT EMPTYING 44 OIL FILTER CARTRIDGE REPLACEMENT 45 FUEL FILTER REPLACEMENT 46 RECOMMENDED LUBRICANTS 46 INFORMATION ABOUT FAILURES 47 TROUBLESHOOTING 47 RESET FUSES 50 DIAGNOSIS OF FAILURES 51 READING ERROR CODES 51 ERROR CODES LIST 52 INFORMATION ABOUT COMPONENT RE...

Page 4: ...ity assurance regime in compliance with UNI EN ISO 9001 standards and with the even stricter prescriptions established by Ford Chry sler and General Motors car manufacturer association under the QS 9000 Quality System Standard for the manufacture of Diesel engines Moreover its environ mental management system has been certified against the ISO 14001 standard This is the result of a working plan wh...

Page 5: ...t is always at hand and you can consult it at all times Besides the actual installation of the engine this manual may contain additio nal 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 specifications is pointed out by a few symbols whose meanin...

Page 6: ...l the references and indica tions needed for a safe operation A Manufacturer identification 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 ...

Page 7: ...ce Service or to an authorised workshop see atta ched documentation Address booklet of assistance and spare part centres Further information are available in the website www vmmotori it in the Con tacts Request Info section WARRANTY CONDITIONS ATTACHED DOCUMENTATION The warranty conditions are stated in the attached documentation see Warranty sheet The stated documentation is supplied to the clien...

Page 8: ...sorbs the galva nic currents L Fuel filter It traps any impurity L1 Oil filter It traps any impurity M Oil sump It contains the engine lubri cation oil N Electronic control unit It controls the engine functions P Water pump It feeds the freshwater cooling circuit ___________________________________ Q Water pump It feeds the seawater cooling circuit R High pressure injection pump It feeds the injec...

Page 9: ...trolytic zinc K Wet exhaust gas sleeve G Air filter H Turbocharger D Coolant manifold Z1 Boiler connec tion X Exhaust manifold Z Fluid Cooler A Electrolytic zinc K Waste gate valve F Thermostatic valve J Tech Library http engine od ua ...

Page 10: ...ctronic control unit N Rail S1 Fuel Filter L Starter V1 Cooler C Oil filter L1 Oil sump M Intercooler E Coolant filler plug U1 Coolant expansion tank U Fresh water pump P High pressure injection pump R Alternator belt T Alternator belt tensioner T1 Seawater pump Q Seawater pump inlet Y Tech Library http engine od ua ...

Page 11: ...P A engines MR704 MR706 DIMENSIONS A mm 705 929 B mm 758 758 C mm 786 788 GENERAL DATA Cycle Four stroke Diesel Total displacement litres 2 776 4 164 No of cylinders n 4 6 Bore and stroke mm 94x100 94x100 Compression ratio 17 5 1 17 5 1 Induction type Turbocharged and inter cooled circuit Dry air filter Cooling Water circuit Cooler water water Crankshaft rotation Anticlockwise observing the engine...

Page 12: ...grees 15 15 Maximum permanent crosswise inclination Degrees 25 25 POWER AND TORQUE Maximum operating speed rpm 3800 3800 Maximum power kW CV rpm LX 169 1 kW 230 0 CV 3800 rpm LX 257 3 kW 350 0 CV 3800 rpm kW CV rpm LH 154 4 kW 210 0 CV 3800 rpm LH 235 3 kW 320 0 CV 3800 rpm kW CV rpm LS 125 0 kW 170 0 CV 3800 rpm LS 198 6 kW 270 0 CV 3800 rpm Maximum torque Nm kgm rpm LX 480 Nm 2600 rpm LX 700 Nm ...

Page 13: ...0 Important Do not use fuels with specifications other than those indicated Fuel supply Gear pump integrated in high pressure injection pump Injector supply High pressure injection pump LUBRICATION CIRCUIT Type of lubrication Forced lubrication Circuit fuel supply Rotor pump Oil change including filter standard sump litres kg 9 8 13 8 12 3 Oil quantity at minimum level standard sump litres kg 5 6 ...

Page 14: ... distilled water and 50 petronas Paraflu Up protective radiator fluid with monoethylene glycol and organic inhibitor formula tion complying with ASTM D 3306 type 1 Standards Colour of fluid RED ELECTRIC SYSTEM Total capacity of the coo ling circuit V 12 12 Setting pressure of the expansion tank V 14 14 Alternating current gene rator nominal current A 110 110 Starter motor output kW 2 3 2 3 Tech Li...

Page 15: ... phases should have been taken into account since the development of the initial project The designer has to observe with the engine fixing 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 o...

Page 16: ... down in the applicable legisla tion regarding safety at the workplace Keep the equipment as much efficient 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 ...

Page 17: ...e a suitable air renewal in the environment to protect the operators from a high concen tration 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 diffe rent materials and in compliance with the legislation in force Electric and electronic...

Page 18: ...ortate direttamente sull imballo e nelle istruzioni per l uso Chi è autorizzato ad eseguire queste ope razioni dovrà se necessario organizzare un piano di sicurezza per salvaguardare l incolumità delle persone direttamente coinvolte The packaging is also made ac cording 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...

Page 19: ...e 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 figure 4 Loosen the screws A and disassem ble the side supports B 5 Move the engine to the installation area If necessar...

Page 20: ...re Hook the lifting device to the fixing points as shown in the figure Before carrying out the lifting identify the barycentre position of the load Warning Caution The brackets of the fixing 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...

Page 21: ...sion 3 packaging and storage This procedure is valid for the follow ing engine situations on a vehicle on a pallet For engines on pallets it is neces sary to install the following accesso ries 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 EXTER...

Page 22: ... air filter is damaged re place it If there are any foreign bodies remove them LUBRICATION SYSTEM this proce dure 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 water cooled engines only ...

Page 23: ...uid leakage and make any necessary repairs Switch off the engine and wait for it to cool down SEAWATER SYSTEM for marine engines and on board auxiliary units only this procedure must be carried out together with the injection system protection procedure Connect the seawater intake of the seawater pump to an auxiliary tank containing a mixture of 40 fresh water and 60 Petronas Paraflu Up protective...

Page 24: ...UID P118 V protective oil can be cleaned with a suitable solvent Check the level of the fluids 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 mani folds are in good condition ...

Page 25: ... into account the technical data of the engine see Technical data and all the risks which may occur during its expected lifetime from installation to disposal During the design and installation phase it is a good idea to consult the installation manual drawn up by VM MOTORI S P A as this contains the installation guidelines Further information are available in the website www vmmotori it in the Co...

Page 26: ... beeper is triggered E Thermometer It indicates the tempe rature of the freshwater coolant F Warning light red It signals that the temperature of the freshwater coolant is too high When indicator lights up the beeper is triggered G Rev counter and hour counter It in dicates the number of engine revolutions and the actual hours of functioning H Digital display in the presence of operating malfuncti...

Page 27: ... Properly pre heat the engine when using it at low temperatures When using the engine at low temperatures lower than 10 C fill it with winter type fuel 6 Use oils and lubricants with suitable features viscosity grade specifications and operating temperature see Recom mended lubricants 7 If the alarm signal which can be acoustic and or visible on the control panel according to the type of installat...

Page 28: ...he cause of the fault Turn the engine off 4 Run the engine at minimum idling speed for 1 2 minutes 5 Turn the ignition key T anticlockwise pos OFF to turn off the engine All the warning lights go off 6 Remove the ignition key and store it in a safe place known only to those in charge In the case of turbocharged engines before switching the engine off it should be run at minimum idle speed for a fe...

Page 29: ...ing on hot surfaces and electric components can cause fires Do not smoke when refuelling or nearby any filling station MAINTENANCE INFORMATION RECOMMENDATIONS FOR MAINTENANCE Keep the equipment as much efficient 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 cons...

Page 30: ...p up if nec essary See Engine cool ant level check After the first 50 hours at the end of running in Engine oil 1 Replacement See Engine oil change Oil filter 2 Replacement See Oil filter car tridge replacement Routine maintenance table after running in Frequency 5 Component Type of in tervention Intervention procedures Reference Every 10 hours Engine oil 1 Level control Top up if nec essary See E...

Page 31: ...x changers engine oil fresh water 4 Cleaning Apply to an authori sed workshop Intercoo ler 4 Cleaning Apply to an authori sed workshop Every 600 hours Coolant 3 Replace See Coolant replacement 1 If the engine has not been in operation for the length of time indicated it must still be changed at least once a year 2 If the engine has not been in operation for the length of time indicated it must sti...

Page 32: ...nce operation fill in the sheet so as to keep a trace of the operations performed and therefore establish the most suitable methods for future operations Date Hours 1 Type of maintenance performed Signature and stamp of workshop 1 Indicate the total number of working hours Tech Library http engine od ua ...

Page 33: ...MR 700 33 Ed 3 2012_11 English 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 ...

Page 34: ...MR 700 34 Ed 3 2012_11 English 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 ...

Page 35: ...MR 700 35 Ed 3 2012_11 English 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 ...

Page 36: ...MR 700 36 Ed 3 2012_11 English 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 ...

Page 37: ...the battery and the liquid level 3 If necessary carry out the scheduled maintenance work see Engine mainte nance It is advisable to start the engine brin ging it to the operating temperature 70 80 C at least once per month The engine must be started once per month if it is installed for emergency purposes If the engine is left idle for prolonged periods carry out the engine protecti ve treatment t...

Page 38: ...e main tenance table after running in Replace the fuel filter according to the established intervals see Routine main tenance table after running in Replace the air filter according to the established intervals see Routine main tenance table after running in Tension again the transmission belt see Method for tightening or loosening the belt Check the tightening of the hydraulic unions see Control ...

Page 39: ...w the procedure below 1 Turn off the engine and remove the ignition key 2 Let the engine cool down adequately to avoid being burnt 3 Prepare a container of appropriate capacity 4 Loosen the screw E 5 Operate the pump F manually to eliminate air from the circuit 6 Check that a flow of clean fuel contai ning no air bubbles is coming out of the bleeder screw E Important When bleeding the fuel circuit...

Page 40: ...en the minimum and maximum marks Do not mix oils of different brands or with different features see Re commended lubricants ENGINE COOLANT LEVEL CHECK Follow the procedure below 1 Start the engine and bring it to the operating temperature 70 80 C 2 Turn off the engine and remove the ignition key 3 Let the engine cool down properly 4 Unscrew the load plug P Warning Caution Open the plug gently to d...

Page 41: ...ol down adequately to avoid being burnt 3 Loosen the belt by moving the ten sioner A until the holes B match and block it with pin C 4 Tension the belt by moving the tensio ner A remove the pin C and release it Warning Caution To tighten the belt it must be cor rectly positioned in the housings on each of the pulleys see Belt repla cement hole B pin C Tech Library http engine od ua ...

Page 42: ...emove the ignition key 2 Let the engine cool down adequately to avoid being burnt 3 Prepare a container of appropriate capacity As for the oil quantity see Spe cifications 4 Unscrew the load plug M 5 Unscrew the plug Q 6 Insert the pump R and screw it to pipe 7 Operate manually the pump to transfer all the oil into the container 8 Pour the new oil until it reaches the correct level on the dipstick...

Page 43: ...ation on the cock S2 as well 11 Unscrew the plug P 12 Pour in the new liquid The liquid level should be included between the mini mum and maximum notches printed on the expansion chamber As for the liquid quantity and type see Specifications 13 Screw again the plug P 14 Turn the engine on and leave it run ning at minimum speed for a few minutes until it reaches working speed 70 80 C 15 Turn off th...

Page 44: ...NG Follow the procedure below 1 Prepare a container of appropriate capacity 2 Unscrew the plug P1 3 Let water flow into the container 4 Screw again the plug P1 5 Carry out the same operation on plug P2 as well plug P1 plug P2 Tech Library http engine od ua ...

Page 45: ... Important Tighten the cap to a tightening torque of 25 Nm 8 Turn the engine on and leave it running at minimum speed for a few minutes until it reaches working speed 70 80 C 9 Check for any oil leaks Warning Caution In the event of oil leaks check the le vel periodically to evaluate the extent of the leak If the amount is excessive contact one of the manufacturer s authorised service centres Impo...

Page 46: ... check for any fuel leaks Warning Caution In the event of fuel leaks identify and eliminate the cause If the problem persists contact one of the manufac turer s authorised service centres Important Do not throw away any polluting material in the environment Carry out their disposal in compliance with the relevant legislation in force RECOMMENDED LUBRICANTS The lubricant recommended by VM MO TORI S...

Page 47: ...the sensor Apply to an authorised workshop The engine does not start Presence of air in the fuel supply circuit Carry out bleeding see Fuel supply circuit bleeding Dirty or faulty injectors Clean or replace injectors Apply to an authorised workshop The injection pump is set incor rectly or is faulty Adjust the pump or replace it Ap ply to an authorised workshop Failure of the start control Replace...

Page 48: ... filter replacement Overload Reduce the load Emission of black smoke from the exhaust pipe Dirty or faulty injectors Clean or replace injectors Apply to an authorised workshop The injection pump is set incor rectly or is faulty Adjust the pump or replace it Ap ply to an authorised workshop Faulty turbocharging turbine Replace the turbine Apply to an authorised workshop Light emission of white smok...

Page 49: ... Apply to an authorised workshop The injection pump is set incor rectly or is faulty Adjust the pump or replace it Apply to an authorised workshop The injection pump timing is not adjusted correctly Adjust pump timing Apply to an authorised workshop Output reduction Clogged fuel filter Replace filter see Fuel filter replacement Presence of air in the fuel supply circuit Carry out bleeding see Fuel...

Page 50: ...rrent must be eliminated before the fuse is reset 1 To repair the protective fuse of the electrical circuit open the fuse box re lay A and replace the fuse which has intervened Important the new fuse must have the same electrical characteristics as the fuse replaced Important If the problem persists contact a VM MOTIRI S P A service centre Fuse relay box A K1 Starter motor relay K2 Main relay F1 2...

Page 51: ...ely contact one of the manufacturer s authorised service centres and provide them with the information shown on the display Button L display H display H Button L Photo 2 Photo 1 READING ERROR CODES In case of malfunction the display H visualises the presence of error codes In the case of one or more error codes the display shows the following caption DTC Photo 1 represents the presence of 6 malfun...

Page 52: ...Plausible Differential Pressure 81 DPF Particulate Filter Active Engine Protection 84 Vehicle Speed Sensor Malfunction 84 NO Description 91 Synchronization Error of Accelerator Pedal Position Sensors 91 Accelerator Pedal Position Error Sensor 1 91 Accelerator Pedal Position Error Sensor 2 91 Position of Accelerator Brake not plausible 91 NO Description 97 Actuator Malfunction of Water Level in Gas...

Page 53: ...ce 157 Rail Pressure Error during Rail Pressure Check from Pressure Regulator 157 Error of Maximum Pressure Limiting Valve PRV Rail 164 Error of Rail Pressure Signal 168 Battery Voltage Error 172 Air Temperature Signal Duty Cycle Error 172 NO Description 173 Exhaust Gas Temperature Sensor Error Bank 1 Position 1 174 Gas oil Temperature Sensor Error 175 Engine Oil Temperature Alarm 175 Signal Error...

Page 54: ...munication between Processor and Control Module 630 Plausibility Error of the Dataset Variant Coding 633 Analogue Digital Channel Error of PCV Fuel Flow Adjustment Valve Control 633 PWM Circuit Malfunction of PCV Fuel Flow Adjustment Valve Control 634 Intake Butterfly Valve Actuator Error 634 Circuit Malfunction of TVA Intake Butterfly Valve Actuator 639 NO Description 641 High Overfeeding Pressur...

Page 55: ...on Specific Error Bank 2 675 Glowplugs Indicator Light Malfunction 676 Glowplugs GCU Control Unit Relay Malfunction 676 Cylinder 1 Glowplug Circuit Malfunction 676 Cylinder 2 Glowplug Circuit Malfunction 676 Cylinder 3 Glowplug Circuit Malfunction 676 Cylinder 4 Glowplug Circuit Malfunction 676 Cylinder 5 Glowplug Circuit Malfunction 676 Cylinder 6 Glowplug Circuit Malfunction 676 NO Description 6...

Page 56: ...ors 3 1109 NO Description 1137 Error Checking the Plausibility of the Exhaust Gas Temperature Sensor Position 1137 Exhaust Gas Temperature Sensor Error Bank 1 Position 1 1138 Error Checking the Plausibility of the Exhaust Gas Temperature Sensor Position 2 1138 Sensor Error of Exhaust Gas Temperature Bank 1 Position 2 1139 NO Description 1213 Circuit Malfunction of MIL Indicator light 1213 NO Descr...

Page 57: ...earbox Control unit Pressure Switch Function Test Failure 1484 Gearbox Control Unit Torque Value of Converter Out of Range 1484 Gearbox Control Unit Switch Valve Blocked 1484 Generic Error of TCU Gearbox Control unit 1484 Internal Error of TCU Gearbox Control unit 1484 Internal Error of TCU Gearbox Control unit Gear Ratio Incorrect 1484 NO Description 1485 Relay Main Control Error 1680 Auxiliary H...

Page 58: ...spare parts and from repairs carried out without the authorisation of the manufacturer When requesting spare parts always contact your nearest VM MOTORI S P A spare parts dealer see Enclosed documentation Spare parts and service centre address booklet and indicate the engine s serial number see Manufactu rer and engine identification BELT REPLACEMENT Follow the procedure below 1 Turn off the engin...

Page 59: ... engine cool down adequately to avoid being burnt 3 Unscrew the nuts A 4 Remove the bracket B 5 Remove the protection C and replace the cartridge D 6 Reposition the protection C 7 Reposition the bracket B and block it Model MR706 Follow the procedure below 1 Turn off the engine and remove the ignition key 2 Let the engine cool down adequately to avoid being burnt 3 Loosen hose clamp A and remove t...

Page 60: ...ENGINE DISPOSAL This operation should be carried out by experienced operators in compliance with the legislation in force concerning safety at the workplace Do not throw away non bio degradable products and non ferrous components rubber PVC resins etc While decommissioning the engine divide all the components depending on their chemical composition and dispose of them accordingly electrolytic zinc...

Page 61: ...MR 700 61 Ed 3 2012_11 English ELECTRICAL SYSTEM ENGINE ELECTRICAL DIAGRAM MR704 Tech Library http engine od ua ...

Page 62: ...MR 700 62 Ed 3 2012_11 English ENGINE ELECTRICAL DIAGRAM MR706 Tech Library http engine od ua ...

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