VM Motori R 750 Series Common Rail Diesel Engine Complete Workshop Service Repair Manual

R 750  VM Order Number 42431133F Edition 7 - 03/2010 Workshop Manual Engine Family R750 R754EU4 R756EU4 R756IE3 R754EU5 R756EU5 R Common Rail Injection System 750 Unitary Displacement 4 (no. of cylinders) 4 x x 4 x 6 (no. of cylinders) x 6 6 x 6 Turbocharged yes yes yes yes yes I (Intercooler) yes yes yes yes yes EU4 - Emissions Certification EURO 4 EC/EPA Stage3A EURO 4 EC/EPA Stage3A x x x E3 - Emissions Certification x x EC/EPA Stage3A x x EU5 - Emissions Certification x x x EURO 5 EC/EPA Stage3B EURO 5 EC/EPA Stage3B

R 750  SECTIONS INTRODUCTION ...................................................................................................................... 6 HANDLING PRECAUTIONS FOR ELECTRIC CIRCUITS ...................................................... 8 SERVICE MANUAL - UPDATING .......................................................................................... 13 GENERAL INFORMATION ..................................................................................................... 16 MAINTENANCE ...................................................................................................................... 18 REMOVAL AND INSTALLATION ........................................................................................... 50 FASTENER TIGHTENING SPECIFICATIONS ....................................................................... 51 SPECIAL TOOLS.................................................................................................................... 52 TIMING SIDE........................................................................................................................... 56 EXHAUST SIDE ...................................................................................................................... 83 FLYWHEEL SIDE.................................................................................................................... 91 BASIC ENGINE...................................................................................................................... 100 ENGINE BLOCK .................................................................................................................... 134 ENGINE BLOCK .................................................................................................................... 135 INJECTION SIDE ................................................................................................................... 151 ENGINE ELECTRICAL .......................................................................................................... 169 ENGINE CONTROL ............................................................................................................... 173 LABOUR TIME GUIDE .......................................................................................................... 190 ELECTRICAL SYSTEM ......................................................................................................... 197

R 750 3 SUMMARY INTRODUCTION ...................................................................................................................... 6 MODELS COVERED ....................................................................................................................................... 6 R 754 AND 756 EU4/EU5 COMMON RAIL INDUSTRIAL ENGINES ARE APPLIED TO VEHICLES OF THE ROAD, SUCH AS ROAD SWEEPERS AND TRUCKS. R 756 IE3 ARE APPLIED TO VEHICLES NOT OF THE ROAD, AGRICULTURAL AND LIFTING APPLICATION. ................................................................................. 6 NOTICE TO USERS OF THIS MANUAL ......................................................................................................... 6 REPLACEMENT PARTS .................................................................................................................................. 7 CLEANLINESS AND CARE OF PRODUCT .................................................................................................... 7 HANDLING PRECAUTIONS FOR ELECTRIC CIRCUITS ...................................................... 8 ENGINE ELECTRONIC CONTROL UNIT ....................................................................................................... 8 PRECAUTIONS FOR ARC WELDING............................................................................................................. 12 SERVICE MANUAL - UPDATING .......................................................................................... 13 GENERAL INFORMATION ..................................................................................................... 16 INTRODUCTION .............................................................................................................................................. 16 HOW TO ORDER THIS MANUAL.................................................................................................................... 16 ENGINE SERIAL NUMBER AND ENGINE PLATE IDENTIFICATION............................................................. 16 MAINTENANCE ...................................................................................................................... 18 ENGINE SPECIFICATIONS ............................................................................................................................. 18 MAINTENANCE INTERVALS .......................................................................................................................... 24 MAINTENANCE SCHEDULE - R750 EURO 4 - IE3 ....................................................................................... 24 MAINTENANCE SCHEDULE - R750 EURO 5 ................................................................................................ 25 ENGINE EXTERNAL VIEWS ........................................................................................................................... 26 ENGINE OIL .................................................................................................................................................... 30 COOLANT ........................................................................................................................................................ 35 AIR FILTER ELEMENT .................................................................................................................................... 38 FUEL SYSTEM ................................................................................................................................................ 41 FUEL FILTER ................................................................................................................................................... 42 ALTERNATOR BELT / POLY - V (SERPENTINE) ........................................................................................... 44 DIESEL PARTICULATE FILTER (DPF) - R 750 EURO 4................................................................................. 46 DIESEL PARTICULATE FILTER (DPF) - R 750 EURO 5................................................................................. 48 EXTENDED STORAGE ................................................................................................................................... 49 REMOVAL AND INSTALLATION ........................................................................................... 50 FASTENER TIGHTENING SPECIFICATIONS ....................................................................... 51 SPECIAL TOOLS.................................................................................................................... 52 TIMING SIDE........................................................................................................................... 56 TIMING GEARS ............................................................................................................................................... 57 OIL PUMP ........................................................................................................................................................ 60 CRANKSHAFT GEAR ...................................................................................................................................... 65 HYDRAULIC PUMP IDLER GEAR (BETWEEN THE CRANKSHAFT AND CAMSHAFT GEARS) ................. 66 INJECTION PUMP IDLER GEAR (BETWEEN THE CAMSHAFT AND INJECTION PUMP GEARS) ............. 69 HYDRAULIC PUMP GEAR ASSEMBLY .......................................................................................................... 70 BELT TENSIONER - (AUTOMATIC TYPE) ...................................................................................................... 74 BELT TENSIONER BRACKET ......................................................................................................................... 75 IDLER PULLEYS.............................................................................................................................................. 76 CRANKSHAFT HUB AND PULLEY ................................................................................................................. 77 WATER PUMP AND PULLEY .......................................................................................................................... 80 TIMING GEAR COVER .................................................................................................................................... 81 FRONT OIL SEAL ............................................................................................................................................ 82 EXHAUST SIDE ...................................................................................................................... 83 TURBOCHARGER ........................................................................................................................................... 83 EGR COOLER ................................................................................................................................................. 84 INTAKE THROTTLE / EGR VALVE & PROPER ACTUATORS ...................................................................... 86 EXHAUST MANIFOLD ..................................................................................................................................... 89 INTAKE MANIFOLD ......................................................................................................................................... 90

R 750 4 FLYWHEEL SIDE.................................................................................................................... 91 CRANKSHAFT END PLAY (AXIAL CLEARANCE) .......................................................................................... 91 FLYWHEEL ...................................................................................................................................................... 92 FLYWHEEL RING GEAR ................................................................................................................................. 95 FLYWHELL HOUSING ..................................................................................................................................... 96 REAR MAIN BEARING CARRIER ................................................................................................................... 98 THRUST WASHERS ........................................................................................................................................ 98 REAR MAIN BEARING ................................................................................................................................... 99 REAR OIL SEAL............................................................................................................................................... 99 CPS TARGET WHEEL BOLT ........................................................................................................................... 99 BASIC ENGINE...................................................................................................................... 100 CYLINDER HEAD GASKET............................................................................................................................. 100 CYLINDER HEAD ............................................................................................................................................ 101 TORQUE PROCEDURE AFTER THE FIRST 20-30 MINUTES OF OPERATION........................................... 104 EXPANSION PLUGS ....................................................................................................................................... 105 CYLINDER HEAD END SPACER .................................................................................................................... 105 VALVE GUIDES ............................................................................................................................................... 106 VALVE SEATS .................................................................................................................................................. 108 VALVE SEAT RECONDITIONING ................................................................................................................... 109 VALVES ............................................................................................................................................................ 110 VALVE SPRINGS ............................................................................................................................................. 112 ROCKER ARM ................................................................................................................................................. 113 VALVE LIFTERS .............................................................................................................................................. 115 VALVE PUSH RODS ........................................................................................................................................ 117 FRACTURED CONNECTING ROD ................................................................................................................. 118 REMOVAL ........................................................................................................................................................ 118 BROACHED CONNECTING ROD ................................................................................................................... 122 REMOVAL ........................................................................................................................................................ 122 PISTON ............................................................................................................................................................ 126 OIL PAN & OIL PICKUP ................................................................................................................................... 131 OIL PICKUP ..................................................................................................................................................... 131 OIL PRESSURE RELIEF VALVE ..................................................................................................................... 132 ENGINE BLOCK .................................................................................................................... 134 CRANKCASE ................................................................................................................................................... 134 ENGINE BLOCK .................................................................................................................... 135 LINER ............................................................................................................................................................... 135 CAMSHAFT...................................................................................................................................................... 138 CAMSHAFT BEARINGS ................................................................................................................................. 141 FRONT JOURNAL CAMSHAFT BUSHING ..................................................................................................... 142 PISTON COOLING JETS (OIL SPRAY NOZZLES) ......................................................................................... 143 CRANKSHAFT ................................................................................................................................................. 144 CRANKSHAFT FRONT MAIN BEARING ........................................................................................................ 150 INJECTION SIDE ................................................................................................................... 151 INJECTION FUEL SYSTEM............................................................................................................................. 151 ELECTRICAL SENSORS ................................................................................................................................ 152 LOW PRESSURE SYSTEM REQUIREMENTS............................................................................................... 156 HIGH PRESSURE PUMP ................................................................................................................................ 157 INJECTOR........................................................................................................................................................ 160 RAIL ................................................................................................................................................................. 162 HIGH PRESSURE FUEL COMPONENTS TIGHTENING PROCEDURE........................................................ 163 OIL FILTER HOUSING ..................................................................................................................................... 164 OIL DELIVERY PIPE TO ROCKER ARM ......................................................................................................... 165 ROCKER ARM COVER ................................................................................................................................... 166 COOLANT MANIFOLD .................................................................................................................................... 166 THERMOSTATIC VALVE ................................................................................................................................ 167 VACUUM PUMP............................................................................................................................................... 168

R 750 5 Introduction ENGINE ELECTRICAL .......................................................................................................... 169 ALTERNATOR .................................................................................................................................................. 169 ALTERNATOR PULLEY ................................................................................................................................... 169 VOLTAGE REGULATOR .................................................................................................................................. 172 ALTERNATOR BRACKET ................................................................................................................................ 172 STARTER ......................................................................................................................................................... 172 ENGINE CONTROL ............................................................................................................... 173 DIAGNOSTIC TROUBLE CODES “EURO 4” .................................................................................................. 173 DIAGNOSTIC TROUBLE CODES “EURO 5” .................................................................................................. 179 LABOUR TIME GUIDE .......................................................................................................... 190 KEY TO DEFINITIONS..................................................................................................................................... 190 ELECTRICAL SYSTEM ......................................................................................................... 197 ELECTRICAL SCHEMATIC DIAGRAMS ........................................................................................................ 197 ENGINE WIRING HARNESS ........................................................................................................................... 199 INSTALLATION ELECTRIC DIAGRAM ............................................................................................................ 203

R 750 6 Introduction MODELS COVERED R 754 and 756 EU4/EU5 common rail industrial engines are applied to vehicles of the road, such as road sweepers and trucks. R 756 IE3 are applied to vehicles not of the road, agricultural and lifting application. NOTICE TO USERS OF THIS MANUAL Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Sym- bol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures. DANGER DANGER—indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING WARNING—indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION CAUTION—indicates a potentially hazardous situation that, if not avoided, may result in minor or modera- te injury or property damage. It may also be used to alert against unsafe practices. This manual has been written and published by the Service Department of VM Motori to aid our dealers’ mechanics and company service personnel when servicing the products described herein. We reserve the right to make changes to this manual at any time and without prior notice in accordance with the Company’s policy of constant product improvement. COPYRIGHT © 2007 July, VM Motori S.p.A. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form, whether electronic or mechanical, or by photocopying, recording or other means without prior permission in writing of VM Motori. Published by VM Motori, from whom further copies may be obtained through your normal literature ordering procedure (refer to front page to identify the order number). A copy of this manual is available from VM Motori web site Customer Reserved Area “Extranet” VM Motori S.p.A. - Service Department, Via Ferrarese 9 - 4404 Cento (FE) ITALY Every reasonable effort is made to ensure that the VM Motori’s publications are accurate, but nothing shown, described or referred to herein should be regarded as an infallible guide to the procedures, mate- rials, specifications, dimensions, design or availability of any particular engine, nor does this publication constitute an offer for the sale of any particular engine. No liability can be accepted by the VM Motori or any Distributor or Dealer for any malfunction, damage, loss, injury or death caused by the use of incorrect or misinterpreted information, omissions or errors that may have arisen during the preparation of this workbook. INTRODUCTION It is assumed that these personnel are familiar with industrial product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of VM Motori Products, including the use of mechanics’ common hand tools and the special VM Motori or recommended tools from other suppliers. We could not possibly know of and advise the industrial trade of all conceivable procedures and of the possible hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to service these products. Refer to dealer service bulletins, warranty, owner manuals and installation manuals for other pertinent information concerning the products described in this manual. Extranet area contained in VM Motori web site is another source of information.

R 750 7 Introduction REPLACEMENT PARTS Use of parts other than the recommended service replacement parts, will avoid the warranty on those parts that are damaged as a result. WARNING When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. CLEANLINESS AND CARE OF PRO- DUCT A VM Motori Product is a combination of many machined, honed, polished and lapped surfaces with tole- rances that are measured in the thousands of a mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not speciﬁcally stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Any time the intake or exhaust openings are expo- sed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note, during any maintenance procedure replacement fasteners must have the same mea- surements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. There- fore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches the origi- nal. Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to ground as soon as possible.

R 750  Introduction HANDLING PRECAUTIONS FOR ELECTRIC CIRCUITS ENGINE ELECTRONIC CONTROL UNIT WARNING IN ORDER TO AVOID ECU DAMAGE PAY ATTENTION TO THE FOLLOWING INSTRUCTIONS: DO NOT CUT ENGINE VOLTAGE OFF DURING ENGINE OPERATION BEFORE CUT ENGINE VOLTAGE OFF THROUGH ELET- TRICAL DEVICES (BREAKERS, SWITCH, ETC.) WAIT FOR 30 SEC. AT LEAST SO THAT THE ECU CAN BE CARRIED OUT THE “AFTER-RUN” PROCEDURE DO NOT USE START BOOSTER TO LET START THE EN- GINE • • •

R 750 9 Introduction It should be kept in mind, while working on the product, that the electrical systems are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Before working on the electrical system, disconnect the (–) battery cable to prevent short circuits. CAUTION Make sure the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. Semiconductor components may otherwise be damaged. When separating connectors, grasp the connectors themselves rather than the harnesses.To separate locking connectors, ﬁrst push them in the direction of the arrows. To reconnect locking connectors, push them together until they click. Before washing the engine, cover electrical parts to keep them dry. (Use plastic sheets or the like.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them. When applying a voltage to a part for inspection pur- poses, check that the (+) and (–) cables are connected properly then gradually increase the voltage from zero. Do not exceed the speciﬁed voltage. Remember that control units and sensors do not ne- cessarily operate on the battery voltage. CAUTION

R 750 0 Introduction • Do not pierce wire insulation with test probes or alligator clips when performing electrical inspections. Doing so can, particularly with the chassis harness, hasten corrosion. INSPECTION OF HARNESSES INSPECTIONS WITH CONNECTORS FITTED TO- GETHER Waterproof connectors • Connect an inspection harness and connector A between the connectors B of the circuit to be ins- pected. Perform the inspection by applying a test probe C to the connectors of the inspection harness. Do not insert the test probe C into the wire-entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust. Non-waterproof connectors Perform the inspection by inserting a test probe C into the wireentry sides of the connectors. An extra-narrow probe is required for control unit connectors, which are smaller than other types of connector. Do not force a regular-size probe into control unit connectors since this would cause damage. INSPECTIONS WITH CONNECTORS SEPARATED Inspections on female terminals Perform the inspection by carefully inserting a test probe into the terminals. Do not force the test probe into the terminals since this could deform them and cause poor connections. Inspections on male terminals Perform the inspection by applying test probes directly to the pins. CAUTION . • Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-cir- cuiting of pins can cause damage to the control unit’s internal circuitry. When using a multimeter to check continuity, do not

VM Motori R 750 Series Common Rail Diesel Engine Complete Workshop Service Repair Manual

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