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Kohler Engine Model KDW 1404 work shop manual

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9. Lubrification circuit 72 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 159 7 Components 1 Coolant filler plug 6 Circulation pump 2 Compensating tank 7 Fan 3 Thermostatic valve 8 Radiator 4 Cylinder block 9 Heat exchanger with relevant pipes Only fitted in LDW
10. Hydraulic pump drive A Third drive You can mount a 2P hydraulic pump on the third drive with Bosch flanging or a 1 PD type one You can draw 7 KW of power from the third drive corresponding to a 37 Nm torque at 3600 rpm engine revolutions Drive ratio engine revs pump revs 1 0 5 Third drive components 1 Splined sleeve 2 Toothed pinion 3 Seal ring 4 Flange for 1 PD hydraulic pump 5 Seal ring Note Sleeve 1 also includes the fuel pump control cam and is fastened with the same standard cam screw with a tightening torque of 80 Nm 90 Tighten pinion 2 to the hydraulic pump at 45 Nm Disassembly Reassembly 66 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 147 148 149 5 TURBO CHARGER Only the LDW 1204 T is supplied with the turbocharger The LDW 1204 T is available in two versions TD 025 03C 2 8 for 3600 r min TD 025 03C 2 0 for 3000 r min TURBOC
11. Turbocharger west gate adjustment Regolazione corsa asta comando valvola Waste gate Disconnect westgate tube 7 from the turbocharger compressor side Using a T joint connect a pressure gauge 4 scale 0 to 2 bar and with the compressed air network pipe complete with reducer 5 The network air supply pressure must be from 1 5 to 2 bar Make a hole B in the pressure gauge pipe of 1 55 mm in diameter This will help bleeding some air and stabilizing pressure in the pressure gauge Set up a dial gauge 6 so that the feeler is rested on terminal 2 Via the pressure reducer 5 convey some air to the actuator so as terminal 2 is pushed forwards by A A 1 mm The pressure read in the pressure gauge must be 830 890 mm Hg 1 11 1 19 bar If the pressure is lower than the given value proceed as follows Unscrew locknut 1 Remove split pin 9 and disconnect rod 8 waste gate control valve Keeping the rod steady tighten terminal 2 until you reach the calibration pressure During the rotation of terminal 2 the rod
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13. 74 Fuel pump drive rod projection 74 Injection advance control and regulation 80 Injection advance for currently used pump injector unit 80 Injection advance references on timing belt protector 81 Injection pump assembly disassembly 76 Injection pumps delivery balancing 83 Injector nozzle projection 79 Injector setting old type 79 Injector spark arres
14. 48 Cylinder roughness 59 Cylinder class 59 CYLINDERS 59 Driving pulley 34 Dry type air filter 29 E G R Circuit 30 31 Exhaust maniflod 32 Flywheel
15. 51 Pre combustion chamber ring nut removal 51 Pre combustion chamber installation 51 Pre combustion chamber removal 51 Pump injector unit Disassembly 45 Pump injector unit non return valve 45 Rear and forward main bearing caps 60 RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING 28 RECOMMENDATIONS FOR OVERHAULS AND TUNING 28 Return pulley
16. 72 73 COOLANT CIRCUIT 72 Coolant circulation pump components 73 Radiator and compensation check and seal tank cap 73 Thermostatic valve 73 8 FUEL SYSTEM 74 83 Closing the oilhole 82 Fuel feeding injection circuit 74 Fuel filter detached from the tank on request 74 Fuel lift pump
17. 34 Fuel rail 44 Fuel tank optional 33 Governor springs 40 Governor springs for Gensets 40 Head gasket 56 Hydraulic pump drive 65 Injection pump control rod 44 Intake Exhaust Injection camshaft lobe height LDW 903 47 Intake manifold
18. 101 Table of tightening torques for the main components 100 13 SPECIAL TOOLS 102 Chapter index 9 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 1 The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24 months from the date of delivery to the first end user For engines fitted to stationary equipment working at constant load and at constant and or slightly variable speed within the setting limits the warranty covers a period up to a limit of 2000 working hours if the above mentioned period 24 months is not expired If no hour meter is fitted 12 working hours per calendar day will be considered For what concerns the parts subject to wear and deterioration injection feeding system electrical system cooling system sealing parts non metallic pipes belts warranty covers a maximum limit of 2000 working hours if the above mentioned period 24 months is not expired For correct maintenance and replacement of these parts it is necessary to follow the instructions reported in the documentation supplied with each engine To ensure the engine warranty
19. 93 Voltage regulator connections 90 10 SETTINGS 94 97 E G R calibration 97 Injection pump flow limiter and standard engine torque gearing device 95 Pump injection delivery standard setting without dynamometric brake 94 Pump injector unit delivery setting with braked engine 96 Pump injector unit timing with speed governor 95 Required settings as most commonly applies 96 Setting the idle maximum standard
20. 40 Speed governor Limiting speed governor 41 Speed governor Reassembly 41 Speed governor components 40 Stop pin rings dismounting and remounting 52 Third drive components 65 Tightening pulley 36 Timing belt Timing pulley arrangement 36 Timing belt cover 35 Chapter index 7 FOCS Workshop Manual_cod 1 5302 351_7
21. 9 SAFETY AND ENVIRONMENTAL IMPACT 11 SAFETY AND WARNING DECALS 10 SAFETY REGULATIONS 10 11 WARRANTY CERTIFICATE 9 2 TECHNICAL INFORMATION 12 23 MANUFACTURER AND ENGINE IDENTIFICATION 14 15 OVERALL DIMENSION 21 23 PERFORMANCE DIAGRAMS 18 20 TECHINICAL SPECIFICATIONS 16 17 TROUBLE SHOOTI
22. 34 Ringfeder type rings on LDW 1204 1204 T 1404 35 Ringfeder type rings on LDW 1204 1204 T 1404 Assembly 35 Rocker arm assembly 45 Rocker arm cover 42 Rocker arm cover gasket 43 Rocker arm pivot dismounting and remounting 46 Shoulder half rings 61 Shoulder half rings oversized elements 62 Speed governor
23. 48 Valve timing Angles 39 Valve timing check 38 Valve specifications 49 Valves 48 5 TURBOCHARGER 66 67 TURBO CHARGER 66 Turbocharger components 66 Turbocharger pressure testing 66 Turbocharger west gate adjustment Regolazione corsa a
24. 89 Alternator battery charger curve 12V 30A 89 Alternator Iskra 14V 33A 85 Alternator Iskra 14V 33A Performance Curve 85 Alternator Marelli type AA 125 R 14V 45A 87 Alternator Marelli type AA 125 R 14V 45A Performance Curve 87 Coolant high temperature lamp sensor 93 ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP 84 Electric starting layout 12V with flywheel alternator 90 Electric starting layout 12V with Iskra alternator 14V 33A 86 Electric starting layout 12V with
25. 55 Piston coolant nozzles 61 Piston ring Clearance between grooves 54 Piston ring mounting order 55 Piston rings End gaps 54 Piston assembly 55 Piston class 53 Piston disassembly and inspection 53 Piston weight 54 Pre combustion chamber
26. PF 905 Filtering surface 2400 cm2 Degree of filtration 2 3 Maximum operating pressure 4 bar See page 24 for periodic maintenance details FUEL SYSTEM 75 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 168 169 8 Pump injector unit Designed by LOMBARDINI the pump injector is exclusive to FOCS series engines The injection system includes two three four identical pumps injector units each one of which feeds a cylinder Note On pumps injector units of recent construction for serial numbers and references see the table on page 78 the pump has been modified see fig 174 Following to this modification and others like the elimination of cap 20 of fig 169 the method of checking the static injection advance has changed as well fig 187 188 as that of injector setting fig 178 Pump injector unit components 1 Seeger ring A Ring nut 2 Tappet B O ring 3 Stop plate C Nozzle 4 Plunger D Spacer 5 Spring E Pressure rod 6 Screw F Spring 7 Bearing G Spacer 8 Lever I Casing 9 Ring nut L Control spiral 10 Plunger guide O ring M Plunger guide 11 Cylinder 12 Delivery valve 13 Gasket 14 Spring 15 Filler 16 Pin When remounting the injector tighten ring nut A at 70 Nm 17 O ring 18 Non return valve 19 O ring 20 Cap screw old type 21 Metal gasket new type Fuel s
27. 94 Setting the idle minimum standard 94 Setting the stop 95 SPEED SETTINGS 94 11 STORAGE 98 99 ENGINE STORAGE NOT INSTALLED 98 PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT 99 PROTECTIVE TREATMENT 98 12 TORQUE SPECIFICATIONS AND USE OF SEALANT 100 101 Table of tightening torques for standard screws coarse thread 101 Table of tightening torques for standard screws fine thread
28. 47 Camshaft timing Belt Reassembly 37 Camshaft timing Belt Tightening and Fastening 38 Camshaft timing Belt tightening tool 38 Camshaft timing pulley Disassembly Assembly 37 Camshaft timing pulley Reference marks 37 Camshaft disassembly 46 Camshaft journal and housing measurement 46 Central main bearing caps 60 Check the clearances between the bearings and the journal 60 Clearances betwee
29. 61 Crankshaft front and back oil seal rings 62 This manual contains pertinent information regarding the repair of LOMBARDINI water cooled indirect injection Diesel engines type LDW 502 602 903 1204 1204 T e LDW 702 1003 1404 updated March 15th 2006 CHAPTER INDEX 6 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 Crankshaft timing pulley 36 Crankshaft check journals and crank 63 Crankshaft lubrication lines 63 Cylinder head assembly 57 Cylinder head tightening procedure LDW 1204 1204 T 1404 57 Cylinder head tightening procedure LDW 502 602 702 903 1003 57 CYLINDER HEAD removal
30. 850 C after 5 seconds Components 1 Sheath 2 Primary Heating Coil 3 Secondary Heating Coil When remounting tighten at a torque of 20 Nm Post heat Glow plug heat time sec Pre heat Coolant temp C Resistance ohm Thermistor input Heating stop Starter motor Bosch DW 12V 1 6 KW Performance Curve The curve was obtained at room temperature of 20 C with a fully charged 88 Ah battery U Starter Motor Voltag n Armature r min I Absorbed Amperage P Starter Output Power KW M Starter Output Torque Nm Electric System 93 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 213 215 214 216 9 Oil pressure switch Fig 215 Characteristics Opening pressure 0 15 0 45 bar for gen sets 1 4 bar Tightening torque 25 Nm Coolant high temperature lamp sensor Fig 216 Characteristics Circuit single pole Voltage range 6 24 V Max Power Absorption 3 W Closing temperature 107 113 C Tightening torque 25 Nm Temperature sensor for control unit In engines fitted with the above mentioned type of control unit the introduction of the glow plugs depends on a temperature sensor that varies preheating temperature in relation to the coolant temperature Characteristics Temperature range 30 50 C Voltage rang
31. 1 3 4 2 LDW 1204 T 4 72 75 1222 22 8 1 3600 31 0 42 0 28 5 38 7 25 8 35 0 98 2400 37 1800 305 0 019 101 2860 109 300 35 25 1 3 4 2 LDW 502 602 LDW 903 LDW 1204 LDW 1204 T 2 Technical information TECHINICAL SPECIFICATIONS Cylinders Bore Stroke Displacements Compression rate Rpm N 80 1269 CEE ISO 1585 DIN 70020 Maximum power NB ISO 3046 1 IFN DIN 6270 NA ISO 3046 1 ICXN DIN 6270 Maximum torque Maximum Torque Available N 3 PTO 3600 Rpm Specific fuel consumption Oil consumption Dry weight of engine Combustion air volume at 3600 Rpm Cooling air volume at 3600 Rpm Axial load allowed on crankshaft both directions Instant operation up to 1 min Max tilt Intermittent operation up to 30 min Permanent operation Combustion sequence ENGINE TYPE At NB power Referred to NB power Measured at NA power Depends on application At 3600 Rpm Measured at NB power 17 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 N mm mm Cm Nm RPM Nm g KWh Kg h Kg l 1 m min Kg LDW 702 2 75 77 6 686 22 8 1 3600 12 5 17 0 11 7 16 10 7 14 5 40 5 2000 37 1800 320 0 009 66 1240 43 300 35 25 LDW 1003 3 75 77 6 1028 22 8 1 3600 19 5 26 5 18 24 5 16
32. Remote air filter 30 Journal and connecting rod pins diameters 63 Main bearings and connecting rod big ends diameters 64 Oil bath air cleaner on request 29 Oil pan removal 52 Oil pump disassembly 42 Oil pump Reassembly 42 PISTON 52 Piston clearance
33. SAE 10W 60 SAE 15W 40 SAE 15W 40 SAE 20W 60 SAE 5W 30 SAE 0W 30 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 SAE 10W 50 35 40 SAE 5W 40 International specifications They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind A P I American Petroleum Institute MIL Engine oil U S military specifications released for logistic reasons ACEA European Automobile Manufacturers Association Tables shown on this page are of useful reference when buying a kind of oil Codes are usually printed out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics Usually a specification showing a following letter or number is preferable to one with a preceding letter or number An SF oil for instance is more performing than a SE oil but less performing than a SG one API MIL Sequences PETROL A1 Low viscosity for frictions reduction A2 Standard A3 High performances LIGHT DUTY DIESEL ENGINES B1 Low viscosity for frictions reduction B2 Standard B3 High performances indirect injection B4 High
34. 1st Oversized element Half rings 1 and 2 0 10 mm on both sides of the bearing 2nd Oversized element Half rings 1 and 2 0 10 mm on one side of the support and 0 20 mm on the other side 3rd Oversized element Half rings 1 and 2 0 20 mm on both sides of the bearing Crankshaft front and back oil seal rings Caution Warning An ambient temperature below 35 C may damage the rings The front oil seal ring 1 inserted into the oil pump cover and the back one 2 in the flywheel side flange If warped hardened or cracked replace them For the replacement Carefully clean the housing Keep the ring immersed in engine oil for about half an hour Drive it into its housing with a buffer exercising a uniform pressure on the whole front surface Be sure that the two surfaces A and B meet on the same level Refill the interior hollow with grease and lubricate the seal lip with thickened oil Note Before major engine overhaul in case of oil leakage in the seal area of rings 3 and 4 you can remedy this by replacing the rings and pushing them about 2 mm deeper with respect to the previous ones If the rings are black it means zones 3 and 4 of the crankshaft are tempered In this case it is necessary to remount a ring of the same colour If the rings are brown it means that zones 3 and 4 of the crankshaft are not tempered In this case it is necessary to remount brown coloured rings Disassembly Reassemb
35. Rocker arm assembly Remove the nuts attaching the rocker arm assembly to the cylinder head When refitting tighten the nuts at a torque of 40 Nm The pin that is hollow inside to allow lubrication is closed at its ends by two caps Note The rocker arm assembly may be removed without removal of the unit injectors Disassembly Reassembly 46 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 m m B C B C A 0 0 1 0 B 0 0 0 8 1 9 8 9 7 1 1 4 0 0 5 1 0 0 0 9 0 0 C 0 3 0 8 1 5 1 0 8 1 69 71 73 70 72 74 4 limit value Rocker arm pivot dismounting and remounting To remove pivot 1 from the support 2 it s necessary to drill out pin 3 using a 4mm drill bit On remounting insert a new pin and reinsert it in bearing surface A 0 to 1 mm Check the rod s state of wear and tear diam B and that of the rocker arm holes diam C Remove the closing caps 4 at the end and carefully clean inside Dimensions mm Camshaft disassembly Loosen the screws and remove the cover 1 Check gasket ring 2 for integrity Remove the drive rod from the fuel pump Gently remove the camshaft slight rotations may be required to avoid binding the camshaft lobes against the camshaft bearing surface bores Note The lift pump drive eccentric 3 is included on the flywheel end of the camshaft and fixed with a screw
36. In case of replacement tighten the eccentric screw at a torque of 80 Nm Camshaft journal and housing measurement Use an inside micrometer gauge for housing diameters and an outside micrometer gauge for journal diameters Disassembly Reassembly 47 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 A B B A B A 0 6 0 7 3 5 3 0 7 3 0 0 0 7 3 5 7 9 6 3 5 8 0 0 5 3 0 0 0 7 1 0 75 76 4 77 Camshaft journals and housings Dimensions mm Note The camshaft journal and cylinder head camshaft bore dimensions are identical for all LDW FOCS series engines LDW 502 602 702 903 1003 1204 1204 T 1404 limit value Camshaft lobe measurement Use an outside micrometer gauge Intake Exhaust Injection camshaft lobe height LDW 903 A1 1st cylinder intake camshaft lobe A2 2nd cylinder intake camshaft lobe A3 3rd cylinder intake camshaft lobe I1 1st cylinder injection camshaft lobe I2 2nd cylinder injection camshaft lobe I3 3rd cylinder injection camshaft lobe S1 1st cylinder exhaust camshaft lobe S2 1st cylinder exhaust camshaft lobe S3 1st cylinder exhaust camshaft lobe H 29 598 29 650 mm intake exhaust camshaft lobe height H1 28 948 29 000 mm injection camshaft lobe height For 1204 T H intake 29 438 29 490 mm H exhaust 29 778 29 830 mm All engines in the series except LDW
37. 0 7 D 0 0 9 2 0 2 0 3 5 4 5 4 0 3 5 4 T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 2 0 5 4 0 4 1 3 0 0 1 2 0 7 C 0 0 3 3 0 4 4 3 5 4 0 6 0 3 0 6 1 A B C D E 6 6 3 4 6 3 4 5 0 1 1 5 4 0 1 1 8 1 0 1 1 0 0 0 1 1 0 2 6 0 8 5 5 8 9 5 7 9 A B C 0 0 4 5 9 3 0 2 0 7 5 0 0 7 0 9 9 6 0 6 9 6 85 86 Valve specifications Exhaust valve A Shaft and head are made of 2 different materials 2 Welded joint 3 Chromium plated joint 4 Portion made of X 45 Cr Si 8 UNI 3992 5 Portion made of X 70 Cr Mn NI N 216 UNI 3992 Intake valve B Material X 45 Cr Si 8 UNI 3992 1 Chromium plated joint Valve guides and valve guide housings Both intake and exhasut valve guides are identical dimensionally and are made from phosphoric gray iron with a pearlitic matrix Dimensions mm Note Valve guides are supplied in finished form further machining is prohibited Valve guides with outside diameter B increased by 0 5 mm are available Valve guide insertion Fit the guides with a punch taking account of value A in relation to the cylinder head surface Dimensions mm Clearance mm B C 0 015 0 050 B C limite usura 0 10 Di
38. 156 Oil filter cartridge Components 1 Gasket 2 Plate 3 Rubber element 4 Spring 5 Filtering element 6 By pass valve 7 Spring Characteristics Maximum operating pressure 7 bar Maximum bursting pressure 20 bar Degree of filtration 15 By pass valve calibration 1 5 1 7 bar Total filtration surface 730 cm2 Total filtration surface for LDW 1204 engine 1450 cm2 Oil pressure check Once remounted fill the engine with oil fuel and coolant Remove the pressure switch fit a union and connect a 10 bar pressure gauge Start the engine and check how pressure is affected by oil temperature Nota With a maximum operating temperature of 120 C at 900 rpm the oil pressure must not be less than 1 bar Oil pressure regulating valve Components 1 Valve 2 Spring 3 Gasket 4 Screw cap Spring length 27 50 27 75 mm Blow the valve s seating with compressed air and carefully clean all the components before remounting them Nota The valve begins to open at a pressure of 4 5 5 5 bar Lubrification circuit 71 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 6
39. 186 187 Static injection advance tuning If the injection advance value found does not correspond to the previously described value adjust the screw E and repeat the test Rotating screw E by turn will change the injection advance by 5 If turned clockwise injection is advanced In the opposite direction injection is delayed Tester and special coupling for injection advance control Old type injection pump 1 Special coupling Serial number 7107 1460 028 2 Injection advance tester Serial number 7271 1460 024 Remove the cap on the pump injector casing and in its place screw on coupling 1 On this coupling tighten the tester 2 Note When reassembling the cap on the pump injector unit check its seal TDC Top Dead Center references D coincides with A TDC of 1st cylinder of all series engines of 4th cylinder LDW 1204 1204 T 1404 and of 2nd cylinder LDW 502 E coincides with A TDC of the 2nd cylinder LDW 903 1003 F coincides with A TDC of 2nd cylinder LDW 602 702 of 3rd and 2nd cylinder LDW 1204 1204 T 1404 G coincides with A TDC of 3rd cylinder LDW 903 1003 Note Following the arrow s rotation direction the combustion order for LDW 903 1003 is D G E 1st 3rd 2nd cylinder respectively As to LDW 1204 1204 T 1404 the sequence is D F D F 1st 3rd 4th and 2nd cylinder Injection advance references on timing belt protector The method of checking injection advance is
40. Important Non approval by Lombardini for any modifications releases the company from any damages incurred by the engine 21 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 LDW 502 LDW 602 LDW 903 2 Technical information OVERALL DIMENSION 22 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 LDW 702 LDW 1204 LDW 1204 T 2 Technical information 23 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 LDW 1003 LDW 1404 2 350 2 177 641 8 58 8 152 9 215 9 30 129 3 54 8 87 534 5 359 1 72 9 328 7 685 7 701 7 218 89 703 5 330 5 236 4 300 5 176 5 25 86 93 329 361 8 151 5 59 6 145 168 4 Technical information LDW 1003 with EGR circuit Gear box and CVT Continuous Variable Transmission 24 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 10 250 300 500 1000 5000 10000 300 250 3 Important Failure to carry out the operations described in the table may lead to technical damage to the machine and or system Engine oil replacement Oil filter replacement ORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING HOURS ORDINARY MAINTENANCE OPERATION DESCRIPTION FREQUENCY x HOURS CHECK REPLACEMENT OVERHAUL ENGINE OIL LEVEL COOLANT LEVEL AIR FILTER DRY TYP
41. When inserting the bearing in the camshaft do it so that the four blocks enter opened so that they can receive the hose and close over it Check the integrity of the sealing rings of the cover Tighten the three screws at a torque of 10 Nm Note With the speed governor mounted the camshaft axial clearance should be zero Disassembly Reassembly 42 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 51 52 53 54 4 Oil pump Reassembly The pump rotors should be coupled on the same side see references 2 and 3 Replace the O ring 1 Tighten the fastening screws to the crankcase at 25 Nm and those of the plate at 10 Nm See page 69 for technical details Oil pump disassembly The FOCS oil pump is supplied as an assembly Lombardini therefore recommends that the oil pump be handled as an assembly from a service standpoint Lombardini does not recommend that the oil pump be disassembled then reassembled for purposes of installation on the engine except during emergency situations Rotate the crankshaft until the crankshaft timing pulley keyway is vertical as shown Remove the oil pump assembly retaining bolts When the crankshaft timing pulley keyway is vertical the oil pump drive keyway A will be at 3 00 o clock allowing removal of the oil pump assembly via relief B Rocker arm cover The engine control components are all on the cylinder head The cover contains part of the lubrication duct
42. value replace piston and rings Note The provided oversize elements are of 0 50 mm and 1 00 mm Piston class The pistons are subdivided according to their diameters into categories A B C These references are shown on the top of the piston see fig 100 Piston supply Pistons at the nominal diameter are only supplied in category A Pistons oversized by 0 50 and 1 00 mm are supplied with reference to the increased level on the piston crown 72 5 73 for LDW 502 602 906 1204 1204 T engines and 75 5 76 0 for LDW 702 1003 1404 engines Class Cylinder mm Piston mm Clearance mm Class Cylinder mm Piston mm Clearance mm Disassembly Reassembly 54 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 A 1 5 4 0 5 2 0 0 1 2 5 4 0 5 2 0 3 5 4 0 0 2 0 105 4 106 107 A 5 2 1 0 0 9 0 0 B 5 8 0 0 0 5 0 0 C 5 7 0 0 0 4 0 0 104 limit value Piston ring Piston rings End gaps mm Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap A Piston ring Clearance between grooves mm Piston weight Weigh pistons when replacing them in order to avoid unbalance Important The difference in weight should not exceed 4 g Disassembly Reassembly 55 FOCS Workshop Manual_cod 1 5302 351_7
43. 0 3 2 5 2 3 0 5 1 specifications PRESCRIBED LUBRICANT In the countries where AGIP products are not available use oil API CF SH for Diesel engines or oil corresponding to the military specification MIL L 2104 C 46152 D CHD ENGINES OIL CAPACITY OIL VOLUME AT MAX LEVEL OIL FILTER INCLUDED OIL VOLUME AT MAX LEVEL WITHOUT OIL FILTER Litres Litres Sheet STD oil sump ENHANCED aluminium oil sump Sheet STD oil sump ENHANCED aluminium oil sump With dynamic balancer Important If you are using oil of a quality lower than the prescribed one then you will have to replace it every 125 hours for the standard sump and every 150 hours for the enhanced sump Danger Attention The engine may be damaged if operated with insufficient lube oil It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion Use proper lube oil preserve your engine Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly Always use oil with the right viscosity for the ambient temperature in which your engine is being operated Danger Attention The used engine
44. 0 3 2 0 7 2 0 6 1 1 4 4 0 1 2 6 6 0 0 3 6 1 6 6 0 0 3 8 8 0 3 3 3 0 0 1 3 0 9 1 1 4 4 0 1 2 6 6 0 0 3 6 1 6 6 0 1 3 8 8 0 3 3 4 0 4 1 4 0 2 1 1 1 4 4 0 1 2 6 6 0 0 3 6 1 6 6 0 0 3 8 8 0 3 3 T 4 0 2 1 1 1 5 5 5 5 2 6 6 0 0 3 6 1 6 6 0 0 3 8 8 0 3 3 196 9 Electric starting layout 12V with Iskra alternator 14V 33A 1 Alternator 2 Starter Motor 3 Battery 4 Glow Plugs 5 Coolant temperature thermistor 6 Glow Plug Controller Timer 7 Key Switch 8 System Fuse 30A for LDW 502 602 702 50 A for LDW 903 1003 80 A for LDW 1204 1204 T 1404 9 Fuse Accessory 5A 10 Fuel Solenoid Valve 11 Glow Plug Indicator Lamp 12 Coolant High Temperature Lamp 13 Coolant High Temperature Switch 14 Oil Pressure Low Lamp 15 Oil Pressure Switch 16 Alternator Charging Lamp 17 Air Filter High Restriction Indicator Lamp 18 Air Filter Restriction Switch 19 Low Fuel Level Lamp 20 Low Fuel Level Switch A Accessory Position B Off Position C On Position D Starting Position Note Battery 3 not supplied by LOMBARDINI For assembly we recommend a battery with the following characteristics see table below Engine type Starter motor class epicyclic type Kw Capacity K20 Ah Rapid discharge intensity DIN Standards at 18 C A Capacity K20 Ah
45. 1003 1204 T 1404 B D 0 015 0 039 B D limit value 0 060 Nota When driving the small end bearing make sure both oilholes are aligned Connecting tod weight Weigh connecting rods when replacing them in order to avoid unbalance Important The difference in weight should not exceed 10 g The difference in weight of the pre assembled connecting rod piston and pin must not exceed 14 g Disassembly Reassembly 59 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 120 121 4 122 124 125 123 Connecting rod alignment Utilizzare un calibro con piano di riscontro o un comparatore come in figura Controllare l allineamento degli assi utilizzando lo spinotto del pistone lo scarto A 0 015 mm limite 0 030 mm Piccole deformazioni si possono correggere sotto una pressa agendo con sforzi graduali CYLINDERS Reset the dial gauge with a calibrated ring check the diameter D in points 1 2 and 3 repeat the same operation rotating the dial gauge by 90 at the same heights Check any wear in zone X where the piston rings operate and if it is greater than the 0 05 mm max limit given adjust the cylinder to the next increased value 72 000 mm for LDW 502 602 903 1204 1204 T engines 75 000 mm for LDW 702 1003 1404 engines Cylinder roughness Caution Warning Do not treat the cylinder s internal surfaces with an emery cloth The angle of the crossed processing marks must be between
46. 1204 T engine 5 Thermostat for liquid temperature indicator COOLANT CIRCUIT Danger Attention The coolant circuit is pressurised Do not check it before the engine has cooled down and also in that case open the radiator cap or expansion tank plug with caution When there is an electric fan do not approach a hot engine because it could also come on with the engine off The liquid coolant is a pollutant and therefore must be disposed of with care according to environmental provisions COOLANT CIRCUIT 73 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 160 161 162 163 7 Radiator and compensation check and seal tank cap Remove the cap from compensation tank cap and check that the liquid is at the correct level Replace the cap with a new one provided with hand air pump socket Compress air at a pressure of 1 bar for about two minutes Check that there are no drips in the radiator The tank cap is supplied with a vacuum relief valve 1 and an overpressure valve 2 Overpressure valve opening pressure of 0 7 bar Thermostatic valve 1 Stainless steel or brass casing 2 Wax bulb 3 Air relief hole Characteristics Opening temperature 83 87 C Max stroke at 94 C 7 mm Liquid recycling 30 80 l h Coolant circulation pump components 1 Rotor 2 Front seal gasket 3 Pump casing 4 Exhaust hole 5 Bearing 6 Pulley 7 Shaft Not
47. 3 5 3 A 5 5 B 3 0 2 0 0 2 C 3 5 1 0 5 1 D 0 0 0 1 E 6 9 F 7 0 173 174 175 Pumping element old type injection pump 1 Plunger 2 Upper plunger section 3 Plunger barrel 4 Delay notch 5 Control slot Dimensions mm Pumping element 1 Plunger 2 Upper plunger section 3 Plunger barrel 4 Delay notch 5 Control slot Pump injector unit se no 6590 285 control data 1 Delivery control lever on stop position 2 Delivery control lever on maximum delivery position Injector setting pressure 140 155 bar Rpm rating is that of the crankshaft nominal value inlet hole diameter outlet hole diameter Rod stroke form max delivery position mm start position mm3 stroke Rpm Aluminium crankcase INJECTION PUMP Dimensions Fuel system 78 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 231 2 272 0 235 2 272 272 1 272 272 235 4 235 4 235 3 235 4 6590 262 6590 283 6590 235 6590 272 6590 285 6590 286 6590 307 6590 290 6590 287 6590 290 502 602 903 1204 502 MINI CAR 1204 T 502 602 903 1204 502 602 903 1204 502 MINI CAR 1204 T 702 1003 1404 11 13 11 13 4 6 8 10 8 10 lt 2999 g min 12 14 gt 3000 g min 11 13 6 8 8 10 lt 2999 g min 12 14 3000 360
48. 5 22 4 67 0 2000 37 1800 300 0 013 87 1850 63 300 35 25 LDW 1404 4 75 77 6 1372 22 8 1 3600 26 0 35 2 24 5 33 3 22 4 30 5 84 0 2000 37 1800 325 0 019 98 2470 88 300 35 25 LDW 702 LDW 1003 LDW 1404 2 Technical information Cylinders Bore Stroke Displacements Compression rate Rpm N 80 1269 CEE ISO 1585 DIN 70020 Maximum power NB ISO 3046 1 IFN DIN 6270 NA ISO 3046 1 ICXN DIN 6270 Maximum torque Maximum Torque Available N 3 PTO 3600 Rpm Specific fuel consumption Oil consumption Dry weight of engine Combustion air volume at 3600 Rpm Cooling air volume at 3600 Rpm Axial load allowed on crankshaft both directions Instant operation up to 1 min Max tilt Intermittent operation up to 30 min Permanent operation At NB power Referred to NB power Measured at NA power Depends on application At 3600 Rpm Measured at NB power ENGINE TYPE 18 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 LDW 502 LDW 602 LDW 903 2 Technical information PERFORMANCE DIAGRAMS N DIN 70020 Automotive rating intermittent operation with variable speed and variable load NB DIN 6270 Rating with no overload capability continuous light duty operation with constant speed and variable load NA DIN 6270 Continuous rating with overload capability continuous heavy duty wi
49. 6 1 0 8 4 5 5 0 8 4 D m m 0 5 0 0 4 1 2 0 0 4 0 0 1 0 4 4 0 4 1 3 0 0 1 2 0 7 W D L C m m 9 5 0 1 5 3 2 0 1 5 8 9 0 1 5 D m m 0 5 0 0 4 1 2 0 0 4 0 0 1 0 4 T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 2 0 5 W D L A C m m 4 7 0 0 2 2 0 0 0 0 2 0 B D m m 6 6 0 0 1 2 0 0 0 3 1 0 4 0 4 1 3 0 0 1 2 0 7 W D L A C m m 8 7 0 0 3 2 0 0 0 0 2 0 B D m m 6 6 0 0 1 2 0 0 0 3 1 0 143 4 144 Clearances between the bearings and corresponding pins See figures 143 144 Dimensions mm Nota Both for crankshaft bearings and for connecting rod big end bearings internal diameter are undersized by 0 25 and 0 50 mm Main bearings and connecting rod big ends diameters Dimensions mm The dimensions given refer to tightened bearings For tightening torque see figures 116 e 126 Ref Ref Tolerance Tolerance Ref Clearance Ref Clearance Limit value Limit value Disassembly Reassembly 65 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 145 146 4
50. 62 64 61 63 4 Valve Rocker arm clearance Important Setting should be performed when the engine is cold Bring each cylinder piston to top dead center on the compression stroke and set clearance A at 0 20 mm for both the intake and exhaust valves For greater convenience clearance check B is accepted In this case the value is 0 15 mm Crankcase breather LDW 502 For LDW 602 702 903 1003 1204 1204 T 1404 engines the exhaust gases exit from the cylinder head cover see Fig 53 54 In the LDW 502 engine the exhaust gases exit directly from the crankcase via cover 1 Remove the cover check the integrity of the air valve and oil decanting wire gauze Fuel rail When removing the fuel feeding pumps A with the rail holders B pay attention that the sealing O rings C remain in their seats When refitting tighten the rail holder screws at a torque of 4 Nm Injection pump control rod Depending on the engine model the injection pump control rod will link two three or four injectors to the engine governor Screws 1 and 2 are pivoted on the delivery control lever of each pump injector B unscrew the screws and remove spring 3 When refitting tighten the screws 1 and 2 at a torque of 1 1 Nm and make sure that they stop on lever B of each pump injector and not on rod A To carry out the delivery equalisation of the injection pumps see page 83 To carry out the timing of the injection pumps and speed governor
51. BE STOPPED IMMEDIATELY WHEN 1 The engine rpms suddenly increase and decrease 2 A sudden and unusual noise is heard 3 The colour of the exhaust fumes suddenly darkens 4 The oil pressure indicator light turns on while running TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation Always perform these simple checks before removing or replacing any part TECHNICAL INFORMATION Clogged fuel pipes Clogged fuel filter Air or water in the fuel circuit Tank cap breather blocked Faulty fuel pump Lack of fuel Excessive valve clearances Absence of valve clearances Incorrect speed governor leverages Speed governor spring broken or disengaged Idle low Worn out or stuck rings Worn out cylinders Worn out valve guides Bad valve seal Bearing shells of bearing cap piston rod rocker worn out E G R valve blocked open Governor leverages not running Cylinder head gasket damaged Faulty timing system Supplementary starter spring broken or disengaged Clogged air filter Prolonged operation at idle Incomplete run in Overloaded engine Glow plug fuse burned Faulty glow plug control relay Flat battery Unclear or mistaken cable connection Faulty starter switch Faulty starting motor Faulty glow plugs Engine overheats Oil and fuel dripping from the exhaust Excessive oil consumption Oil level increase Oil p
52. Marelli type AA 125 R 14V 45A alternator 88 Flywheel Alternator 88 Oil pressure switch 93 Pre heating glow plug 92 Pre heating glow plug control unit with coolant temperature sensor 92 STARTER MOTOR Bosch DW 12V 1 1 KW 91 Starter motor Bosch 12V 1 6 Kw 91 Starter motor Bosch DW 12V 1 1 KW Performance Curve 91 Starter motor Bosch DW 12V 1 6 KW Performance Curve 92 Temperature sensor for control unit
53. Rapid discharge intensity DIN Standards at 18 C A Normal starting conditions Heavy duty starting conditions max allowed Electric System 87 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 9 197 198 Alternator Marelli type AA 125 R 14V 45A Characteristics Nominal voltage 14V Nominal current output 45A Maximum Rpm 14000 giri 1 Maximum peak Rpm for 15 15000 giri 1 Bearing Pulley End 6203 2Z Bearing Voltage Regulator End 6201 2Z C3 Voltage regulator RTT 119 A Rotation viewed at puley end Clockwise Note Use only high temperature grease when servicing bearings Tighten nut 1 at a torque of 60 Nm Alternator Marelli type AA 125 R 14V 45A Performance Curve The curve was obtained at room temperature of 25 C with a costant 13 V battery voltage P1 Power Output KW I Current Output Amps Efficiency Note The RPM shown is that of the alternator The value of the rpm axis must be multiplied by 1000 Alternator speed is a function of engine speed and the crankshaft pulley diameter If the engine pulley is 88 mm then the alternator speed ration is 1 3 1 If the engine pulley is 108 mm then the alternator speed ratio is 1 6
54. apply some Moly slip antiseizure compound on the screw thread and tighten at 360 Nm Note When pulley reference mark A aligns with the timing cover reference mark B the flywheel side piston is at TDC Disassembly Reassembly 35 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 25 26 27 Ringfeder type rings on LDW 1204 1204 T 1404 It is possible to draw of the power from the second drive of LDW 1204 1204 T 1404 engines If you want to draw the entire power it is necessary to mount the Ringfeder rings on the crankshaft handle Components 1 Puleggia appropriata 6 Ringfeder external ring 2 Screw M6 7 Spacer flange 3 Screw M16 x 1 5 8 Shoulder plate 4 Ringfeder internal ring 9 Crankshaft 5 Screw M8 Ringfeder type rings on LDW 1204 1204 T 1404 Assembly Refer to figures 25 and 26 Clean and oil the parts involved in the mounting with engine oil Insert into pulley 1 the internal ring 4 and the external ring 6 then flange 7 by tightening it temporarily with its screws Before assembling the pulley 1 in the crankshaft taper insert shoulder ring 8 Lock the crankshaft using tool 7107 1460 051 Tighten the screws 2 at a torque of 10 Nm Tighten the screws 3 at a torque of 360 Nm Tighten the screws 5 uniformly in criss cross pattern in three distinct phases 1 phase 15 Nm 2 phase 35 Nm 3 phase torque check Timing belt cover Loosen the five screws and remove th
55. at a standstill Only clean the coolant system when the engine is at a standstill When cleaning the oil cooled air filter make sure that the old oil is disposed of in the correct way in order to safeguard the environment The spongy filtering material in oil cooled air filters must not be soaked in oil The reservoir of the separator pre filter must not be filled with oil The oil must be drained whilst the engine is hot oil T 80 C Particular care is required to prevent burns Do not allow the oil to come into contact with the skin Pay attention to the temperature of the oil filter when the filter itself is replaced Only check top up and change the coolant fluid when the engine is off and cold Take care to prevent fluids containing nitrites from being mixed with others that do not contain these substances since Nitrosamine dangerous for the health can form The coolant fluid is polluting and must therefore be disposed of in the correct way to safeguard the environment During operations that involve access to moving parts of the engine and or removal of rotating guards disconnect and insulate the positive wire of the battery to prevent accidental short circuits and to stop the starter motor from being energized Only check belt tension when the engine is off Only use the eyebolts installed by LOMBARDINI to move the engine These lifting points are not suitable for the entire machine in this
56. case the eyebolts installed by the manufacturer should be used General remarks and safety information GENERAL SAFETY DURING OPERATING PHASES The procedures contained in this manual have been tested and selected by the manufacturer s technical experts and hence are to be recognised as authorised operating methods A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual Holes must be lined up methodically and with the aid of suitable equipment Do not use your fingers to carry out this operation to avoid the risk of amputation Some phases may require the assistance of more than one operator If so it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved Do not use flammable liquids petrol diesel etc to degrease or wash components Use special products Use the oils and greases recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities aris
57. ed_ rev 06 Timing belt removal 36 Vacuum pump and vacuum pump flange 33 Valve Rocker arm clearance 44 Valve guide insertion 49 Valve guides and valve guide housings 49 Valve recess and seat sealing width 50 Valve seats and housings Dimensions 50 Valve springs 48 Valve stem sealing rings Reassembly
58. from zero adjust the regulator block nuts to move it in relation to the rod 3 in the direction that goes from the flywheel to the timing With the brake at a braking curve N constant load the engine slowing it down to 2 800 rpm Acting on the accelerator look for the E G R valve closing point pressure of the vacuum pressure gauge or mercury gauge equal to zero Note Pay attention to determine the precise closing point by slightly accelerating the engine the vacuum value in the E G R operation pipe should immediately increase Measure the engine consumption in order to calculate the mm3 stroke value If the calculated value is less than 18 8 mm3 stroke adjust the adjusting nut making it closer to the end of the rod 3 to increase the calibration When the required value of 18 8 mm3 stroke has been reached and a power of around 7 KW tighten the adjusting nuts Settings 98 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 11 If the engine is not to be used for long periods check the storage environment the type of packaging and make sure these conditions will allow proper maintenance If necessary cover the engine with protective sheeting Do not store the engine directly on the ground in damp environments in areas exposed to the elements near sources of danger including less visible hazards such as high voltage power lines etc Caution Warning If the engine is not to be
59. gearing device allows to be carried out by lever L will increase the injection pump delivery and the torque will hit its maximum value Important The stroke H varies depending on which engine torque gearing device is fitted on the engine Settings 96 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 w K h w K g 2 0 5 0 0 2 2 1 5 5 3 8 1 2 9 1 9 9 2 5 8 2 0 0 6 3 2 7 7 5 1 1 0 2 1 0 4 3 6 2 3 2 0 6 0 0 2 2 5 3 7 7 4 1 5 5 1 9 7 2 5 6 2 0 0 6 3 2 9 9 9 8 3 9 0 4 3 6 2 3 3 0 9 0 0 2 2 8 0 1 1 9 9 5 0 1 4 7 2 1 6 2 0 0 6 3 6 0 5 1 8 5 0 6 2 4 3 8 2 3 4 0 2 1 0 0 2 2 8 7 4 1 5 7 9 7 2 7 2 8 5 2 0 0 6 3 2 2 0 2 4 4 8 5 4 0 4 3 6 2 3 T 4 0 2 1 0 0 6 3 0 5 9 2 5 3 6 3 0 9 2 4 8 2 224 10 Pump injector unit delivery setting with braked engine 1 Run the engine to the maximum speed 2 Screw flow limiter C see fig 219 3 Load the engine up to the power and number of revs required by the application s manufacturer 4 Check that consumption is within the values allowed for in the settings table see below If consumption is not within the given figures it is necessary to change the balance conditions shown to t
60. holes N of holes Piston clearance 1 hole 2 holes 3 holes N of notches Piston clearance 1 notch 2 notches 3 notches Disassembly Reassembly 57 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 113 114 115 Cylinder head assembly Use a torque wrench equipped with a device for angular tightening Measure the length of each screw normal length 89 5 90 5 mm Replace it if it exceeds 92 mm Proceed as follows Cylinder head tightening procedure LDW 1204 1204 T 1404 Following the numerical order shown in the diagram the bolts must be tightened in three phases 1st phase 50 Nm 2nd phase Rotate the wrench 90 in a clockwise direction 3rd phase Rotate the wrench again 90 in a clockwise direction Cylinder head tightening procedure LDW 502 602 702 903 1003 Important Once the head has been correctly tightened it should not be retightened except if it is disassembled again Before mounting it is advisable to lubricate stem shank and underhead of screws with SPARTAN SAE 460 oil A For LDW 502 602 702 models B For LDW 903 1003 models Following the numerical order shown in the diagram the bolts must be tightened in three phases 1st phase 50 Nm 2nd phase Rotate the wrench 90 in a clockwise direction 3rd phase Rotate the wrench again 90 in a clockwise direction For LDW 502 with pressure cast aluminium crankcase With head H tightening bolts 1st
61. of the camshaft and of the rocker arms as well as part of the engine vent system Components 1 Oil preassure switch 2 Camshaft lubrification port 3 Rocker arm lubrification port 4 Oil exhaust hose from sump vent system 5 Air valve with oil decanting wire gauze Note During remounting be careful with oil exhaust hose 4 that needs to be properly inserted into its housing on the cylinder head Disassembly Reassembly 43 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 55 4 56 57 58 Rocker arm cover gasket The rocker arm cover gasket A ensures the seal of the lubrication circuit for the camshaft and rocker arm shaft Always replace it and mount it with especial care above all in zones 1 and 2 where for greater safety it is advisable to apply a few drops of silicon sealant Tighten the rocker arm cover screws at a torque of 9 Nm Crankcase vacuum regulator valve Components 1 Gland Nut 2 Bushing 3 Body 4 Diaphragm 5 Cap Cover 6 Clip Lock 7 O Ring 8 Washer 9 O Ring 10 Valve 11 Spring 12 Tube 13 Hose The vacuum relief valve is an engine safety device Its function is that of limiting the vacuum whenever it tends to increase Without this should the air filter be clogged the oil contained in the carter may be sucked back into intake manifold causing the condition for engine runaway Disassembly Reassembly 44 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 59 60
62. page 80 shows both piston lowering expressed in mm with respect to the TDC and the corresponding rotation of the crankshaft expressed in degrees The static injection advance in degrees 11 to 13 refers to all engines for adjustments from 1500 3600 rpm Test head B assembly Remove fuel pipe A and mount one test head B in its place per pump injector The test heads complete with pipes are supplied together with instrument ref 7104 1460 069 Preliminary steps to pump injector unit delivery balancing test Closing the oilhole To perform this test you must remove the rocker arms cover and close hole 1 with an M 8x1 25 or M 10x1 5 screw on latest model engines not longer than 8 mm Also remove the copper gasket If the camshaft and rocker arms are dry lubricate them with engine oil Note If you only want to check the nozzle it is not necessary to balance the deliveries provided that when you dismount the rod you do not loosen adjusting screws 1 and 2 fig 193 Fuel system 83 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 8 192 193 Injection pumps delivery balancing In case the balancing error read on the test pieces is greater than 2 cm min then injection pumps deliveries should be adjusted Plate 4 and rod 3 are blocked by screws 1 and 2 Loosen them Move plate 4 rightwards with respect to rod 3 if you want to increase delivery If moved leftwards delivery decreases Make very s
63. see page 95 Disassembly Reassembly 45 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 0 2 1 3 0 9 2 0 6 2 0 5 W D L B D E 5 8 1 0 1 0 6 5 2 5 1 7 0 7 T 4 0 2 1 W D L B D E 5 1 1 5 0 5 6 5 9 5 1 7 0 7 65 66 4 67 68 Pump injector unit non return valve Non return valve A immediately stops the engine whenever the stop is activated Dimensions mm Note If the value of B is not achieved the two rings C are not subject to enough compression to ensure the seal any fuel loss would contaminate the lubrication oil and consequently damage the engine F metal gasket Pump injector unit Disassembly When the removal but not replacement of a unit injector is required the following procedure may be used to avoid the need for other adjustments Rotate the engine until the unit injector cam lobe 2 forces the cam follower 1 to the highest position then insert a suitable sized hardened pin into the hole 3 and rotate the engine until the cam follower 1 is at the lowest position In this way the injection advance regulator 4 remains calibrated Note If you dismount more than one pump injector unit make sure to reinstall them in the appropriate housing with relative drive rod 5 before mounting lubricate the drive rod at its two ends with MOLYSLIP AS COMPOUND 40 type
64. testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 5 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C above 25 C Note Consult LOMBARDINI for power torque curves and specific consumptions at rates differing from those given above Important Non approval by Lombardini for any modifications releases the company from any damages incurred by the engine 20 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 LDW 702 LDW 1003 LDW 1404 2 Technical information N DIN 70020 Automotive rating intermittent operation with variable speed and variable load NB DIN 6270 Rating with no overload capability continuous light duty operation with constant speed and variable load NA DIN 6270 Continuous rating with overload capability continuous heavy duty with constant speed and constant load C NB Specific fuel consumption at NB power Mt Torque at N a Range of application for continuous operation In case of application outside this range please contact LOMBARDINI The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 5 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C above 25 C Note Consult LOMBARDINI for power torque curves and specific consumptions at rates differing from those given above
65. used for more than 1 month it is necessary to apply protective measures that are valid for 6 months see Protective treatment Important If after the first 6 months the engine is still not to be used it is necessary to carry out further measures to extend the protection period see Protective treatment 1 Check that the engine oil and coolant are up to level 2 Fill up with fuel containing 10 AGIP RUSTIA NT 3 Run the engine at minimum idle speed for 15 minutes 4 Switch off the engine 5 Remove the lubrication oil 6 Fill the sump with protective oil AGIP RUSTIA C 7 Start the engine and check for fuel and oil leaks 8 Bring the engine to of the maximum speed for 5 10 minutes 9 Switch off the engine 10 Empty the fuel tank completely 11 Spray SAE 10W oil on the exhaust and intake manifolds 12 Close all openings to prevent foreign bodies from entering 13 Thoroughly clean all external parts of the engine using suitable products 14 Treat non painted parts with protective products AGIP RUSTIA 100 F 15 Loosen the alternator fan belt 16 If necessary cover the engine with protective sheeting Caution Warning In countries in which AGIP products are not available find an equivalent product AGIP RUSTIA NT MIL L 21260 P10 grade 2 AGIP RUSTIA C MIL L 644 P9 AGIP RUSTIA 100 F MIL C 16173D Important After a year of engine inactivity the coolant loses its properties and must
66. 0 g min 13 14 gt 3600 g min 8 176 Lombardini injection system is being steadily implemented seeking the best performance of its engines For this reason the pump injector body has been modified three times in the course of its evolution Three different pump injectors are shown in the top figure Old type injector pump it is characterised by its high pressure hole Intermediate injector pump is characterised by not having the high pressure hole the hole can be there but it is only used to control the injector and injection advance and by the locating peg between inlet and outlet holes Current pump injector it is characterised by its offset inlet and outlet holes These are also oversized due to the absence of the high pressure hole REFERENCE N CODE N ENGINE TYPE INJECTION ADVANCE VALUE SPECIAL TOOLS LOCATING PEG OFFSET HOLES HIGH PREASSURE HOLE REFERENCE NUMBER OLD TYPE INJECTOR PUMP INTERMEDIATE INJECTOR PUMP CURRENT PUMP INJECTOR ADVANCE 1460 028 1460 024 INJECTOR SETTING 1460 028 T D C 1460 048 ADVANCE 1460 028 1460 024 INJECTOR SETTING 1460 028 T D C 1460 048 ADVANCE 1460 028 1460 024 INJECTOR SETTING 1460 028 T D C 1460 048 ADVANCE 1460 05
67. 1 Electric System 88 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 199 200 9 Electric starting layout 12V with Marelli type AA 125 R 14V 45A alternator 1 Alternator 2 Starter Motor 3 Battery 4 Glow Plugs 5 Coolant temperature thermistor 6 Glow Plug Controller Timer 7 Key Switch 8 System Fuse 30A for LDW 502 602 702 50 A for LDW 903 1003 80 A for LDW 1204 1204 T 1404 9 Fuse Accessory 5A 10 Fuel Solenoid Valve 11 Glow Plug Indicator Lamp 12 Coolant High Temperature Lamp 14 Oil Pressure Low Lamp 15 Oil Pressure Switch 16 Alternator Charging Lamp 17 Diode 18 Air Filter Restriction Switch 19 Air Filter Restriction Switch 20 Low Fuel Level Lamp 21 Low Fuel Level Switch A Accessory Position B Off Position C On Position D Starting Position Note Battery 3 not supplied by LOMBARDINI for battery characteristics see page 89 Flywheel Alternator 12V 20A with three cables at output 12V 30A with two cables at output 1 Flywheel 2 Ring gear 3 Magnet ring Rotor 4 Stator Electric System 89 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 9 201 202 Alternator battery charger curve 12V 20A three cables at output This curve is obtained at 20 C The statistical charging output of the flywheel alternator is 10 to 5 of the values shown Alternator battery charger curve 12V 30A two cables at output This curve is obtained at 20 C The statis
68. 1 7 8 0 9 5 0 1 5 0 1 1 1 1 3 3 7 0 1 9 8 0 0 3 9 0 0 1 6 0 6 0 7 3 7 0 9 6 7 0 9 1 9 4 0 7 9 5 0 3 2 6 0 8 8 8 3 0 2 7 4 0 3 9 4 0 7 7 9 2 0 2 6 3 0 8 7 3 0 6 8 1 2 0 6 6 2 0 7 7 2 0 182 183 8 2 0 6 2 0 5 4 0 2 1 3 0 9 5 8 2 0 9 5 6 1 2 7 2 9 9 9 2 0 0 5 1 0 1 8 2 0 6 2 0 5 4 0 2 1 3 0 9 5 8 2 0 9 5 6 1 2 7 2 0 0 0 3 gt 4 1 2 1 2 0 5 7 0 3 0 9 5 6 2 7 2 0 0 6 3 0 0 0 3 2 1 0 1 3 0 0 1 2 0 7 4 0 4 1 0 9 2 0 9 5 6 4 5 3 2 9 9 9 2 0 0 5 1 0 1 8 3 0 0 1 2 0 7 4 0 4 1 0 9 2 0 9 5 6 4 5 3 2 0 0 6 3 0 0 0 3 4 1 2 1 3 0 0 1 2 0 7 4 0 4 1 0 9 2 0 9 5 6 4 5 3 2 0 0 6 3 gt 5 1 3 1 T 4 0 2 1 0 9 2 0 9 5 6 4 5 3 2 0 0 6 3 0 0 5 1 8 6 Injection advance control and regulation Dismount the rocker arm cover see page 40 Position the device on the head in contact with cylinder no 1 Mount the dial gauge on the valve controlled by tool ref 1460 048
69. 1204 T have intake exhaust and injection cams with the same height of H and H1 If wears on the cams exceeds by 0 1 mm the minimum value given H and H1 replace the crankshaft Disassembly Reassembly 48 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 78 79 81 80 82 4 83 CYLINDER HEAD removal Important Do not remove the cylinder head when hot to avoid deformation lf cylinder head is deformed by more than 0 10 mm level it off by removing a maximum of 0 20 mm For the cylinder head tightening procedure see page 57 Valves To remove the valves it is necessary to remove the collets place a spacer under the valve head press strongly on the spring cap as shown in the picture Components 1 Valve stem 2 Valve stem seal ring 3 Spring seat 4 Spring 5 Spring cap 6 Collets Valve stem sealing rings Reassembly To prevent deformation of the sealing ring 1 as it is inserted onto the valve guide insert it onto tool 7107 1460 047 2 after lubricating the sealing ring and proceed as shown int the picture ensuring that gasket 1 is completely fitted Valve springs Measure free height with a gauge Free height A 46 mm Note If the free height A is less than 43 5 mm replace the spring Disassembly Reassembly 49 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 84 T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 2 0 5 4 0 4 1 3 0 0 1 2
70. 3 40 63 98 135 193 260 333 500 680 Nm 0 9 1 8 3 8 6 3 16 31 54 84 131 181 256 344 444 656 906 Nm 1 2 2 4 5 7 5 19 37 65 101 158 218 308 413 533 788 1088 Nm 1 4 2 9 6 10 25 49 86 135 210 290 410 550 710 1050 1450 4 6 4 8 5 6 5 8 6 8 8 8 10 9 12 9 Nm 0 5 1 1 2 3 3 8 9 4 18 32 51 79 109 154 206 266 394 544 Nm 1 9 4 1 8 5 14 35 69 120 190 295 405 580 780 1000 1500 2000 Nm 2 3 4 9 10 17 41 83 145 230 355 485 690 930 1200 1800 2400 R gt 400N mm2 R gt 500N mm2 R gt 600N mm2 R gt 800N mm2 R gt 1000N mm2 R gt 1200N mm2 Nm 10 21 20 36 38 56 84 122 117 173 164 229 293 431 600 Nm 14 28 26 48 45 75 113 163 157 230 218 305 390 575 800 Nm 13 26 24 45 42 70 105 153 147 213 204 287 367 533 750 Nm 17 35 33 59 56 94 141 203 196 288 273 381 488 719 1000 Nm 20 42 39 71 68 113 169 244 235 345 327 458 585 863 1200 Nm 27 56 52 95 90 150 225 325 313 460 436 610 780 1150 1600 Nm 38 79 73 135 125 210 315 460 440 640 615 860 1100 1600 2250 Nm 45 95 88 160 150 250 380 550 530 770 740 1050 1300 1950 2700 4 6
71. 32 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 15 16 13 14 2 1 1 1 Exhaust maniflod Danger Attention Let the exhaust manifold cool before dismounting to avoid scalds and burns When you dismount the exhaust manifold check that the inside is properly clean and free from cracks or breaks Replace gaskets every time you remove the manifold Tighten nuts at 25 Nm Vacuum pump and vacuum pump flange Unscrew the three fastening screws 1 that fix the vacuum pump to the flange and remove the vacuum pump Unscrew the fastening screws that fix the flange to the engine crankcase and remove it Components 1 Vacuum pump 2 Clic clamp 86 50 3 Vacuum pump flange 4 Vacuum pump gasket 5 Vacuum pump flange gasket 6 Three way union for vacuum pump 7 Vacuum pump pipe 8 Screw 9 Screw When reassembling tighten the screws 8 that fix the flange to the cylinder head to the specified torque of 10 Nm and the screws 9 that fix the vacuum pump to the flange at the specified torque of 15 Nm Exhaust manifold engines with EGR Remove the E G R pipe 1 Unscrew the locking nuts 2 and remove the exhaust manifold and the seal Note When reassembling the exhaust manifold check that the inside is properly clean and free from cracks or breaks Note Replace the gasket each time the manifold is reassembled Tighten the nuts at the prescribed torque of 25 Nm Disassembly Reass
72. 4 8 5 6 5 8 6 8 8 8 10 9 12 9 12 M 8x1 M 10x1 M 10x1 25 M 12x1 25 M 12x1 5 M 14x1 5 M 16x1 5 M 18x1 5 M 18x2 M 20x1 5 M 20x2 M 22x1 5 M 24x2 M 27x2 M 30x2 Table of tightening torques for standard screws coarse thread Resistance class R Quality Dimensions Diameter Resistance class R Quality Dimensions Diameter Table of tightening torques for standard screws fine thread Torque specifications and use of sealant 102 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 7107 1460 127 7107 1460 030 7271 1460 024 7107 1460 053 7107 1460 029 7107 1460 027 7107 1460 031 7107 1460 028 7107 1460 047 7107 1460 048 7107 1460 049 7107 1460 051 7107 1460 056 7107 1460 074 13 Injection pumps delivery balancing instrument Precombustion chamber extractor Injection pump static injection advance tester old type Sheet metal for insertion of main bearings in the crankcase Ring nut wrench for fastening pump injector pumping element Precombustion chamber wrench Precombustion chamber adjusting rod Coupling for static injection advance control and setting of old type injection pumps injector Device for mounting valve guide gasket intake and exhaust side Valve lowering device for injection advance control Timing belt tightening tool Crankshaft clamping tool Tool for injection advance control and setting of inj
73. 45 and 55 These must be uniform and distinct in both directions Average roughness must be between 0 5 and 1 m The whole surface of the cylinder affected by contact with the piston rings must be rendered with the plateau method Cylinder class The pistons A B C locations are shown on the piston crown while those for the cylinders are found on the crankcase in the points shown by the arrows see picture Note For LDW 502 with an aluminium crankcase the cast iron cylinders can be adjusted normally to increase values by 0 5 and 1 0 mm The cylinders are not to be changed Disassembly Reassembly 60 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 126 127 129 128 130 4 Rear and forward main bearing caps Important Before the final tightening check the coplanarity of the two levels with a ground bar On remounting the rear main bearing cap 1 replace the lateral rubber gaskets 2 keeping in mind that projections A and B of the support must be 0 5 1 0 mm cut off any exceeding portions Do the same with the front bearing cap Before reintroducing the bearings in the crankcase place between their surfaces two plates C and D 0 1 mm thick se no 7107 1460 053 Tighten the screws at a torque of 60 Nm Note It is advisable to apply a few drops of silicon sealant on the surface of the gasket slot 2 Central main bearing caps The central support caps are marked with locations that c
74. 502 engines only 3 Camshaft pulley timing mark for LDW 602 702 903 1003 1204 1204 T and 1404 engines Camshaft timing pulley Disassembly Assembly Unscrew screw 1 and remove the pulley No extractor is needed When refitting tighten the screw at a torque of 80 Nm Note Assess any wear caused by the lip of the seal ring on the pulley tang Camshaft timing Belt Reassembly Important Remove the distributor toothed belt from its protective wrapping only when mounting it Make the connections for toothed belt fig 33 and that of pulley fig 34 fit together Insert the belt as in figure 35 taking account of the direction of the arrows A impressed on it direction of rotation Tighten the nut 1 by hand until the belt tightener rests on surface of the crankcase Start by mounting the camshaft pulley belt then mount crankshaft s pulley Do not mount driven belts Disassembly Reassembly 38 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 39 4 40 38 Camshaft timing Belt Tightening and Fastening Insert the torque wrench in the suitable tool so that the A axis of the key fig 39 is at 90 to the B axis of the tool in fig 38 Tighten in clockwise direction at 20 Nm Maintaining the belt tension tighten nut 3 with another torque wrench at 40 Nm after having remounted the drive pulley Rotate the crankshaft a few times and check that the tension is as described above The check must b
75. 6 INJECTOR SETTING 1460 028 T D C 1460 048 ADVANCE INJECTOR SETTING 1460 074 T D C 1460 048 ADVANCE INJECTOR SETTING 1460 074 T D C 1460 048 ADVANCE INJECTOR SETTING 1460 074 T D C 1460 048 ADVANCE INJECTOR SETTING 1460 074 T D C 1460 048 Fuel system 79 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 8 177 178 179 181 180 Injector setting old type Connect the injector to a hand pump after removing cap screw 20 fig 169 By means of the tool se no 7107 1460 028 check that the setting pressure is 130 145 bar Adjust if necessary by changing the spacer located under the spring There are eleven different spare part spacers from 1 to 2 mm When you replace the spring the setting should be made at a pressure higher than 10 bar to compensate for adjustments in operation Check the needle seal by slowly actuating the hand pump for 10 seconds until you reach abt 130 bar If the nozzle drips replace it Injector spark arrester Every time you remove the pump injector you must replace the spark arrester the copper gasket the oil O ring as well as the 2 fuel O rings Insert the spark arrester in the i
76. E RADIATOR EXCHANGE SURFACE VALVE CLEARANCE ADJUSTMENT FAN ALTERNATOR BELT STRETCH COOLING LIQUID HOSES SETTING AND INJECTORS CLEANING FUEL PIPES RUBBER INTAKE HOSE AIR FILTER AND INTAKE MANIFOLD INTERIOR RADIATOR CLEANING ALTERNATOR AND STARTING MOTOR ENGINE OIL OIL FILTER FUEL FILTER ALTERNATOR BELT COOLANT FILTER ELEMENT PANEL AIR FILTER FUEL PIPES COOLING LIQUID HOSES RUBBER INTAKE HOSE AIR FILTER AND INTAKE MANIFOLD TIMING BELT DRY AIR CLEANER EXTERNAL CARTRIDGE DRY AIR CLEANER INTERNAL CARTRIDGE PARTIAL TOTAL AFTER 6 CHECKS WITH CLEANING In case of low use every year In case of low use every 2 years The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates The air filter must be cleaned and replaced more frequently In very dusty conditions Once removed the timing belt should be replaced even if its scheduled motion period is not over EVERY 4000 HOURS AFTER 3 CHECKS WITH CLEANING MAINTENANCE RECOMMENDED OIL TYPE REFILLING ENHANCED OIL SUMP STANDARD OIL SUMP ROUTINE ENGINE MAINTENANCE 25 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 CF CE CD CC CB CA SA SB SC SD SE SF SG L 2104 D E L 46152 B C D E SH API SJ SL CH 4 CG 4 CF 4 CF 2 MIL 3 SAE 20W SAE 30 SAE 40 SAE 10W 30 SAE 10W 40
77. HARGER Turbocharger pressure testing Install a 0 2bar pressure gauge at position A after removing the existing plug Start the engine and operate at low idle for five minutes to allow warm up Increase the engine speed to 3000 r min or 3600 r min depending on engine specification while applying full Nb load to the engine See page 10 for the power output curve The gauge pressure at full speed full load should be 0 87 0 91 bar 655 685 mm Hg If the pressure setting does not reach specification adjust the turbocharger waste gate 8 as is defined on page 48 Turbocharger components 1 Waste gate tube 2 Attuatore 3 Collare 4 Corpo turbina 5 Anello seeger 6 Chiocciola compressore 7 Spessore 8 Dado 9 Controdado 10 Albero con turbina 11 Segmento 12 Parafiamma 13 Cuscinetto 14 Seeger 15 Spessore 16 Segmento 17 Deflettore olio 18 Manicotto reggispinta 19 O ring 20 Cuscinetto reggispinta 21 Anello reggispinta 22 Cuscinetto 23 Anello seeger 24 Anello seeger 25 Supporto cuscinetti 67 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 150 5
78. INE MAINTENANCE 24 SAE Classification 25 4 DISASSEMBLY REASSEMBLY 28 65 Air filter support 30 Air restriction switch 29 Alternator Cooling fan belt drive 33 Big end bearing 58 Camshaft journals and housings Dimensions 47 Camshaft lobe measurement
79. NG 12 13 3 MAINTENANCE RECOMMENDED OIL TYPE REFILLING 24 27 ACEA Regualtions ACEA Sequences 25 API MIL Sequence 25 COOLANT 27 FUEL SPECIFICATIONS 27 International specifications 25 LUBRICANT 25 PRESCRIBED LUBRICANT 26 ROUTINE ENG
80. Via lever 1 of the tool open the valve until it comes into contact with the piston Then rotate the crankshaft until the TDC is read in the dial gauge Then reset the hundredths Remove the fuel pipes Remove the O ring in contact with the non return valve and replace it with the appropriate gasket equipment component part ref 1460 074 Once the check has been completed remove the gasket and refit the O ring Connect tool 1460 074 on pump n 1 This will automatically position the control lever to the maximum delivery The tool is provided with 3 4 couplings for connection to a tank that must be not lower than 30 cm from the pumps level Coupling 2 is equipped with a plastic pipe with internal drip collecting wire Put cylinder 1 under compression and open the tank tap Fuel diesel will start to flow out from coupling 2 Slowly rotate the engine towards TDC 1 until the diesel fuel stops leaking out At this point with lever 1 of fig 182 move again the valve until it touches the piston and read on the dial gauge how many hundredths are missing from the previously reset value TDC To convert hundredths into degrees consult the table below Repeat the operation on the other cylinders Injection advance for currently used pump injector unit With aluminuim crankcase Engine Code Reference n Rpm Fuel system 81 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 8 184 185
81. an be numbers as in the diagram or dots The same locations are given on the crankcase Couple the caps with the same references and on the same side In any case locate the bearing s two centring notches that are to be found on the same side Tighten the screws simultaneously at a torque of 60 Nm Check the clearances between the bearings and the journal Use the Perfect Circle Plastigage type calibrated wire A and put it at the centre of the bearing with a bit of grease Tighten the screws at a torque of 60 Nm Find out the clearance value checking the wire s compression with the appropriate graduated scale supplied in the same pack and available on the market For clearance values between the journals connecting rod pin and the relevant bearings see page 64 Disassembly Reassembly 61 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 A B C D 5 8 0 0 8 0 4 3 0 5 1 6 1 5 131 132 4 133 134 135 A m m 3 1 3 0 0 3 1 0 5 0 B m m 0 1 3 2 5 0 3 2 0 5 3 2 Piston coolant nozzles Caution Warning The piston has a recess so that during up down movements and vice versa it cannot come into contact with the nozzle When remounting the nozzle be careful that it is placed so that when the piston goes past it is in the centre of the recess They are in the supercharged LDW 1204 T engine and are housed ne
82. any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely For safety and convenience you are advised to place the engine on a special rotating stand for engine overhauls Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved In order to fix assemblies and or components securely the operator must tighten the fastening parts in a criss cross or alternating pattern Assemblies and or components with a specific tightening torque must initially be fastened at a level lower than the assigned value and then subsequently tightened to the final torque DISASSEMBLY REASSEMBLY RECOMMENDATIONS FOR OVERHAULS AND TUNING Important To locate specific topics the reader should refer to the index Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine Before carrying out any operation clean the assemblies and or components thoroughly and eliminate any deposits or residual material Wash the components with special detergent and do not use steam or hot water Do not use flammable products pe
83. ar the main bearings Components 1 Washer 2 Nozzle 3 Washer 4 Joint tighten to 12Nm 5 Valve opening pressure 1 1 2 bar 6 Spring Characteristics mm Shoulder half rings So as to keep them in their seats during assembly put a bit of grease The half rings must be assembled with the slots A as in the figure Thickness of half rings is equal to 2 31 2 36 mm They are supplied as spare parts as increased thickness 0 1 and 0 2 mm see below Crankshaft axial clearance After tightening the main bearings measure the axial clearance A between the crankshaft flywheel side shoulder and the main bearing half rings If the clearance is not within the given value check value B If need be fit oversized half rings see below Limit value Ref Clearance Disassembly Reassembly 62 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 C B A d t S 0 2 9 2 2 7 8 7 2 2 0 0 1 3 2 0 5 0 3 2 3 1 3 0 0 3 1 0 1a 0 2 1 3 2 7 8 9 2 2 0 0 3 3 2 0 5 2 3 2 2a 0 2 2 3 2 7 8 0 3 0 0 4 3 2 0 5 3 3 2 3a 0 2 3 3 2 7 8 1 3 2 0 0 5 3 2 0 5 4 3 2 136 138 137 4 Shoulder half rings oversized elements Dimensions mm A of Fig 134 B of Fig 135 Grinding B as per relevant table you can mount the following half rings
84. ary terminals 2 4 5 6 7 10 and 12 are also accessible from the front under the fuse access door BLACK BLACK BLUE RED ORANGE PURPLE BLUE RED BLACK GRAY WHITE GREEN LIGHT BLUE PINK BROWN PUSH ON CONNECTION STARTING MOTOR BATTERY CONNECTION POST GLOW PLUGS FUEL SOLENOID ALTERNATOR CONNECTOR EXCITATION TERMINAL COOLANT TEMP THERMISTOR FOR GLOW TIMER RELAY COOLANT HIGH TEMP SWITCH LOW FUEL LEVEL SWITCH LOW OIL PRESSURE SWITCH BLACK BLACK AIR FILTER RESTRICTION INDICATOR COOLANT TEMP SENDING UNIT YELLOW ELECTRIC SYSTEM 85 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 9 194 195 Alternator Iskra 14V 33A Nominal voltage 14V Nominal current output 33A Maximum Rpm 12 000 giri 1 Maximum peak Rpm 13 000 giri 1 Voltage regulator AER 1503 Rotation viewed at puley end Clockwise Tighten nut 1 at a torque of 35 45 Nm Alternator Iskra 14V 33A Performance Curve The curve was obtained at room temperature of 25 C with 13 V battery voltage Note The rpm shown on the table are referred to the alternator Engine rpm alternator rpm ratio with driving pulley diameter 88 mm 1 1 23 Electric System 86 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 2 0 5 2 1 4 4 0 1 2 6 6 0 0 3 1 1 4 4 0 1 2 6 6 0
85. at the side hole of the pre combustion chamber aligns with the glow plug hole To make sure that both the holes align appropriately use tool 7107 1460 031 1 inserting it into the glow plug hole Tighten the ring nut twice 1st tighten at a torque of 100 Nm 2nd tighten at a torque of 180 Nm Chack that clearance A is 3 68 4 1 mm Disassembly Reassembly 52 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 97 98 4 99 101 100 102 Oil pan removal Danger Attention The used engine oil can cause skin cancer if kept frequently in contact for prolonged periods If contact with oil cannot be avoided wash carefully your hands with water and soap as soon as possible Do not disperse the oil in the ambient as it has a high pollution power Remove the fixing screws Insert a spacer 1 in the forward and rear main bearings Detach the silicon from the main bearing rubber bulb seals When re mounting apply Silicone Dow Corning 7091 as shown in the picture Tighten the screws at a torque of 10 Nm Before starting the engine make sure that 1 the oil drain plug is tightened correctly 2 the engine has been refilled with the prescribed quantity of oil see page 26 PISTON Remove the connecting rod big end cap Remove the piston connecting rod assembly Note The LDW 502 s piston is different from the LDW 602 in terms of its combustion chamber The LDW 1204 T piston is d
86. be replaced ENGINE STORAGE NOT INSTALLED PROTECTIVE TREATMENT STORAGE 99 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 11 PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT After a period of inactivity and before installing and running the engine it is necessary to carry out a few measures in order to ensure that it runs at maximum efficiency 1 Remove the protective sheeting 2 Eliminate any blockages in the exhaust and intake ducts 3 Use a cloth soaked in degreasing product to remove the external protective treatment 4 Remove the intake manifold 5 Inject lubrication oil no more than 2 cm3 into the valves and install the intake manifold 6 Adjust the alternator fan belt tension 7 Turn the flywheel manually to check the movement of the mechanical parts 8 Refill the tank with fresh fuel 9 Start the engine and run at of the maximum speed for 5 10 minutes 10 Switch off the engine 11 Remove the protective oil to replace with engine oil 12 Introduce new oil see Lubricants up to the correct level marked on the dipstick 13 Replace the filters air oil fuel with original spare parts 14 Empty the cooling circuit completely and pour in the new coolant up to the correct level Caution Warning Over time a number of engine components and lubricants lose their properties even when the engine is not in use and so it is important to consider whether they need re
87. bricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently The countries in which diesel normally has a low sulphur content are Europe North America and Australia FUELS FOR LOW TEMPERATURES It is possible to run the engine at temperatures below 0 C using special winter fuels These fuels reduce the formation of paraffin in diesel at low temperatures If paraffin forms in the diesel the fuel filter becomes blocked interrupting the flow of fuel Fuel can be Summer up to 0 C Winter up to 10 C Alpine up to 20 C Arctic up to 30 C For all fuel types the cetane number cannot be lower than 51 AVIATION KEROSENE AND RME FUELS BIOFUELS The only Aviatin fuels that may be used in this engine are JP5 JP4 JP8 and JET A if 5 oil is added For more information on Aviation fuels and Biofuels RME RSME please contact the Lombardini applications department Fuel with low sulphur content Fuel with high sulphur content PRESCRIBED LUBRICANT ENGINE TYPE CAPACITY Litres Without radiator Maintenance Recommended oil type Refilling COOLANT Danger Attention The fluid coolant circuit is pressurized Inspections must only be made when the engine has cooled and even in this case the radiator or expansion chamber plug must be unscrewed with the utmost caution If an electric fan is installed do not approac
88. cod 1 5302 351 WORKSHOP MANUAL FOCS Engine Series 3 Manuale officina FOCS_cod 1 5302 350_7 ed_ rev 06 PREFACE Every attempt has been made to present within this service manual accurate and up to date technical information However development on the LOMBARDINI series is continuous Therefore the information within this manual is subject to change without notice and without obligation The information contained within this service manual is the sole property of LOMBARDINI As such no reproduction or replication in whole or part is allowed without the express written permission of LOMBARDINI Information presented within this manual assumes the following 1 The person or people performing service work on LOMBARDINI series engines is properly trained and equipped to safely and professionally perform the subject operation 2 The person or people performing service work on LOMBARDINI series engines possesses adequate hand and LOMBARDINI special tools to safely and professionally perform the subject service operation 3 The person or people performing service work on LOMBARDINI series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand This manual was written by the manufacturer to provide technical and operating information to authorised LOMBARDINI after sales service centres to carry out assembly disassembly overhauling rep
89. e 6 24 V Temperature max 150 C Max tightening torque 30 Nm Electric System 94 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 217 218 10 219 SPEED SETTINGS Setting the idle minimum standard After filling the engine with oil fuel and coolant start it and let it warm up for 10 minutes Turn the screw 1 to adjust the idle speed at 850 to 900 rpm Tighten then the locknut Note If you loosen screw 1 speed decreases To the opposite direction speed increases Setting the idle maximum standard After setting the idle speed turn screw 2 and regulate the idle maximum at 3800 rpm Block then the locknut When the engine reaches its setting power the maximum rpm will stabilise at 3600 rpm Note If you loosen screw 2 speed increases To the opposite direction speed decreases Pump injection delivery standard setting without dynamometric brake This adjustment must be performed with the dynamometric braked engine Without this the regulation is approximate In this case proceed as follows Unlock the maximum flow limiter lock nut Fully screw in flow limiter C Run the engine to the maximum speed that is 3800 rpm Loosen flow limiter C until the engine revs start to decrease Screw flow limiter C by 2 5 turns Tighten the lock nut Note If the engine under maximum load emits too much smoke unscrew C Tighten C if at t
90. e The pump for LDW 1204 1204 T 1404 engines is different from the one of the other series fig 148 due to the presence of a ring between rotor 1 and gasket 2 Coolant circuit 74 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 164 165 166 167 8 Fuel feeding injection circuit Components 1 Fuel Tank 2 Fuel filter 3 Fuel feeding tube 4 Fuel lift pump 5 lnjection pump 6 Injector 7 Fuel rail passage rubber joint 8 Injector exhaust pipe 9 Fuel tank cap 10 Solenoid valve Note The tank complete with filter is supplied on request Fuel pump drive rod projection The protrusion A of drive rod 2 from the cylinder head surface is 1 66 2 18 mm The check must be carried out with cam 1 idle as in the figure Block the two fuel pump fastening nuts simultaneously at 24 Nm Check the length of the drive rod and if it is not the right size replace it Drive rod length 153 15 153 35 mm Fuel lift pump Components 1 Fuel lift pump 2 Push rod 3 Seal ring The fuel pump is membrane type It is driven by camshaft cam via a drive rod It is equipped with an external manual fuel lever Characteristics With the control cam at 1500 rpm the delivery rate is 75 l hours and the self adjusting pressure is at 0 55 to 0 65 bar Fuel filter detached from the tank on request 1 Air relief valve 2 Bearing 3 Cartridge 4 Rubber element 5 Filtering element Cartridge characteristics Filtering paper
91. e particularly in the case of unusual vibrations Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify assess and monitor the influence of its own activities products services etc on the environment Procedures for identifying the extent of the impact on the environment must consider the following factors Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact In order to minimise the impact on the environment the manufacturer now provides a number of indications to be followed by all persons handling the engine for any reason during its expected lifetime All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution When discontinuing use of the engine select all components according to their chemical characteristics and dispose of them separately 12 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 2 POSSIBLE CAUSE TROUBLE FUEL CIRCUIT ELECTRIC SYSTEM MAINTENANCE SETTINGS REPAIRS TROUBLE SHOOTING THE ENGINE MUST
92. e carried out with the appropriate Nippon Denso tension measuring instrument halfway along the longest section of the belt the value for a cold engine must be 15 2Kg Valve timing check A Intake valve B Exhaust valve Rotate the engine in the normal direction of rotation until the No 1 piston flywheel side approaches TDC compression stroke Check the balance of intake and exhaust valves A and B placing the two micrometers testers on the valve collars Camshaft timing Belt tightening tool Position belt preload tool 7107 1460 049 1 over the timing belt idler adjustment ear 2 See Camshaft timing Belt Tightening and Fastening Disassembly Reassembly 39 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 41 Valve timing Angles The angle values are determined by turning the driving shaft clockwise S Piston at top dead centre I Piston at bottom dead centre Intake valve open Intake valve closed Exhaust valve open Exhaust valve closed Timing angles for operating purposes valve clearance 0 25 mm 16 before S 36 after I 36 before I 16 after S Timing angles for checking puposes valve clearance 2 mm 21 after S closes in I 2 after I 20 before S Timing angles for operating purposes LDW 1204 T valve cleara
93. e cover When rifitting tighten the screws at a torque of 10 Nm Check the peripheral rubber sealing gasket and the two dust protection rings of the two pulleys if mounted Disassembly Reassembly 36 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 28 29 31 30 32 4 33 Tightening pulley Components 1 Nut 2 Washer 3 Pulley 4 Bearing 5 Shaft Support 6 Mounting plate 7 Tensioning lever Timing belt removal Important When you remove the distributor belt replace it even if its prescribed operation time has not expired yet Danger Attention Always check that the positive pole of the battery is insulated Remove the belt tensioner 1 Remove the timing belt off the timing pulley For assembly see fig 36 Timing belt Timing pulley arrangement Components 1 Camshaft pulley 2 Timing belt 3 Crankshaft pulley 4 Coolant pump pulley 5 Belt tensioner pulley Crankshaft timing pulley Al rimontaggio fare attenzione che la chiavetta rimanga inserita nella propria sede Note Reference mark 1 on the crankshaft timing pulley and reference mark 2 on the oil pump housing are timing marks When aligned No 1 piston flywheel side is at TDC Disassembly Reassembly 37 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 34 35 36 37 Camshaft timing pulley Reference marks 1 Timing reference mark on cylinder head 2 Camshaft pulley timing mark for LDW
94. e gasket 3 Components 1 Exhaust manifold 2 E G R Pipe 3 E G R Valve 4 Vacuum pump 5 Three way union 6 Vacuum pump pipe 7 Thermovalve vacuum pump connection pipe 8 Vacuum valve thermovalve connection pipe 9 Vacuum valve E G R connection pipe 10 Thermovalve 11 Vacuum valve 12 ON OFF sensor control cam 13 Intake duct Intake manifold Remote air filter Unscrew the the fastening screws 1 that fix the intake duct to the intake manifold unit Unscrew the two fastening screws 2 of the intake manifold from the engine crankcase Lift the intake manifold and disengage the hook of the min max cylinder from the same manifold fig 212 Disassembly Reassembly E G R Circuit 31 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 10 11 9 12 5 5 6 4 9 6 4 Disassembly Reassembly E G R Circuit Operation The main function of the E G R Exhaust Gas Recirculation system is the reduction in emission of NOx nitrogen oxides gases harmful to people and the environment via lowering the combustion temperature The system takes a certain quantity of exhaust gas from the exhaust manifold 1 fig 8 via the E G R pipe 2 to the E G R valve 3 This valve is opened by the vacuum created in pipes 6 7 8 and 9 by vacuum pump 4 fig 8 only when a thermovalve 10 placed in contact with the engine refrigerant fluid reaches a te
95. ector for pump injector unit se no 6590 272 Tool for injection advance control and setting of injector for pump injector unit se no 6590 285 6590 307 6590 290 SPECIAL TOOLS DESCIPTION Part N SPECIAL TOOLS 103 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06
96. ed_ rev 06 4 108 109 111 110 Piston ring mounting order A 1 ring internal tapered and torsional B 2 ring internal tapered and torsional C 3 Oil control ring D Chrome plated area E Chrome plated area Note When there is writing on the surface of a piston ring mount that surface with face upward Piston clearance The piston in the TDC top dead centre position may extend or be short of the upper surface of the cylinder Determinare the clearance of each piston using a dial indicator to measure the difference between the two surfaces piston crown and upper cylinder surface To determine the piston clearance and by consequence which copper gaske is most suitable it is necessary to consider the A value of the piston that projects furthest Piston assembly Important Before re mounting lubrificate the piston pin piston cylinder and conncecting rod big end bearing Couple the piston to the connecting rod inserting the pin after lubricating it just via thumb pressure Insert the two pin stop rings and check that they are properly housed in their seats see fig 101 Using piston ring compression pliers introduce the piston into the cylinder so that combustion chamber A is directly under the precombustion chamber parallel to the head Couple the piston connecting rod to the crankshaft For tightening the head connecting rod see fig 115 116 Disassembly Reassembly 56 FOCS W
97. embly 33 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 17 18 19 4 20 Alternator Cooling fan belt drive Danger Attention Check the belt tension only with the engine off Tension adjustment Loosen screws 1 and 2 Adjust the belt tension so that a 100N force at the midpoint of the belt center as shown results in a 10 15mm deflection See page 24 for periodic maintenance details Cooling fan Danger Attention Carry out the cooling fan disassembly only after isolating the positive battery cable to prevent accidental short circuiting and consequently the activation of the starter motor Carefully clean and check all blades Replace the fan even if there is only a single damaged blade See pages 16 17 for cooling air flow volume Fuel tank optional Danger Attention To avoid explosions or fire outbreaks do not smoke or use naked flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the plug to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting After disconnecting the fuel pipes unscrew the anchoring brackets screws and remove the fuel tank Completely empty the tank and check that no impurities are found inside Check that cap breather hole is not clogged Disassembly Reassembly 34 FOCS Worksho
98. essentially the same as that described in fig 182 with one difference instead of using the device se no 7107 1460 048 with which you measure piston lowering with respect to the Top Dead Centre you use references A and C on the timing belt protector and reference D located on engine pulley When D coincides with A the piston has reached its TDC When D coincides with C the piston is in injection advance position Fuel system 82 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 188 189 8 190 191 Static injection advance regulation Fill the tank and operate the fuel pump Set the pump injector delivery control rod ref A fig 187 at half stroke Bring the piston to the top dead centre of compression Fit a 13 mm hexagon wrench on the injection advance adjusting screw lock nut By turning the wrench forth and back you prime the injection pump thus enabling the tester to be drained With the piston at its TDC operate lever 2 fig 188 and bring the drain valve into contact with the piston Then reset dial gauge Go back of a turn moving the crankshaft anticlockwise Then turn forward again very slowly observing the fuel level inside the tester As soon as the level changes then stop You reached the static injection advance By actuating lever 2 check piston lowering with respect to the TDC that shall be between 0 89 and 1 24 mm for LDW 602 903 1204 and between 0 73 and 1 02 for LDW 502 engine model The table on
99. h a hot engine since the fan itself could start up even when the engine is at a standstill Coolant fluid is polluting it must therefore be disposed of in the correct way Do not litter The anti freeze protection liquid AGIP ANTIFREEZE SPEZIAL must be used mixed with water preferably decalcified The freezing point of the cooling mixture depends on the product concentration in water it is therefore recommended to use a 50 diluted mixture which guarantees a certain degree of optimal protection As well as lowering the freezing point the permanent liquid also raises the boiling point Coolant refueling For information concerning the capacity of Lombardini radiators please contact Lombardini directly The total volume for refilling the cooling liquid varies according to the type of engine and radiator 28 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 Important To locate specific topics the reader should refer to the index Besides disassembly and reassembly operations this chapter also includes checking and setting specifications dimensions repair and operating instructions Always use original LOMBARDINI spare parts for proper repair operations The operator must wash clean and dry components and assemblies before installing them The operator must make sure that the contact surfaces are intact lubricate the coupling parts and protect those that are prone to oxidation Before
100. he brake altering the load and the speed governor Redo the consumption check on the stabilised engine 5 Unscrew limiter C until the engine rpm start to decrease Lock the limiter using the lock nut 6 Completely release the brake and check the rpm at which the engine stabilises The performance of the speed governor must meet the class required by the application s manufacturer 7 Stop the engine 8 Recheck the valve clearance with the engine cold Specific fuel consumption Time sec per 100 cm3 Power NB curve Rpm Engine Required settings as most commonly applies Refers to power curve NB see pages 18 20 and after run in Settings 97 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 225 10 E G R calibration Mount a T branch on vacuum valve E G R valve connection pipe 1 and connect it to a vacuum pressure gauge with 1 bar bottom scale so as to be able to read the degree of vacuum within the pipe Note It is also possible to use a mercury column 1 metre long since the maximum suction pressure exerted by the vacuum pump is 720 mmHg Adjust the position of the accelerator lever via the regulator block so that the internal adjusting nut 2 is about 5 mm from the end of the thread Accelerate the engine up to 3 600 rpm with valve closed this means that the value showed on the vacuum pressure gauge or on the mercury column should be 0 In case it is different
101. his condition is also essential when it comes to routine and above all extraordinary maintenance operations which in the latter case must only be carried out by persons specifically trained by LOMBARDINI and who work in compliance with the existing documentation Variations to the functional parameters of the engine adjustments to the fuel flow rate and rotation speed removal of seals demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve LOMBARDINI from all and every liability for deriving accidents or for failure to comply with the laws in merit On starting make sure that the engine is as horizontal as possible unless the machine specifications differ In the case of manual start ups make sure that the relative actions can take place without the risk of hitting walls or dangerous objects also considering the movements made by the operator Pull starting with a free cord thus excluding self winding starting only is not permitted even in an emergency Make sure that the machine is stable to prevent the risk of overturning Become familiar with how to adjust the rotation speed and stop the engine Never start the engine in a closed place or where there is insufficient ventilation Combustion creates carbon monoxide an odourless and highly poisonous gas Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousnes
102. his load there is no smoke and if the engine does not reach its maximum power SETTINGS 95 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 220 221 222 223 10 Setting the stop Remove the rocker arms cover and completely unloosen screw B Push rod A to the right and keep it in this position see figure Tighten screw B until it touches rod A Release rod A and tighten again screw B by a 0 5 1 0 turn Tighten the lock nut Pump injector unit timing with speed governor Loosen the screws C of each pump injector unit If it is not connected connect spring D to rod A with this operation the speed governor blocks are closed Move plates B of each pump injector unit rightwards see figure with this operation the pumps injector unit are at their maximum delivery Tighten screws C at 1 1 Nm Re balance the deliveries Note Spring D is the start up fuel supplement spring with the engine stopped pull rod A to the right by bringing the pump injector unit delivery to the maximum value until the speed governor comes into operation with the engine running Injection pump flow limiter and engine torque gearing device Flow limiter C has the function of limiting the injection pump s maximum delivery The same mechanism acts also as a torque gearing device Indeed under torque spring N operating lever L overcomes the resistance of spring M located in the plunger barrel The stroke H that the torque
103. ifferent from that of the LDW 1204 in term of its cooling nozzle s slot bleed and an insert in the first section s hollow The Ricardo type of combustion chamber is used for LDW 702 1003 1404 engines Stop pin rings dismounting and remounting Extract the ring inserting a pointed tool in hollow A On remounting insert rings with the points turned downwards inside the corners 15 Disassembly Reassembly 53 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 103 T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 2 0 5 W D L A 0 0 0 2 7 0 9 9 1 7 0 4 9 1 7 0 3 9 1 7 0 7 0 0 0 5 0 0 B 0 1 0 2 7 0 0 0 2 7 0 5 9 1 7 0 4 9 1 7 C 0 2 0 2 7 0 1 0 2 7 0 6 9 1 7 0 5 9 1 7 4 0 4 1 3 0 0 1 2 0 7 W D L A 0 0 0 5 7 0 9 9 4 7 0 4 9 4 7 0 3 9 4 7 0 7 0 0 0 5 0 0 B 0 1 0 5 7 0 0 0 5 7 0 5 9 4 7 0 4 9 4 7 C 0 2 0 5 7 0 1 0 5 7 0 6 9 4 7 0 5 9 4 7 Piston disassembly and inspection Remove the stop rings and remove the pin see fig 101 Remove the piston rings and clean the slot Measure diameter Q at height A from the base of skirt A 9 mm If the diameter is worn more than the 0 05 mm minimum given
104. is valid the engine installation considering the product technical features must be carried out by qualified personnel only The list of the Lombardini authorized dealers is reported in the Service booklet supplied with each engine Special applications involving considerable modifications to the cooling lubricating system for ex dry oil sump filtering system turbo charged models will require special written warranty agreements Within the above stated periods Lombardini Srl directly or through its authorized network will repair and or replace free of charge any own part or component that upon examination by Lombardini or by an authorized Lombardini agent is found to be defective in conformity workmanship or materials Any other responsibility obligation for different expenses damages and direct indirect losses deriving from the engine use or from both the total or partial impossibility of use is excluded The repair or replacement of any component will not extend or renew the warranty period Lombardini warranty obligations here above described will be cancelled if Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected and altered Lombardini engines are not used according to the instructions reported in the Use and Maintenance booklet supplied with each engine Any seal affixed to the engine by Lombardini has been tampered
105. kshop Manual_cod 1 5302 351_7 ed_ rev 06 4 90 91 92 93 95 94 96 Pre combustion chamber Components 1 Pre combustion chamber 2 Pre heating glow plug 3 Pre combustion chamber ring nut 4 Cylinder head The pre combustion chamber does not normally require removal or service if service is necessary follow the procedure described below Pre combustion chamber ring nut removal The pre combustion chamber is fixed to the cylinder head by a ring nut so before removing the pre combustion chamber it is necessary to unscrew the pre combustion chamber ring nut Use the special tool 7107 1460 027 1 to romve the ring nut 2 Pre combustion chamber removal Before proceeding with removing the pre combustion chamber it is necessary to remove the pre heating glow plug Screw special tool 7107 1460 030 1 into the pre combustion chamber Carefully but sharply slide the slide hammer 2 up the special tool shaft until contact is made with end of the tool The hammer effect of the special tool will extract the pre combustion chamber 3 Note There are many types of precombustion chambers for the various engines described as follows LDW 502 LDW 602 903 1204 1204 T LDW 702 1003 1404 Pre combustion chamber installation The pre combustion chamber has a hole on the side where the pre heating glow plug 2 must be inserted When re fitting introduce the the new pre combustion chamber into the cylinder head so th
106. lacement and tuning operations As well as employing good operating techniques and observing the right timing for operations operators must read the information very carefully and comply with it scrupulously Time spent reading this information will help to prevent health and safety risks and financial damage Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases FOCS Engine Series 4 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 CUSE ATLO 7 04 90 6 15 03 2008 1 5302 351 50563 Drafting body Document code Edition Issue date Review date Model N Revision REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Endorsed 5 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 CHAPTER INDEX 1 GENERAL REMARKS AND SAFETY INFORMATION Pag 9 11 GENERAL SAFETY DURING OPERATING PHASES 11 GENERAL SERVICE MANUAL NOTES 9 GLOSSARY AND TERMINOLOGY
107. ly 63 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 139 140 141 4 142 T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 2 0 5 W D L A m m 0 0 0 8 4 4 8 9 7 4 0 0 9 7 4 B m m 0 0 0 0 4 4 8 9 9 3 0 0 9 9 3 4 0 4 1 3 0 0 1 2 0 7 W D L A m m 0 0 0 1 5 1 8 9 0 5 0 0 9 0 5 B m m 0 0 0 0 4 4 8 9 9 3 0 0 9 9 3 Crankshaft lubrication lines Caution Warning During repairs when compressed air is used it is important to wear protective goggles A Crankshaft LDW 502 B Crankshaft LDW 602 702 Put the crankshaft in a bath of crude oil Remove the caps and clean lines 1 and 2 or 3 and 4 with a bit blow with compressed air Reposition the new caps in their seating and check the seal Note The LDW 502 crankshaft with aluminium crankcase is not interchangeable with the cast iron crankcase having different counterweights Journal and connecting rod pins diameters Dimensions mm Crankshaft check journals and crank Use a micrometer for the outsides Disassembly Reassembly Ref Ref Tolerance Tolerance Limit value Limit value 64 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 2 0 5 W D L C m m 4 8 9 7 4
108. mall movements with the plate Tighten screws 1 and 2 at a torque of 1 1 Nm Note Each time a pump injector is replaced it is necessary to balance the deliveries Instrument connection Place the instrument 1 se no 7104 1460 127 at least 20 cm above the pump injector level Connect pipe A outlet from every instrument test piece with pipe A inlet of every pump injector and pipe B return to the instrument with pipe B outlet from the pump injector Open tap 2 and 3 of each pipe and fill the instrument with diesel Start the engine and bring it to 1500 rpm idle running Close the fuel supply to the engine from the instrument s tank using lever 4 and after 1 minute observe the levels in the test piece If a level goes down more than the others it is necessary to decrease the delivery of the corresponding pump see below and vice versa to increase the delivery if the level increases Fuel system 84 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 12 2 10 7 6 5 9 9 ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP UPON REQUEST AUXILIARY TERMINALS Positive pole under key 6 3 Negative pole Earth 6 3 Signal for temp water instrument 4 75 Signal for electric rev counter 4 75 Oil pressure signal 4 75 Protected socket available 4 75 Protected socket available 4 75 Rear connection Jumper with 6 for alternator protection Control panel auxili
109. mounting flange to ring gear face Note Please refer to your local BOSCH distributor for service parts repair criterion and warranty service Starter motor Bosch 12V 1 6 Kw Rotation Clockwise A 29 50 31 5 mm distance from starter mounting flange to ring gear face Note Please refer to your local BOSCH distributor for service parts repair criterion and warranty service Starter motor Bosch DW 12V 1 1 KW Performance Curve The curve was obtained at room temperature of 20 C with a fully charged 66Ah battery U Starter Motor Voltag n Armature r min I Absorbed Amperage P Starter Output Power KW M Starter Output Torque Nm Electric System 92 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 0 0 0 7 0 0 4 2 0 0 1 0 6 4 0 2 0 0 2 0 4 5 9 2 5 3 2 5 6 1 5 3 1 5 0 1 5 8 0 8 0 6 0 7 0 4 0 2 3 0 5 210 212 211 9 209 Pre heating plug control unit with coolant temperature sensor To avoid white smoke immediately following start up post heat for about 5 seconds see table For electrical connections see figures 196 199 203 Pre heating glow plug Characteristics Nominal voltage 12 5V Current absorption 12A 14A after 5 seconds Sheath surface temperature
110. mperature of 40 C b the on off sensor control cam 12 opens the vacuum valve 11 at a determined accelerator position Once the E G R valve is opened the exhaust gas enters the intake manifold 13 via the intake flange The same logic controls the closure of the E G R valve Disassembly Disengage the control rod catch 1 with a screwdriver from the accelerator control rod 2 fig 9 Disconnect the accelerator control rod 2 from the accelerator control lever 3 fig 9 Disconnect the thermovalve vacuum pump connection pipes 7 fig 8 and vacuum valve thermovalve connection pipe 8 fig 8 from the thermovalve Unscrew the two fastening screws 5 that fix the E G R pipe 6 to the E G R valve 4 figures 10 11 and 12 Remove the intake manifold See Intake manifold Remote air filter on page 30 Figure 7 Unscrew the fastening screw of the E G R pipe support bracket 9 fig 10 from the engine crankcase and disengage the E G R pipe from the exhaust manifold Reassembly When reassembling pay attention to the repositioning of the gaskets and to the precise connection of the pipes 6 7 8 9 fig 8 These pipes should be carefully fitted on the appropriate connections Tighten the screws to specified torque see Table of tightening torques for the main components on page 100 For the calibration of the E G R system see E G R calibration on page 97
111. mping element old type injection pump 77 Chapter index 8 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 Setting of injector according to current pump injector unit 79 Static injection advance regulation 82 Static injection advance tuning 81 TDC Top Dead Center references 81 Test head B assembly 82 Tester and special coupling for injection advance control Old type injection pump 81 9 ELECTRIC SYSTEM 84 93 Alternator battery charger curve 12V 20A
112. n the bearings and corresponding pins 64 CONNECTING ROD 58 Connecting rod alignment 59 Connecting rod with bearings and pin 58 Connecting tod weight 58 Cooling fan 33 Crankcase breather LDW 502 44 Crankcase vacuum regulator valve 43 Crankshaft axial clearance
113. nce 0 25 mm 10 before S 42 after I 56 before I 16 after S Timing angles for checking puposes LDW 1204 T valve clearance 2 mm 31 after S 1 after I 11 before I 29 before S Disassembly Reassembly 40 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 42 44 45 48 43 46 4 SPEED GOVERNOR The weight type mechanical governor is driven directly by the camshaft and is housed with the cylinder head Components 1 Thrust washer 2 Spool 3 Flyweight assembly Note In engines with the minimum maximum see fig 49 the weights are lightened by 25 Governor springs for Gensets In the section view of the leverages the 4 ball bearings A are highlighted They are mounted on engines for generator sets adjusted at 1 500 1 800 rpm and on other particular applications on request Governor springs Unscrew the pin that attaches it to the cylinder head To remove it as shown in the figure it is necessary to dismount the camshaft It could also be removed from the accelerator box side by unscrewing the torque gearing device Before reassembling it check value A 45 to 46 mm and the parallelism of the two levels B that must not exceed 0 05 mm Note There are 5 different types of regulator springs C These change according to the engine adjustment standard spring for 3 600 r
114. ng remove any tools that were used to service the engine and or machine Make sure that all guards have been refitted General remarks and safety information Important remarks and features of the text are highlighted using symbols which are explained below Danger Attention This indicates situations of grave danger which if ignored may seriously threaten the health and safety of individuals SAFETY AND WARNING DECALS Caution Warning This indicates that it is necessary to take proper precautions to prevent any risk to the health and safety of individuals and avoid financial damage Important This indicates particularly important technical information that should not be ignored SAFETY REGULATIONS 11 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 1 During operation the surface of the engine can become dangerously hot Avoid touching the exhaust system in particular Before proceeding with any operation on the engine stop it and allow it to cool Never carry out any operation whilst the engine is running The coolant fluid circuit is under pressure Never carry out any inspections until the engine has cooled and even in this case only open the radiator plug or expansion chamber with the utmost caution wearing protective garments and goggles If there is an electric fan do not approach the engine whilst it is still hot as the fan could also start operating when the engine is
115. njector housing with surface A pointing upwards Tighten simultaneously both nuts that fasten it to the head at 20 Nm For engines with the injectors fixed with self locking nuts tighten the nuts at 23 Nm See page 24 for periodic maintenance details Injector nozzle projection To avoid excessive compression of the spark arrester A fig 181 check projection B of the nozzle fig 179 B 6 80 7 05 mm If this measure is larger put spacer 2 between ring nut 1 and copper gasket 3 0 25 mm thick spacers are available Setting of injector according to current pump injector unit Remove the non return valve leaving its metal gasket and fit a cap screw in its place that is part of tooling 7107 1460 074 Mount then head 1 and coupling 2 Then connect a hand pump as shown in the picture The pressure setting must be 140 155 mm bar Fuel system 80 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 2 0 5 W D L m m T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 W D L m m 4 0 4 1 3 0 0 1 2 0 7 W D L m m 8 1 7 4 9 1 7 6 3 2 8 6 4 2 7 1 9 3 7 1 5 1 1 2 5 0 2 2 6 1 3 4 5 1 6 7 8 1 6 5 9 1 5 1 8 5 3 1 1 5 6 1 1 2 7 1 4 1 4 8 1 1 0 4 4 1 1 0 5 1 3 1 2 2 0 1 2 4 2 1 6 9 2 1 2 1
116. oil can cause skin cancer if kept frequently in contact for prolonged periods If contact with oil cannot be avoided wash carefully your hands with water and soap as soon as possible Do not disperse the oil in the ambient as it has a high pollution power Maintenance Recommended oil type Refilling 27 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 API CF4 CG4 API CF CD CE 3 1 90 LDW 1204 T 0 90 1 75 1 30 LDW 602 702 LDW 1204 1404 LDW 903 1003 0 75 LDW 502 FUEL SPECIFICATIONS To achieve optimum performance of the engine use good quality fuel with certain characteristics Cetane number minimum 51 indicates the ignition quality A fuel with a low cetane number may cause problems when starting from cold and have a negative effect on combustion Viscosity 2 0 4 5 centistokes at 40 C this is the resistance to flow and performance may decline if not within the limits Density 0 835 0 855 Kg litre a low density reduces the power of the engine and density that is too high increases performance and opacity of the exhaust Distillation 85 at 350 this is an indication of the mixture of different hydrocarbons in the fuel A high ratio of light hydrocarbons may have a negative effect on combustion Sulphur maximum 0 05 of the weight high sulphur content may cause engine wear In those countries where diesel has a high sulphur content it is advisable to lu
117. orkshop Manual_cod 1 5302 351_7 ed_ rev 06 3 0 9 2 0 6 2 0 5 W D L m m A 6 0 1 7 9 0 8 4 0 9 3 0 6 1 1 7 0 1 5 2 1 7 1 1 8 4 0 0 4 0 T 4 0 2 1 4 0 2 1 W D L m m A 6 0 1 7 9 0 8 4 0 9 3 0 6 1 1 7 0 1 5 2 1 7 1 1 8 4 0 0 4 0 3 0 0 1 2 0 7 W D L m m A 1 9 0 2 8 0 3 6 0 4 5 0 1 0 1 0 9 0 0 1 1 2 0 1 3 6 0 5 5 0 4 0 4 1 W D L m m A 1 9 0 2 8 0 1 6 0 2 5 0 1 0 1 2 9 0 0 1 1 2 0 1 1 6 0 3 5 0 112 4 Head gasket Important Remove the cylinder head gasket seal from its protective covering only when you are going to mount it The gasket thickness is identified by the number of notches located in point B Choose the appropriate gasket considering that each A value on the table corresponds to a gasket with no hole one hole two holes or for the 1404 one notch two notches three notches The A value relates to figure 111 Each time you dismount the head you must replace the gasket N of holes Piston clearance 0 holes 1 hole 2 holes N of holes Piston clearance 1 hole 2 holes 3
118. p Manual_cod 1 5302 351_7 ed_ rev 06 21 22 23 4 24 Return pulley Remove the center bolt 1 and slide the pulley from the engine Components 1 Bolt 6 Bearing 2 Washer 7 Spacer 3 Spacer 8 Bearing 4 Pulley 9 Snap Ring 5 Snap Ring Note On remounting thoroughly clean out the threads of screw 1 and tighten at 25 Nm Flywheel Danger Attention During dismounting be particularly careful not to let the flywheel fall as this can be very dangerous for the operator Use protective goggles while removing the starter ring gear Unscrew the screws that fasten it to the crankshaft In order to replace the ring gear it is necessary to disassemble the flywheel Cut the ring gear in several places using a chisel and remove it Heat the new ring gear uniformly and keep it at a temperature of 300 C for 15 20 minutes Insert the ring gear into its seat and place it carefully on the rim of the flywheel eave to the ring gear to cool gently before reassembling the flywheel When refitting tighten the screws at 80 Nm Driving pulley Important To loosen or screw in screw 1 at the set torque you must always stop the crankshaft and not other parts of the engine Locking the crankshaft remove the engine starter and installing the fixture tool 1460 051 Remove the pulley after having unscrewed central screw 1 and proceed with the four lateral screws The central bolt 1 is left handed When reassembling
119. phase 60 Nm With head 8 8 tightening bolts 1st phase 40 Nm 2nd phase Eseguire una rotazione della chiave in senso orario di 90 3rd phase Proseguire con una rotazione della chiave in senso orario di 90 Disassembly Reassembly 58 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 116 117 119 118 4 CONNECTING ROD Caution Warning While reassembling the big end bearings we suggest cleaning all parts thoroughly as well as proper greasing in order to avoid risks of seizure at the first start Big end bearing After connecting rod from crankshaft disconnection check the following While reassembling be sure the two centring notches A an B are on the same side Tighten the connecting rod big end cap screws simultaneously at a torque of 40 Nm Note The big end bearing is supplied both at the nominal value and undersized by 0 25 and 0 50 mm In the LDW 502 engine with light alloy crankcase the connecting rod is aluminium type and not provided with connecting rod big end bearing and small end bush Connecting rod with bearings and pin Dimensions mm A 126 48 126 52 106 98 107 02 for LDW 502 B 18 015 18 025 20 015 20 025 for LDW 702 1003 1204 T 1404 C 40 021 40 050 bearing tightened at 40 Nm D 17 996 18 000 19 996 20 000 for LDW 702 1003 1204 T 1404 E 50 900 51 100 54 000 55 100 for LDW 702
120. placing based not only on the mileage but also on age and wear 15 Install the engine and make the necessary connections and unions 16 Make sure that electrical contacts are intact and efficient 17 Check that the engine oil and coolant are up to level 18 Start the engine and keep at minimum speed for a few minutes 19 Check for leaks and if necessary find and eliminate the cause 20 Switch off the engine 21 Double check that the engine oil and coolant are up to level Storage 100 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 1 1 40 12 20 15 10 9 60 10 10 5 24 40 8 20 40 80 12 50 15 7 360 80 25 40 4 80 M 3 spec 8x1 8x1 25 12x1 25 20X1 5 6 6x1 M 10 M 6 M 6 5x0 8 8x1 5 M 10 8x1 25 M 8 M 10 10x1 25 M 6 30x1 5 10x1 25 10 12x1 5 6x1 16x1 5 sin 10x1 25 12x1 5 12x1 5 18 TCEI 4x1 5 10x1 5 62 63 p 44 116 p 58 131 132 p 61 210 211 p 92 55 p 43 126 130 p 60 97 98 p 52 50 p 41 167 p 74 39 p 38 181 p 79 68 p 45 146 p 65 90 96 p 51 13 14 p 32 22 24 p 34 34 p 37 215 p 93 152 153 p 69 113 115 p 57 64 p 44 21 p 34 270 270 638 Silicon 7091 270 242 242 12 TORQUE SPECIFICATIONS AND USE OF SEALANT Table of tightening torques for the main components POSITION Torque Nm Diam amp pi
121. pm for 3 000 rpm for 2 400 to 2 600 rpm for 1 800 rpm and for 1 500 rpm Speed governor components 1 Oil seal 2 Screw 3 Support 4 O Ring 5 Bearing 6 Retainer 7 Screw 8 Flyweight assembly 9 Spool 10 Thrust washer Disassembly Reassembly 41 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 49 50 Speed governor Limiting speed governor With applications for the automotive sector the regulator spring C fig 45 is replaced by a device plunger barrel that only enables a constant speed at the minimum and maximum rpm rating Components 1 Nut 2 Idle speed spring 3 Max speed spring 4 Case 5 Register 6 Spring ring 7 Actuation rod Note There are six maximum springs in a different colours to distinguish them from the six respective adjustments Red color for 3000 giri 1 No color 3200 giri 1 Black 3600 giri 1 Orange 3750 giri 1 White 4200 giri 1 Green 4300 giri 1 Brown 4500 giri 1 Speed governor Reassembly Caution Warning While reassembling check the integrity of the components and check that they operate correctly Bad operation of the speed governor can cause serious damage to the engine and to people being near to it Remount in reverse order to Fig 44
122. ponents 1 Reset buttione 2 25 Tab connection Note The indicator is calibrated at 600 650 mm of water column for LDW 502 602 702 903 1003 1204 1404 and 370 420 mm of water column for LDW 1204 T Oil bath air cleaner on request Important Check the sealing rings regularly Replace the sealing rings if hardening or damage is noted 1 Upper Housing 6 Oil level reference mark 2 Diaphragm Seat 7 Reservoir bowl 3 Diaphragm 8 Outer seal ring 4 Polyurethane upper element 9 Inner seal ring 5 Metal wool lower eleme Note Carefully clean the reservoir bowl and both elements with clean diesel fuel Blow the lower element dry with compressed air Dry the upper element by squeezing out excess diesel fuel then drying with suitable cloths Fill the reservoir with clean engine oil to the reference mark See page 24 for periodic maintenance and replacement details Disassembly Reassembly 30 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 5 6 8 7 4 1 1 2 2 2 2 1 4 2 7 6 5 13 10 3 9 8 11 12 Air filter support The support for air filter 1 incorporates the intake manifold and the accelerator control box Remove all bolts that secure the air filter support 1 to the cylinder head Carefully pull the air filter support from the cylinder head Using suitable pliers release the governor spring 2 from the air filter support assembly Replace th
123. quality direct injection HEAVY DUTY DIESEL ENGINES E1 OBSOLETE E2 Standard E3 Heavy conditions Euro 1 Euro 2 engines E4 Heavy conditions Euro 1 Euro 2 Euro 3 engines E5 High performances in heavy conditions Euro 1 Euro 2 Euro 3 engines ACEA Regualtions ACEA Sequences OBSOLETE DIESEL PETROL CURRENT LUBRICANT SAE Classification In the SAE classification oils differ on the basis of their viscosity and no other qualitative characteristic is taken into account The first number refers to the viscosity when the engine is cold symbol W winter while the second considers viscosity with the engine at r gime The criteria for choosing must consider during winter the lowest outside temperature to which the engine will be subject and the highest functioning temperature during summer Single degree oils are normally used when the running temperature varies scarcely Multi degree oil is less sensitive to temperature changes Mineral base Semi synthetic base Synthetic base SAE Grade Maintenance Recommended oil type Refilling 26 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 AGIP SINT 2000 5W40 API SJ CF ACEA A3 96 B3 96 MIL L 46152 D E 3 LDW 1204 T 4 3 4 1 LDW 1404 LDW 1204 LDW 903 LDW 1003 LDW 602 LDW 702 LDW 502 1 5 2 5 1 4 2 4 1 6 2 5 1 5 2 4 2 4 3 8 2 3 3 7 3 2 5 2 3 0 5
124. reassure too low White smoke Black smoke Non uniform speed No acceleration Engine starts but stops Engine does not start High noise level Inadequate performance 13 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 2 INJECTION LUBRICATION CIRCUIT COOLING CIRCUIT POSSIBLE CAUSE TROUBLE Technical information High oil level Low oil level Dirty or blocked pressure regulation valve Worn oil pump Air to the oil suction hose Faulty manometer or pressure switch Oil in sump suction hose blocked Oil in sump drainage pipe blocked Faulty spray nozzles Turbo engines only Damaged injector Damaged injection pump valve Incorrectly calibrated injector Worn or damaged pumping element Incorrect injection pump delivery setting delivery equalisation Hardened pump injector control rod Cracked or broken pre combustion chamber Incorrect adjustment of the injection systems delivery equalisation advance Insufficient refrigerant fluid Defective fan radiator or radiator cap Defective thermostatic valve Loss of refrigerant fluid from the radiator hoses engine crankshaft or water pump Inside of radiator or coolant lines obstructed Defective or worn water pump Alternator fan drive belt loose or torn Heat exchange surface of the radiator clogged Engine overheats Oil and fuel dripping from the exhaust Excessive oil consumption Oil level increase Oil preassure
125. rection anticlockwise viewed from the flywheel side of the engine 10 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 1 LOMBARDINI Engines are built to supply their performances in a safe and long lasting way To obtain these results it is essential for users to comply with the servicing instructions given in the relative manual along with the safety recommendations listed below The engine has been made according to a machine manufacturer s specifications and all actions required to meet the essential safety and health safeguarding requisites have been taken as prescribed by the current laws in merit All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined by LOMBARDINI which thus declines all liability for any accidents deriving from such operations The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine operation in particular along with the relative routine maintenance work The user must read these instructions carefully and become familiar with the operations described Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of the machine The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and the deriving dangers T
126. s and death The engine must not operate in places containing inflammable materials in explosive atmospheres where there is dust that can easily catch fire unles specific adequate and clearly indicated precautions have been taken and have been certified for the machine To prevent fire hazards always keep the machine at least one meter from buildings or from other machinery Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation Fuel is inflammable The tank must only be filled when the engine is off Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil Make sure that no soundproofing panels made of porous material are soaked in fuel or oil Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil Fully tighten the tank plug each time after refuelling Do not fill the tank right to the top but leave an adequate space for the fuel to expand Fuel vapour is highly toxic Only refuel outdoors or in a well ventilated place Do not smoke or use naked flames when refuelling The engine must be started in compliance with the specific instructions in the operation manual of the engine and or machine itself Do not use auxiliary starting aids that were not installed on the original machine e g Startpilot Before starti
127. sassembly Reassembly 50 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 4 87 T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 2 0 5 W D L m m A 5 4 0 4 3 0 2 0 4 3 5 4 3 5 4 4 0 6 3 5 9 5 B 5 1 1 4 3 6 0 1 4 3 C 1 4 0 0 3 0 2 0 0 3 D 6 1 1 0 3 8 0 1 0 3 4 0 4 1 3 0 0 1 2 0 7 W D L m m A 5 4 2 5 3 0 2 2 5 3 5 4 3 5 4 4 0 6 3 5 9 5 B 5 1 3 5 3 6 0 3 5 3 C 1 4 2 1 3 0 2 2 1 3 D 6 1 3 1 3 8 0 3 1 3 1 1 88 89 T 4 0 2 1 4 0 2 1 3 0 9 2 0 6 2 0 5 W D L m m D 8 0 5 0 1 1 S 7 1 6 1 0 2 4 0 4 1 3 0 0 1 2 0 7 W D L m m D 0 1 7 0 3 1 S 6 1 0 2 Valve seats and housings Dimensions Press valve seats into the housings Note Valve seatsare supplied in finished form further machining is prohibited Valve recess and seat sealing width Dimensions mm Grind valve seats with fine emery paste After grinding check the valve recess D relative to the cylinder head surface and the seat sealing width S Disassembly Reassembly 51 FOCS Wor
128. should not undergo any torsion Turbocharger 68 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 151 6 Danger Attention The engine can be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed Use suitable oil in order to protect the engine Nothing more than lubrication oil can influence the performances and life of an engine Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston rings to jam and will lead to rapid wear on the cylinder liner the bearings and all other moving parts Engine life will also be notably reduced The oil viscosity must suit the ambient temperature in which the engine operates Danger Attention Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time Wear protective gloves to avoid touching used oil If contact with the oil is unavoidable you are advised to wash your hands with soap and water as soon as possible Dispose of old oil in the correct way as it is highly polluting LUBRIFICATION CIRCUIT Components 1 Pressure gauge 9 Oil filler cap 2 Rocker shaft 10 Camshaft 3 Connecting rod pin 11 Oil pressure regulating valve 4 Oil filter cartridge 12 Oil pump 5 Journal 13 Crankshaft 6 Oil drain pl
129. sta comando valvola Waste gate 67 6 LUBRIFICATION CIRCUIT 68 71 Internal oil filter and oil sump return pipe 69 LUBRIFICATION CIRCUIT 68 Oil filter cartridge 70 Oil pressure check 70 Oil pressure regulating valve 70 Oil pump 69 Oil pump clearance between rotors 69 7 COOLANT CIRCUIT
130. tch mm Riference figure and page n Sealant Injection pump control rod Connecting rod Union for the nozzle LDW 1204 T Glow plugs Oil filter cartridge M 20x1 5 union Camshaft bearing M 6 screws Rocker arm cover Main bearing caps Oil pan Camshaft bearing support screw Glow plug cable nuts Fuel lift pump nuts Belt tensioner nut External Stop control lever nut Pump injector unit fixing nut Rocker arm assembly support nut Fuel pump cam Flywheel side oil seal ring flange Pre combustion chamber ring nut Vacuum pump fixing screws Belt tensioner Crankcase Speed governor lever screw Driving pulley Camshaft timing pulley Oil pressure switch Oil drain plug Cylinder head Injection pipe Flywheel Tighten the two nuts that fasten each pump injector unit at the same time For engines with the injectors fixed with self locking nuts tighten the nuts at 23 Nm Tighten these in two phases the first phase at 100 Nm the second phase at 180 Nm See page 51 figures 95 96 See page 57 Aluminium connecting rod with 35 Nm tightening torque 101 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 R gt 400N mm2 R gt 500N mm2 R gt 600N mm2 R gt 800N mm2 R gt 1000N mm2 R gt 1200N mm2 Nm 0 7 1 5 3 5 13 25 43 68 105 145 205 275 355 525 725 Nm 0 6 1 4 2 8 4 7 12 2
131. ter 79 Instrument connection 83 Plunger barrel ring nut assembly disassembly 76 Plunger injection pump reassembly 76 Preliminary steps to pump injector unit delivery balancing test 82 Pump injector unit 75 Pump injector unit se no 6590 285 control data 77 78 Pump injector unit components 75 Pumping element 77 Pu
132. th constant speed and constant load C NB Specific fuel consumption at NB power Mt Torque at N a Range of application for continuous operation In case of application outside this range please contact LOMBARDINI The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 5 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C above 25 C Note Consult LOMBARDINI for power torque curves and specific consumptions at rates differing from those given above Important Non approval by Lombardini for any modifications releases the company from any damages incurred by the engine 19 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 LDW 1204 LDW 1204 T 2 Technical information N DIN 70020 Automotive rating intermittent operation with variable speed and variable load NB DIN 6270 Rating with no overload capability continuous light duty operation with constant speed and variable load NA DIN 6270 Continuous rating with overload capability continuous heavy duty with constant speed and constant load C NB Specific fuel consumption at NB power Mt Torque at N a Range of application for continuous operation In case of application outside this range please contact LOMBARDINI The above power values refer to an engine fitted with air cleaner and standard muffler after
133. tical charging output of the flywheel alternator is 10 to 5 of the values shown Electric System 90 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 A S T E A A S I R P A S A S C I N I T A C U D G 5 3 6 8 0 R R 0 5 9 2 1 B 0 5 9 2 1 E L L 5 7 4 5 0 C 5 2 6 8 0 203 204 205 9 Electric starting layout 12V with flywheel alternator 1 Alternator 2 Starter Motor 3 Battery 4 Glow Plugs 5 Coolant temperature thermistor 6 Glow Plug Controller Timer 7 Key Switch 8 System Fuse 40A 9 Fuse Accessory 5A 10 Fuel Solenoid Valve 11 Glow Plug Indicator Lamp 12 Coolant High Temperature Lamp 13 Coolant High Temperature Switch 14 Oil Pressure Low Lamp 15 Oil Pressure Switch 16 Alternator Charging Lamp 17 Voltage regulator 18 Air Filter High Restriction Indicator Lamp 19 Air Filter Restriction Switch 20 Low Fuel Level Lamp 21 Low Fuel Level Switch A Accessory Position B Off Position C On Position D Starting Position Note Battery 3 not supplied by LOMBARDINI Cable colour Yellow Red Red Green Brown Conncetion dimensions Width Thickness Voltage regulator connections Electric System 91 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 9 206 207 208 STARTER MOTOR Bosch DW 12V 1 1 KW Rotation Clockwise A 17 5 19 5 mm distance from starter
134. too low White smoke Black smoke Non uniform speed No acceleration Engine starts but stops Engine does not start High noise level Inadequate performance 14 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 2 Technical information MANUFACTURER AND ENGINE IDENTIFICATION Engine type Engine serial number Maximum operating speed Number of the customer version form K 15 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 2 Name plate for EPA rules applied on rocker arm cap EC directives certification references punched on the engine plate Technical information 16 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 N mm mm Cm Nm RPM Nm g KWh Kg h Kg l 1 m mm Kg LDW 502 2 72 62 505 22 8 1 3600 9 8 13 4 9 1 12 4 8 2 11 2 28 7 2400 37 1800 326 0 007 60 910 36 300 35 25 LDW 602 2 72 75 611 22 8 1 3600 11 8 16 0 10 3 14 0 9 2 12 5 34 5 2200 37 1800 282 0 007 65 1640 43 300 35 25 LDW 903 3 72 75 916 22 8 1 3600 17 2 23 4 15 6 21 2 13 7 18 6 53 5 2000 37 1800 300 0 012 85 1650 63 300 35 25 1 3 2 LDW 1204 4 72 75 1222 22 8 1 3600 24 2 33 2 22 0 30 0 19 9 27 0 75 1 2200 37 1800 290 0 017 96 2200 88 300 35 25
135. trol diesel etc to degrease or wash components Use special products Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them Apply a layer of lubricant over all surfaces to protect them against oxidation Check all components for intactness wear and tear seizure cracks and or faults to be sure that the engine is in good working condition Some mechanical parts must be replaced en bloc together with their coupled parts e g valve guide valve etc as specified in the spare parts catalogue Danger Attention During repair operations when using compressed air wear eye protection RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING 29 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 1 2 4 3 4 Dry type air filter Danger Attention Never clean the filtering element with highly flammable solvents Danger of explosion Important Blow compressed air crossways over the external part and inside the cartridge at a pressure no greater than 5 atm or if necessary knock the front of the cartridge repeatedly against a flat surface Components 1 Cover 2 Filter element 3 Support Air filter specifications Filtration level 13 14 m Filtration area 4470 cm per LDW 502 602 903 702 1003 Filtration area 7150 cm per LDW 1204 1404 See page 24 for periodic maintenance details Air restriction switch Com
136. uale officina FOCS_cod 1 5302 350_7 ed_ rev 06 La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione Lombardini se r serve le droit de modifier n importe quel moment les donn es report es dans cette publication Data reported in this issue can be modified at any time by Lombardini Lombardini vorbeh lt alle Rechte diese Angabe jederzeit ver ndern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicaci n 42100 Reggio Emilia Italia ITALY Via Cav del Lavoro Adelmo Lombardini 2 Cas Post 1074 Tel 39 0522 3891 Telex 530003 Motlom I Telegr Lombarmotor R E A 227083 Reg Impr RE 10875 Cod fiscale e Partita IVA 01829970357 CEE Code IT 01829970357 E MAIL atlo lombardini it Internet http www lombardini it cod 1 5302 351 FOCS Engine Series
137. ug 14 Oil suction filter 7 Oil dipstick 15 Turbosupercharger with corresponding pipes only fitted in LDW 1204 T models 8 Bleed LUBRIFICATION CIRCUIT 69 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 3 0 0 1 3 0 9 2 0 7 2 0 6 2 0 5 3 4 4 5 3 3 4 0 4 1 T 4 0 2 1 4 0 2 1 5 6 6 3 0 0 1 3 0 9 2 0 7 2 0 6 2 0 5 3 9 1 5 4 4 4 0 4 1 T 4 0 2 1 4 0 2 1 5 8 2 152 154 155 153 6 Internal oil filter and oil sump return pipe Clean with petrol the internal oil filter 1 and oil sump return pipe 2 blow also some compressed air Replace sealing rings 3 and 4 Tighten oil drain plug at a torque of 40 Nm Oil pump The oil pump mounted on LDW 502 602 903 engines has a lower delivery rate than that mounted on LDW 1204 1204 T engines Oil pump delivery test at 1000 revs per minute with an oil temperature of 120 C Delivery test at 3600 rpm with an oil temperature of 120 C Oil pump clearance between rotors Measure the clearance A between teeth as in figure the maximum value is 0 171 mm Clearance wear limit should be 0 250 mm See page 42 for assembly and disassembly Lubrification circuit Engine Delivery l 1 Pressure bar Engine Delivery l 1 Pressure bar 70 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 157 158 6
138. with or removed Spare parts used are not original Lombardini Feeding and injection systems are damaged by unauthorized or poor quality fuel types Electrical system failure is due to components connected to this system which are not supplied or installed by Lombardini Engines have been disassembled repaired or altered by any part other than an authorized Lombardini agent Following expiration of the above stated warranty periods and working hours Lombardini will have no further responsibility for warranty and will consider its here above mentioned obligations for warranty complete Any warranty request related to a non conformity of the product must be addressed to the Lombardini Srl service agents GENERAL SERVICE MANUAL NOTES 1 Use only genuine Lombardini repair parts Failure to use genuine Lombardini parts could result in sub standard performance and low longevity 2 All data presented are in metric format That is dimensions are presented in millimeters mm torque is presented in Newton meters Nm weight is presented in kilograms Kg volume is presented in liters or cubic centimeters cc and pressure is presented in barometric units bar GENERAL REMARKS AND SAFETY INFORMATION WARRANTY CERTIFICATE GLOSSARY AND TERMINOLOGY For clarity here are the definitions of a number of terms used recurrently in the manual Cylinder number one is the timing belt side piston Rotation di
139. ystem 76 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 170 171 172 8 Plunger barrel ring nut assembly disassembly To disassemble ring nut 9 fig 169 use the suitable wrench A se no 7107 1460 029 When refitting tighten it a torque of 34 Nm Plunger injection pump reassembly To be able to insert the plunger in its barrel press with a finger and at the same time slowly rotate lever 8 fig 171 until guide M of the plunger fig 172 enters the lever seating Note If by mistake the plunger is mounted with the spiral in the wrong direction the pump won t function there is no danger that the engine runs away Injection pump assembly disassembly Disassemble the unit following the progressive order of fig 169 Reassemble following the same steps in reverse order During reassembly turn the plunger spiral L towards the non return valve 19 as follows Fuel system 77 FOCS Workshop Manual_cod 1 5302 351_7 ed_ rev 06 8 A B C D E F 2 0 5 7 0 3 0 9 5 6 5 5 0 5 1 5 5 1 0 5 1 3 5 1 5 6 9 9 5 3 0 0 1 5 6 5 9 5 3 6 9 9 0 2 0 6 2 0 5 4 0 2 1 3 0 9 5 8 2 0 9 5 6 0 6 T 4 0 2 1 4 0 4 1 3 0 0 1 2 0 7 0 9 2 0 9 5 6 5 6 5 9 0 0 6 3 3 2 9 1 5 9 0 0 2 1 4 2 5 1 0 0 3 8

Kohler Engine Model KDW 1404 work shop manual

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