Kohler Lombardini LDW FOCS 502 Euro 2, Service Manual

Page: 4 / 98

4
Service Manual LDW FOCS 502 automotive _ cod. ED0053027270 - 3° ed_rev. 02
1 GENERAL REMARKS AND SAFETY
- PURPOSE OF THE MANUAL .................................. 2
- PREFACE ................................................................. 3
- GENERAL SERVICE MANUAL NOTES .................... 3
- GLOSSARY AND TERMINOLOGY........................... 3
- GENERAL SAFETY REGULATIONS ..................... 6-7
- Regulations for lifting the engine ............................. 7
- GENERAL SAFETY DURING OPERATING PHASES 8
- SAFETY AND ENVIRONMENTAL IMPACT .............. 8
- Information and safety signals ................................ 9
- Explanation of the safety pictograms......................10
2 TECHNICAL INFORMATION
2.1 GENERAL DESCRIPTION OF THE ENGINE .............. 9
2.2 TECHNICAL SPECIFICATIONS ............................12-13
2.4 ALTERNATOR LOAD CURVE DIAGRAMS ................15
2.5 LUBRICANTS ...........................................................16
2.5.1 SAE Classification .....................................................16
2.5.2 API/MIL sequences ...................................................16
2.5.3 ACEA Standards .......................................................16
2.5.4 Recommended oil .....................................................16
2.6
OPERATING PRINCIPLE FOR LUBRICATION ..........17
2.7 OPERATING PRINCIPLE FOR COOLING .................17
2.8 OPERATING PRINCIPLE FOR FUEL INJECTION .....18
2.9 WIRING DIAGRAM ....................................................19
2.10 SPECIAL TOOLS AND EQUIPMENT
FOR MAINTENANCE .................................................21
2.11 TABLE OF TIGHTENING TORQUES ........................ 22
2.12 TABLE OF SEALANTS ..............................................24
2.13 ROUTINE ENGINE MAINTENANCE ..........................24
3 MALFUNCTIONS
3.1 LOOKING FOR MALFUNCTIONS ............................25
4 STORING THE ENGINE
4.1 HANDLING AND LIFTING .........................................27
4.2 STORING THE ENGINE (UNINSTALLED)..................27
4.3 STORING THE ENGINE (INSTALLED) .......................27
4.4 PROTECTIVE TREATMENT .......................................28
4.5 PREPARING THE ENGINE FOR
OPERATION (UNINSTALLED) ...................................28
4.7 PREPARING THE ENGINE FOR
OPERATION (INSTALLED) ........................................ 29
5 REMOVING THE ASSEMBLIES
5.1 RECOMMENDATIONS FOR REMOVING
THE ASSEMBLIES ....................................................31
5.2 REMOVING THE EXHAUST AND INTAKE
MANIFOLDS ..............................................................31
5.2.1 Disassembling the intake manifold ...........................31
5.2.2 Disassembling the exhaust manifold ....................... 32
5.3
REMOVING THE COOLING FAN BELT DRIVE ........ 32
5.3.1 Disassembling the cooling fan belt
(with external alternator) ........................................... 33
5.3.2 Disassembling the cooling fan belt
(with internal alternator) ............................................ 33
5.4 REMOVING THE TIMING BELT DRIVE .................... 33
5.4.1 Disassembling the timing belt casing ...................... 33
5.4.2 Disassembling the timing belt ................................. 34
5.4.3 Disassembling the pulleys
(camshaft and crankshaft) ....................................... 34
5.5 REMOVING THE CYLINDER HEAD ......................... 35
5.5.1 Disassembling the rocker arm cover ....................... 35
5.5.2 Disassembling the rocker arms ............................... 35
5.5.3 Disassembling the fuel pump .................................. 35
5.5.4 Disassembling the injection-pumps ........................ 36
5.5.5 Disassembling the precombustion chamber ........... 36
5.5.6 Disassembling the speed governor
and flow limiter ......................................................... 36
5.5.7 Disassembling the camshaft.................................... 38
5.5.8 Disassembling the cylinder head ............................ 38
5.6
REMOVING THE CRANK GEAR
AND CRANKCASE .................................................. 38
5.6.1 Disassembling the flywheel ..................................... 38
5.6.2 Disassembling the oil pump ..................................... 39
5.6.3 Disassembling the crankcase and crankshaft ......... 40
5.6.4 Disassembling the connecting rod and piston .........41
5.7
DISASSEMBLING THE VALVES ................................41
5.8 DISASSEMBLING the piston.................................... 42
6 OVERHAULS AND TUNING
6.1 RECOMMENDATIONS FOR OVERHAULS
AND TUNING ............................................................ 43
6.1.1 Shaft seals ................................................................ 43
6.1.2 O-rings ..................................................................... 43
6.1.3 Bearings ................................................................... 43
6.2
OVERHAULING THE CRANK GEARS
AND CRANKCASE ................................................... 43
6.2.1 Overhauling cylinders and pistons ........................... 43
6.2.2 Dimensional check and overhaul of cylinders ......... 44
6.2.3 Dimensional check and overhaul of pistons ............ 44
6.2.4 Dimensional check of sealing rings ......................... 45
6.2.5 Dimensional check and overhaul of crankshaft ...... 46
6.2.6 Dimensional check and overhaul of
connecting rods ........................................................47
6.2.7 Checking parallelism of the connecting rod axes ....47
6.2.8 Checking and overhauling the fuel pump .................47
6.2.9 Overhauling the decanting device ........................... 49
6.3
OVERHAUL OF CYLINDER HEAD AND
RELATED COMPONENTS ....................................... 49
6.3.1 Checking and overhauling the cylinder head ......... 49
6.3.2 Checking and overhauling the rocker arm pin ......... 50
6.3.3 Checking and replacing the camshaft ......................51
6.3.4 Checking and replacing the fuel pump drive rod .... 52
6.3.5 Checking and overhauling the valves ...................... 53
6.3.6 Adjusting valve-rocker arm clearance ..................... 54
6.3.7 Checking clearance volume ..................................... 54
6.3.8 Calibrating the injector ............................................. 55
6.3.9 Checking and overhauling the speed governor ....... 55
6.4
CHECKING TIMING BELT RATING .......................... 56
6.4.1 Valve adjustments .................................................... 56
6.5
DIAGRAM OF TIMING BELT RATES .........................57
6.6 ADJUSTING STATIC INJECTION TIMING.................57
6.7 BALANCING INJECTION-PUMP DELIVERY .......... 60
6.8 ADJUSTING MINIMUM AND MAXIMUM
IDLE SPEED RPMS ................................................. 62
6.9 ADJUSTING INJECTION DELIVERY ....................... 62
6.9.1 Adjusting injection delivery (without dyno brake) .... 62
6.9.2 Adjusting injection delivery (with dyno brake) ......... 63
6.10 CHECKING OIL PRESSURE .................................... 63
7 INSTALLATION OF ASSEMBLIES
7.1 RECOMMENDATIONS FOR INSTALLING
THE ASSEMBLIES ................................................... 65
7.2 PRE-ASSEMBLY OF
SEALING RINGS – PISTONS .................................. 65