Kohler Lombardini LDW FOCS 502 Euro 2, Service Manual

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Service Manual LDW FOCS 502 automotive _ cod. ED0053027270 - 3° ed_rev. 02
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Information is given in a logical order in terms of timing
and sequence of operations. The methods have been
selected, tested and approved by the manufacturer’s
technical experts.
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This chapter describes procedures for controlling,
overhauling and tuning assemblies and/or individual
components.
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Important
• To locate specific topics, the reader should refer to the
index.
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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.
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The operator must comply with the specific measures
described in order to avoid errors that might cause damage
to the engine.
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Before carrying out any operation, clean the assemblies
and/or components thoroughly and eliminate any deposits
or residual material.
6.1 RECOMMENDATIONS FOR OVERHAULS AND TUNING
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Wash the components with special detergent and do not
use steam or hot water.
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Do not use flammable products (petrol, diesel, etc.) to
degrease or wash components. Use special products.
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Dry all washed surfaces and components thoroughly with a
jet of air or special cloths before reassembling them.
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Apply a layer of lubricant over all surfaces to protect them
against oxidation.
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Check all components for intactness, wear and tear, seizure,
cracks and/or faults to be sure that the engine is in good
working condition.
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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.
6.1.1 Shaft seals
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Lubricate the seal before introducing it to its seat.
- Avoid “rolling” the gasket during the attachment phase.
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Use special extractors or plugs to remove bearings.
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Clean the bearings thoroughly. Check their condition and,
if they are fully intact, lubricate all over, otherwise replace
with original spares.
6.2 OVERHAULING THE CRANK GEARS AND CRANK CASE
- Clean the shaft thoroughly and make sure that it is not
damaged or scored or has become oval-shaped in the
areas of contact with the seals.
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Lubricate the seal lips, and pointing them in the right
direction, place them in their seat using a special pad.
- Do not use a hammer directly on the gaskets during assembly,
to avoid damaging them.
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Be careful not to damage the gaskets while joining them to
the shaft.
6.2.1 Overhauling cylinders and pistons
Before deciding what kind of overhaul needs to be done, it
is important to carry out a dimensional check and verify the
correspondence of cylinders, pistons, sealing rings, crankshaft
and connecting rods.
6.1.2 O-Rings
6.1.3 Bearings
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Do not use a hammer directly on the bearings during assembly,
to avoid damaging them.
OVERHAULS AND TUNING