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Kohler Lombardini LDW FOCS 502 Euro 2, Service Manual

The Kohler Lombardini LDW FOCS 502 Euro 2 is a reliable and efficient engine suitable for a variety of applications. Ensure proper maintenance and repairs with the Service Manual available for free download from manualshive.com. This manual provides detailed instructions for keeping your engine running smoothly.

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6

Service Manual LDW FOCS 502 automotive _ cod. ED0053027270 - 3° ed_rev. 02

Note :

Summary of Contents for Lombardini LDW FOCS 502 Euro 2

Page 1: ...LDW FOCS 502 Automotive SERVICE MANUAL...

Page 2: ...e and replace them when they are no longer legible Information description and pictures in this manual reflect the state of the art at the time of the marketing ofengine However development on the eng...

Page 3: ...the flywheel side of the engine PREFACE Every attempt has been made to present within this use and maintenance accurate and up to date technical information However development on the Lombardini serie...

Page 4: ...mbling 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 c...

Page 5: ...TIMING BELT DRIVE 78 7 7 1 Assembling the timing belt pulley 78 7 7 2 Assembling the timing belt 78 7 7 3 Assembling the belt drive cover 79 7 8 INSTALLATION OF THE COOLING FAN BELT DRIVE 80 7 8 1 Ass...

Page 6: ...ldren and animals must be kept at a sufficient distance from the machine to prevent any danger resulting from its operation Fuel is flammable so the tank must be filled only when the engine is turned...

Page 7: ...approved to lift additional weights Do not use different methods to lift the engine than those described herein In case different methods are used no warranty shall be granted for any consequential da...

Page 8: ...recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities arise particularly in the case of unusual...

Page 9: ...s vapors can ignite Store fuel only in approvedcontainers inwellventilated unoccupiedbuildings Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes...

Page 10: ...out the operation Use sound absorbing protections before carrying out the operation Electric shock Danger of severe scalding or death Fluids under high pressure Danger of fluids penetration Lethal ex...

Page 11: ...head B Engine block C Crankcase D Timing belt assembly E Flywheel and crankshaft assembly F Air intake assembly G Cooling fan H Negative pressure vent valve L Alternator M Oil filter N Exhaust manifo...

Page 12: ...4 stroke diesel Number of cylinders Bore x stroke Displacements Compression rate Intake Air filter dry Filter capacity Filtering surface Cooling Water Driving shaft rotation Clockwise from distributio...

Page 13: ...antity including filter I Maximum oil quantity excluding filter I Oil pressure at minimum speed with oil temperature of 120 C no lower than 1 bar Oil filter cartridge Maximum operating pressure Maximu...

Page 14: ...14 2 Service Manual LDW FOCS 502 automotive _ cod ED0053027270 3 ed_rev 02 TECHNICAL INFORMATION...

Page 15: ...agram Reading taken after heat stabilisation at 25 C and constant voltage 13 5V To determine engine r p m s check the gear ratio adapted to pulleys Reading taken after heat stabilisation at 20 C and c...

Page 16: ...ification showing a following letter or number is preferable to one with a preceding letter or number SAE Classification In the SAE classification oils differ on the basis of their viscosity and no ot...

Page 17: ...escription Pressure switch Rocker arm pin Connecting rod big end pin Oil filter cartridge Main jurnal Oil drain plug Oil dipstick Air vent Oil refilling pump Camshaft Oil pressure regulating valve Oil...

Page 18: ...supply pump Note the tank is supplied complete with filter on request Rif 1 2 3 4 5 6 7 8 9 10 Description Tank Fuel filter Supply pipe Supply pump Injection pump Injector Fuel rail Exhaust pipe Plug...

Page 19: ...oolant temperature monitoring sensor Glow plug pre heating control box Ignition switch 50A fuses 5A fuses Electrostop device or electrical fuel lift pump Glow plugs indicator Coolant temperature indic...

Page 20: ...ant temperature monitoring sensor Glow plug pre heating control box Ignition switch 50A fuses 5A fuses Electrostop device or electrical fuel lift pump Glow plugs indicator Coolant temperature indicato...

Page 21: ...delivery Precombustion chamber extractor Pinwrenchforringnutonpump injector pumping element Precombustion chamber pin wrench Tool for mounting intake exhaust valve guide gasket Tool for lowering injec...

Page 22: ...2 R 800N mm2 R 1000N mm2 R 1200N mm2 Nm Nm Nm Nm Nm Nm Nm Nm 0 5 0 7 0 6 0 9 1 1 4 1 9 2 3 1 1 1 5 1 4 1 8 2 2 2 9 4 1 4 9 2 3 3 2 8 3 8 4 5 6 8 5 10 3 8 5 4 7 6 3 7 5 10 14 17 9 4 13 12 16 19 25 35 4...

Page 23: ...ws for fixing crankshaft Crankcase screws for fixing engine block Screw for speed governor bearing support cover Preheating glow plugs cable nuts Fuel supply pump nuts Nut for synchronous timing belt...

Page 24: ...tightening pulley M 10 Cylinder head plug 18 Engine and engine block cylinder head plug 30 TECHNICAL INFORMATION REGULARITY KM x 1000 Km PROCEDURE DETAIL CLEANING Pump injectors Radiator fan CHECK Va...

Page 25: ...ked pressure relief valve Worn oil pump Air in the oil intake pipe Faulty pressure gauge or switch Clogged oil suction hose ELECTRICAL SYSTEM Burnt fuse on pre heating glow plugs Failure in glow plugs...

Page 26: ...26 3 Service Manual LDW FOCS 502 automotive _ cod ED0053027270 3 ed_rev 02...

Page 27: ...see Protective treatment first 6 months of inactivity If after the first 6 months the engine is still not to be used it is necessary to carry out a further measure to extend the protection period see...

Page 28: ...uns at maximum efficiency 1 Remove the protective treatment 2 Removeanyblockagesfromtheexhaustandintakeducts 3 Use a cloth soaked in degreasing product to remove the external protective treatment 4 Re...

Page 29: ...ndefficient 4 Check the filters for aging air oil fuel and if necessary replace them with original spares Important Over time a number of engine components and lubricants lose their properties even wh...

Page 30: ...30 4 Service Manual LDW FOCS 502 automotive _ cod ED0053027270 3 ed_rev 02...

Page 31: ...ex 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 Before proceeding with operations make sure t...

Page 32: ...ve the exhaust manifold L 3 Remove the gaskets M 4 Close the openings and ducts to prevent foreign bodies from entering 1 1 Remove the cooling fan A Important The cooling fan belt drive comes in more...

Page 33: ...Disassembling the timing belt casing 1 Disassemble the starter motor 2 Install tool 7107 1460 051 to inhibit rotation of the crankshaft 3 Loosen the screw G Warning The screw is left handed Turn cloc...

Page 34: ...he timing belt 1 Twist the pulley nut M to fully loosen the belt N 2 Removethebelt N workingitawayinsequencefirst from the pulley and P and then from the others Important The timing belt must always b...

Page 35: ...e to extract the drive rod 3 Let go of the rocker arm and remove the drive rod 4 Repeat the same operation on the other injector 5 Remove the rocker arm pin and support D 5 5 3 Disassebling the fuel p...

Page 36: ...rtant If injector pumps are to be used during installation do not loosen the screws L1 in order to not balance injector pump deliveries during tuning 3 Unscrew the screws M 4 Remove the connecting rod...

Page 37: ...30 onto the precombustion chamber S and remove it 5 5 6 Disassembling the speed governor and flow limiter 1 Remover the cover T 2 Extract the weights assembly U from the camshaft 3 Remove the fuel flo...

Page 38: ...the drive rod has been removed and rotate the camshaft gently to remove it easily 5 6 REMOVING THE CRANK GEAR AND CRANKCASE 5 5 8 Disassembling the cylinder head 1 Remove the cylinder head A 2 Take o...

Page 39: ...ankshaft 3 Bringpistonnumberone flywheelside tothetopdead centre with the oil pump activation key in line with break in the flange in order to be able to remove it Important You should in no way try t...

Page 40: ...aft 1 Remove the flange H 2 Tske off the gasket L 3 Remove the crankcase M 4 Remove the connecting rod cap N Warning Before removing the cap mark the area of contact with the connecting rod in order t...

Page 41: ...order to recognise and match it up during reassembly Important Be careful not to damage the half bearing during removal 1 Place the cylinder head on the workbench 2 Pressdownhardonthecup A usingthesp...

Page 42: ...70 3 ed_rev 02 1 Remove the stop ring B 2 Extract the wrist pin C to separate the piston D from the connecting rod E Important Keep each connecting rod together with its piston and wrist pin 5 8 DISAS...

Page 43: ...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 repl...

Page 44: ...ry cloth Protect the contact surfaces with lubricant oil to prevent them from rusting The table shows the reference values and their class only applies to new engines Important Pistons with nominal di...

Page 45: ...nal table of sealing rings 3 Put the sealing rings on the piston in the order shown in the figure Important Place the sealing rings with the markings facing up towards the upper part of the piston cro...

Page 46: ...r measure the inside diameters of the crankshaft A2 and connecting rod B2 half bearings Important Crankshaft half bearings cannot be replaced separately If the crankshaft needs to be ground establish...

Page 47: ...does not exceed 10g to prevent weight imbalances see Table of connecting rod dimensions Protect the contact surfaces with lubricant oil to prevent them from rusting 6 2 7 Checking parallelism of the c...

Page 48: ...original spare 9 Replacethevalve G thespring F thegasket E and the plug D 10 Fill the sealing ring C with grease and lubricate the rim with oil 11 Mount the new sealing ring C using a special tool Im...

Page 49: ...h an original spare 5 Slip ona new gasket D 6 Replace the cover B and fix it using the screws 7 Replace the pipe A and fasten it using the clamp 8 Mount the starter motor and tighten the screws to a t...

Page 50: ...ker arm from the pivot pin B 5 Thoroughly clean the components 5 Usingamicrometermeasure thediametersofthepivot pin and the rocker arms see Table of dimensions pin rocker arm If the diameters do not c...

Page 51: ...he camshaft In order to carry out a control of the camshaft it is necessary to disassemble it from the cylinder head See Disassembling the camshaft for the correct procedure 1 Using a dial indicator m...

Page 52: ...and 2 18mm If the distance does not correspond to this value replace the drive rod with an original spare 3 Assemble the fuel pump see Assembling the fuel pump If the dimensions of cam involutes are l...

Page 53: ...valve seats 6 Removeanydebris cleanthevalveseatholdercarefully and scrape the mouth 7 Lubricate the new valve seats and put them into the holder manually 8 Use the special tool to put the valve seats...

Page 54: ...e made in two different points the contact area between the rocker arm and the camshaft 0 15mm and or the contact area between the rocker arm and the valve 0 2mm 3 Repeat the same operation on the oth...

Page 55: ...calibration is still not achieved the spring see Nozzle injector replacement must be replaced 7 Afterreplacingthespring calibrateat10barshigherthanthe optimal operating calibration of 140 155 bars Whe...

Page 56: ...set them to zero 6 Rotatethecrankshaftclockwiseuntilthedialindicator moves away from zero 7 Measure the rotation angle of the crankshaft by using the magnetic goniometer The value registered indicate...

Page 57: ...closes 2 after I bottom dead center 5 after I bottom dead center 18 before S top dead center 6 6 ADJUSTING STATIC INJECTION TIMING In order to adjust injection timing it is necessary to remove the roc...

Page 58: ...base G on cylinder head 10 Rotatethecrankshaftclockwiseuntiltheinjectioncam actsontherockerarmthatcontrolstheinjectorpump In these conditions the piston is near the compression top dead centre 11 Plac...

Page 59: ...ble for establishing injection timing Important When converting refer to the table value that is nearest to the registered one see Conversion table for establishing injection timing For a good engine...

Page 60: ...el rail and fasten the screws without tightening them 26 Tighten the screws to a final torque of 4 Nm 27 Slip on a new gasket P 28 Reassemble the rocker arm cover see Assembling the rocker arm cover I...

Page 61: ...uel rail Important The O rings must always be replaced with original spares whenever the fuel rail is disassembled 16 Assemble the fuel rail and fasten the screws without tightening them completely 17...

Page 62: ...JUSTING MINIMUM AND MAXIMUM IDLE SPEED RPMS only for Euro 2 engines 6 9 ADJUSTING INJECTION DELIVERY 6 9 1Adjustinginjectiondelivery withoutdynobreak only for Euro 2 engines 1 Loosen locknut A 2 Firml...

Page 63: ...the screw B with the locknut A 8 Deactivate the dyno brake and take note of the stabilized engine speed 9 Switch off the engine and leave to cool 10 Check the valve rocker arm clearance see Adjusting...

Page 64: ...64 6 Service Manual LDW FOCS 502 automotive _ cod ED0053027270 3 ed_rev 02 Note...

Page 65: ...opics the reader should refer to the index The operator must wash clean and dry components and assemblies before installing them The operator must make sure that the contact surfaces are intact lubric...

Page 66: ...piston D andinstallthe connecting rod B complete with cap 4 Insertthewristpincompletelyandfastenwiththelock ring Important Make sure the lock rings are positioned correctly in their seats Lubricate th...

Page 67: ...engine block and the crankcase are perfectly clean and dry 1 Assemble the pipe A with the oil suction filter 2 Mount the new O rings A1 3 Carefully clean and lubricate the cylinders and the connecting...

Page 68: ...caps F and put in the screws 6 Tighten the connecting rod cap screws to a temporary torque of 25Nm 7 Tightentheconnectingrodcapscrewstoafinaltorque of 30 Nm 50 Nm x PROGRESS 8 Assemble the crankcase...

Page 69: ...r the correct procedure 1 Using a dial indicator measure the axial shift of the crankshaft Axial shift must be between 0 130 and 0 313mm If axial shift is above these values it is necessary to insert...

Page 70: ...the oil pump make sure there are no malfunctions see Check and overhaul the oil pump Important Check that the contact surfaces are perfectly clean and intact 1 Slip on a new gasket A 2 Insert the oil...

Page 71: ...alternatorsupport E andtightenthescrews to a torque of 2 2Nm 7 5 7 Assembling the flywheel 1 Install the support F and tighten the screws to a torque of 25 Nm 2 Install the flywheel G and put in the s...

Page 72: ...OMPONENTS 3 Apply some anti seize product to the ring nut thread B and to the surface that is in contact with the precombustion chamber 4 Mount the ring nut B 5 Tighten the ring nut to a temporary tor...

Page 73: ...dputinthescrews H 6 Tighten the screws in sequence see diagram to a temporary torque of 40 Nm Important Use a torque wrench with an angle torque tool to tighten the screws 7 Tighten the screws further...

Page 74: ...al versions Consult the diagram when mounting 1 Mount the weights assembly H onto the camshaft 2 Carryoutthisoperationwiththeweightsopensothat they close on the flat part of the spacing collar 3 Check...

Page 75: ...drawing 2 Greasethecoppergasket N andtheoilO ringseals N1 copiously 3 Install the injector pumps Q and fasten the nuts without tightening them 4 Tighten the nuts to a temporary torque of 10 Nm 5 Tight...

Page 76: ...ightening them 16 Tighten the screws to a final torque of 4Nm 17 Mount the rocker arm cover see Assembling the rocker arm cover 7 6 6 Assembling the mechanical fuel pump Important Check that the conta...

Page 77: ...ry torque of 20 Nm 6 Tighten the screws in an alternating pattern to a final torque of 40 Nm 7 Remove the pins and check that the rocker arms B have been inserted correctly 7 6 8 Assembling the rocker...

Page 78: ...DRIVE 7 7 2 Assembling the timing belt 1 Insertthebeltintothepulley C Keepingittaut insert into pulley A Important Keep the reference arrows G directed as shown in the diagram The timing belt must al...

Page 79: ...a few times to settle and position the belt correctly 11 Before doing so make sure that the pulley notches crankshaft and camshaft are lined up with their respective timing notches 12 Insert the tool...

Page 80: ...ightening them 3 Tighten the screws in a crisscross pattern to a final torque of 10 Nm 7 8 INSTALLATION OF THE COOLING FAN BELT DRIVE 4 Mount tool 7107 1460 051 to inhibit rotation of the crankshaft 5...

Page 81: ...ernal alternator With internal alternator 1 Install the belt flange and the pulley hub R 2 Tighten the screws S to a torque of 10 Nm 3 Carry out belt tension see Replacing alternator fan belt With ext...

Page 82: ...blockages in the ducts 4 Put on the new gaskets A 5 Mount the manifold B without tightening the nuts completely 6 Tighten the screws in an alternating pattern to a final torque of 25 Nm 7 9 2 Assembli...

Page 83: ...rical type 1 Check that the contact surfaces are perfectly clean and intact 2 Eliminate any blockages in the ducts 3 Slip on a new gasket L 4 Bring the manifold M up to the cylinder head and hook on t...

Page 84: ...84 7 Service Manual LDW FOCS 502 automotive _ cod ED0053027270 3 ed_rev 02 Notes...

Page 85: ...n place in order to safeguard the operator and any persons involved Alloperations exceptwhereexpresslystatedotherwise must be carried out when the engine is not running and has cooled sufficiently to...

Page 86: ...e to cool 2 Remove the cooling fan 3 Remove the hub and flange 4 Slip off the belt and replace it with an original spare 5 Install the flange and pulley hub 6 Manually rotate the fan to make sure the...

Page 87: ...ve Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Prepare a receptacle to catch leaks 3 Remove the filter A using the spe...

Page 88: ...ool 2 Remove the cover A 3 Extract the cover that is to be replaced B 4 Clean the cover with a jet of air 5 Replace the cartridge with an original spare 6 Mount the cover and hook it carefully into pl...

Page 89: ...ley 9 Regulate belt C tension see Replacing alternator fan belt 10 Reconnect the electrical connectors Warning Replacement may be carried out with the engine installed on the machine 1 Switch off the...

Page 90: ...s 3 Insert the ring gear into its seat and place it carefully on the rim of the flywheel B 4 Leave to the ring gear to cool gently before reassembling the flywheel Important Replacement may be carried...

Page 91: ...rly Important The valve must be heated in order to check weather it is functioning correctly Dipthethermostaticvalveinametalcontainerofwater Useathermometerwithafullscaleof150 Ctomonitor the temperatu...

Page 92: ...coupling 8 13 REPLACING THE PREHEATING GLOW PLUGS Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Remove the intake manifo...

Page 93: ...disassemble the ring nut 9 Important Rotate in an alternating way the ring nut during disassembling to avoid damaging the O ring 10 8 Extract the barrel 11 the valve 12 as well as the parts 13 14 15 8...

Page 94: ...n alternating way the ring nut during assembling to avoid damaging the O ring 10 13 Assemble in sequence all parts 5 4 3 2 on the support 7 14 Press down part 2 to fit the pin A 15 Reassemble the stop...

Page 95: ...the setting see Injector pump setting since it could be necessary to replace the adjusting shim 27 and the spring 26 8 Repeat the same operation on the other injector 9 Assemble the injector pump see...

Page 96: ...96 Service Manual LDW FOCS 502 automotive _ cod ED0053027270 3 ed_rev 02...

Page 97: ...97 Service Manual LDW FOCS 502 automotive _ cod ED0053027270 3 ed_rev 02...

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