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service manual

mod. 051135

REGISTERING DOCUMENT MODIFICATIONS
This document is made up of 98 pages (-sides - excluding
the cover and title page). Pages are numbered in progressive
order

from 051135.01 to 051135.98.

Any modifications to this document must be registered by the
drafting body and approved by the head of the Quality
Management System, with completion of the table below.

Copyright 2005 - Lombardini. Reproduction, even partial, of this document is subject to the manufacturer’s written authorisation. The manufacturer is committed to a policy of continuing improvement and reserves the
right to modify the document, with no obligation to notify, providing that omission to do so constitutes no safety risk. The text may be reproduced in part or in whole, providing that the author is cited. Text and
graphics by: IDM Esperti in Comunicazione Tecnica - Forlì

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ATLO

1-5302-727

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30/06/05

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Summary of Contents for LDW 502

Page 1: ...SERVICE MANUAL code 1 5302 727 ...

Page 2: ...05 Lombardini Reproduction even partial of this document is subject to the manufacturer s written authorisation The manufacturer is committed to a policy of continuing improvement and reserves the right to modify the document with no obligation to notify providing that omission to do so constitutes no safety risk The text may be reproduced in part or in whole providing that the author is cited Tex...

Page 3: ...the timing belt 32 5 4 3 Disassembling the pulleys camshaft and crankshaft 32 5 5 REMOVING THE CYLINDER HEAD 33 5 5 1 Disassembling the rocker arm cover 33 5 5 2 Disassembling the rocker arms 33 5 5 3 Disassembling the fuel pump 33 5 5 4 Disassembling the injection pumps 34 5 5 5 Disassembling the precombustion chamber 34 5 5 6 Disassembling the speed governor and flow limiter 35 5 5 7 Disassembli...

Page 4: ...njection pumps 73 7 6 6 Assembling the mechanical fuel pump 74 7 6 7 Assembling the rocker arms 75 7 6 8 Assembling the rocker arm cover 75 7 7 INSTALLING THE TIMING BELT DRIVE 76 7 7 1 Assembling the timing belt pulley 76 7 7 2 Assembling the timing belt 76 7 7 3 Assembling the belt drive cover 77 7 8 INSTALLATION OF THE COOLING FAN BELT DRIVE 78 7 8 1 Assembling the fan belt drive pulleys 78 7 8...

Page 5: ...per 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 1 2 USING THIS MANUAL This manual is divided into several chapters The first chapter gives general information and details about safety purpose of the manual safety etc The second third and fourth cha...

Page 6: ...Non compliance with this requirement may be hazardous to the health and safety of individuals 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 Som...

Page 7: ... except where expressly stated otherwise must be carried out when the engine is not running and has cooled sufficiently to avoid the risk of burns Do not keep the engine running in areas that are closed and inadequately ventilated Take all necessary precautions to prevent a build up of exhaust fumes Every organisation has a duty to implement procedures to identify assess and monitor the influence ...

Page 8: ... 8 service manual mod 051135 Notes GENERAL REMARKS AND SAFETY ...

Page 9: ... 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 manifold P Starter motor Q Camshaft R Coolant pump S Fuel supply pump T Oil pump 2 1 GENERAL DESCRIPTION OF THE ENGINE TECHNICAL INFORMATION ...

Page 10: ... rotation Combustion sequence Timing system Dry weight of engine Maximum tilt while operating Maximum tilt while operating Maximum tilt while operating Volume of air flow at 3600 RPM Volume of cooling air at 3600 RPM 1 with suction fan 2 with blower fan Maximum operating speed Max power N 80 1269 EEC ISO 1585 DIN 7020 Max power NB ISO 3046 1 IFN DIN 6270 Max power NA ISO 3046 1 ICXN DIN 6270 Maxim...

Page 11: ...temperature of 120 C Oil filter cartridge Maximum operating pressure Maximum combustion pressure Filter capacity By pass valve setting Filtering surface Completely forced Trochoid pump no lower than 1 bar including filter I excluding filter I COOLING CIRCUIT Coolant Thermostatic valve Opening temperature Max stroke at 94 C Liquid return ELECTRICAL EQUIPMENT Nominal voltage Alternator nominal volta...

Page 12: ...5 2 2 3 CHARACTERISTIC CURVE DIAGRAMS Power curve diagram 80 1269 CEE 95 1 CE 3000 tr min Legend NB Power curve MB Torque curve C Specific consumption curve Power curve diagram 80 1269 CEE 95 1 CE 3600 tr min TECHNICAL INFORMATION ...

Page 13: ...ad curve diagram 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 constant voltage 12 5V The alternator turns at the same rate as the engines TECHNICAL INFORMATION ...

Page 14: ... oil Oil type Oil characteristics 2 5 1 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 régime The criteria for choosing must consider during winter the lowest ...

Page 15: ...er 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 pump Crankshaft Oil suction filter Ref Description Coolant refilling plug Compensation tank Thermostatic valve Cylinder block Liquid temperature monitoring thermostat Circulating pump Fan Radiator Ref TECHNICAL INFORMATION ...

Page 16: ... With electrical supply pump Description Tank Fuel filter Supply pipe Supply pump Injection pump Injector Fuel rail Exhaust pipe Plug Solenoid valve Ref Description Tank Fuel filter Supply pipe Electrical supply pump Pump Injector Fuel rail Exhaust pipe Plug Ref Note the tank is supplied complete with filter on request TECHNICAL INFORMATION ...

Page 17: ...light Fuel level indicator Relay normally closed with a 3 second delay 40 50 A Electrical fuel lift pump Ref Description 40A alternator Starter motor Battery recommended 44Ah 210A DIN Preheating glow plugs Coolant 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 temperatur...

Page 18: ...or Fuel level light Fuel level indicator 25 V 10000 µF condensator Electrical fuel lift pump Ref Description 40A alternator Starter motor Battery recommended 44Ah 210A DIN Preheating glow plugs Coolant 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 indicator ...

Page 19: ...lity Dimensions Diameter 2 10 SPECIAL TOOLS AND EQUIPMENT FOR MAINTANANCE 2 11 TABLE FOR TIGHTENING TORQUES The table shows the tightening torques for standard screws and the main components Tightening torques are provided again along with method and sequence in the instructions for assembling components and or assemblies Serial number Serial number Description Description Instrument for balancing...

Page 20: ...eads Quality Dimensions Diameter Description Injector pump connecting rod Aluminium connecting rod Preheating glow plugs Rocker arm cover Crankcase screws 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 pulley Injector pump nut Rocker arm support nuts...

Page 21: ...d plug ø 30 Sealant 2 12 TABLE OF SEALANTS Pump injectors Radiator fan Valve and rocker arm clearance Engine oil Solenoid valve operation Oil vapor recovery Fuel pipe and connections Coolant Alternator belt Timing belt Alternator Air filter element Engine oil Oil filter Fuel filter Coolant Alternator belt Timing belt Fuel pipes PROCEDURE CHANGE DETAIL REGULARITY KM per 1000 Km CLEANING CHECK After...

Page 22: ... 22 service manual mod 051135 2 Notes TECHNICAL INFORMATION ...

Page 23: ...fan control belt Advance injection Delayed injection Incorrect governor tinkage adjustment Broken or loose governor spring Low idle setting Worn or stuck piston rings Worn or scored cylinders Worn valve guides Valves stuck Worn crankshaft connecting rod bearings Non sliding speed governor leverage Driving shaft not turning freely Damaged head gasket Slack pump injector control rod Incorrect pump i...

Page 24: ... 24 service manual mod 051135 3 MALFUNCTIONS ...

Page 25: ... measures that are valid for 6 months 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 Protective treatment after 6 months of inactivity 4 3 STORING THE ENGINE INSTALLED If the engine has been installed on a machine and is not due to be used for ext...

Page 26: ...e protective treatment 2 Remove any blockages from 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 replace the intake manifold 6 Adjust the alternator fan belt tension 7 Turn the flywheel manually to check the movement of the mechanical pa...

Page 27: ...lters 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 when the engine is not in use and so it is important to consider whether they need replacing based not only on the number of hours of use but also on age and wear 5 Check that the engine oil and coolant are up to level 6 Start t...

Page 28: ... 28 service manual mod 051135 4 STORING THE ENGINE ...

Page 29: ...he 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 Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved For safety and convenience you are advised to place the engine on a special rotating st...

Page 30: ...L 3 Remove the gaskets M 4 Close the openings and ducts to prevent foreign bodies from entering 1 Remove the cooling fan A Important The cooling fan belt drive comes in more than one version with external or internal alternator 5 3 REMOVING THE COOLING FAN BELT DRIVE with internal alternator with external alternator REMOVING THE ASSEMBLIES ...

Page 31: ...asing 1 Disassemble the starter motor 2 Install tool 7107 1460 051 to inhibit rotation of the crankshaft 3 Loosen the screw G Caution Warning The screw is left handed Turn clockwise to unscrew 4 Remove the hub E and flange 5 Remove the pulley F washers and spacer 5 3 2 Disassembling the cooling fan belt with internal alternator 1 Remove the hub E and flange 2 Remove the belt D 3 Remove the pulley ...

Page 32: ...lley nut M to fully loosen the belt N 2 Remove the belt N working it away in sequence first from the pulley and P and then from the others Important The timing belt must always be replaced with an original spare part whenever it is removed 5 4 3 Disassembling the pulleys camshaft and crankshaft 1 Remove the pulley P 2 Remove the pulley Q REMOVING THE ASSEMBLIES ...

Page 33: ...e 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 pump 1 Disconnect the supply pipe G1 from the union 2 Remove the supply pump G 3 Remove the O ring G2 4 Extract the drive rod H 5 5 1 Disassebling the rocker arm cover 1 Remove the negative pressure vent valve A 2 Remove t...

Page 34: ... to be used during installation do not loosen the screws LI in order to not balance injector pump deliveries during tuning 3 Unscrew the screws M 4 Remove the connecting rod M1 5 Dismount the injection pumps N 5 5 5 Disassembling precombustion chamber 1 Disconnect the electric cable P 2 Remove the preheating glow plugs Q 3 Unscrew the ring nut R using the special pin wrench 7107 1460 027 pin wrenc...

Page 35: ... 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 flow limiter V 4 Unscrew the pin and extract the governor tinkage adjustment pin W extractor 7107 1460 027 REMOVING THE ASSEMBLIES ...

Page 36: ...emoved 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 off the gasket B 5 6 1 Disassembling the flywheel 1 Disassemble the starter motor A 2 Install tool 7107 1460 051 to inhibit rotation of the crankshaft 3 Remove the flywheel B tool 7107 1460 027 REMOVING THE ASSEMBLIES ...

Page 37: ...er one flywheel side to the top dead 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 to force removal of the pump if its activation key is not lined up with the break in the flange 4 Remove the oil pump F 5 Take off the gasket G crankshaft oil pump activation key REMOVING THE ASSEMBLIES ...

Page 38: ...ske off the gasket L 3 Remove the crankcase M 4 Remove the connecting rod cap N Caution Warning Before removing the cap mark the area of contact with the connecting rod in order to recognise the right position during reassembly 5 Remove the crankshaft P and place it in a container for washing REMOVING THE ASSEMBLIES ...

Page 39: ...atch it up during reassembly Important Be careful not to damage the half bearing during removal 1 Place the cylinder head on the workbench 2 Press down hard on the cup A using the special tool 3 Remove the half collets B blocking the cup A the spring C the collar D and the gasket E 5 7 DISASSEMBLING THE VALVES 4 Remove the valves F Important Keep components together during the disassembly phase in...

Page 40: ... 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 DISASSEMBLING THE PISTON Notes 3 Remove the stop rings F REMOVING THE ASSEMBLIES ...

Page 41: ...heck 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 6 1 1 Shaft seals Lubricate the seal before introducing it to its seat Avoid rolling the gasket during the attachment...

Page 42: ...ass only applies to new engines 6 2 3 Dimensional check and overhaul of pistons 1 Clean the piston thoroughly D 2 Using a micrometer measure the piston 9mm from the base of the skirt 3 Check the table to identify the class from the values detected The class letter is engraved on the piston If clearance between cylinder and piston is greater than 0 05mm the piston and sealing rings must be replaced...

Page 43: ...ings Dimensional 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 crown 4 Using a thickness gauge measure the clearance of each sealing ring If clearance L does not correspond to the values shown replace the sealing rings with original spares see Table of ...

Page 44: ...re the diameter of the main journals A1 and crank pins B1 Important Crankshaft half bearings cannot be replaced separately If the crankshaft needs to be ground establish the diameters of the connecting rod and crank pins in order to choose the matching measurements available of connecting rod and half bearing spare parts see Table of diameters of connecting rods and half bearings When grinding the...

Page 45: ... 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 Important Protect the contact surfaces with lubricant oil to prevent them from rusting 6 2 7 Checking parallelism of the connecting rod axes 1 Insert the wrist pin V in the connecting rod small end 2 Use a dial indicator to check that ther...

Page 46: ...e valve G the spring F the gasket 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 Important Given the particular function played by this sealing ring it is important to use only original spares 12 Mount the rotors H with the referance notches facing upwards so that they are visible 13 Using a thickness gaug...

Page 47: ...a 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 torque 45 Nm 6 3 OVERHAUL OF CYLINDER HEADAND RELATED COMPONENTS 6 3 1 Checking and overhauling the cylinder head 1 Place the cylinder head on a surface plate and position it with the corners on the stud bolts 2 Using a dial indic...

Page 48: ...e rocker arm from the pivot pin B 4 Thoroughly clean the components 5 Using a micrometer measure the diameters of the pivot pin and the rocker arms see Table of dimensions pin rocker arm If the diameters do not correspond to the values shown replace the pin and if necessary the rocker arms with original spares If the pin can be re used remove the plugs and clean the inside carefully to eliminate r...

Page 49: ...ft 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 measure the diameters of the seats X and with a micrometer find out the diameters of the camshaft øa b see Table of camshaft dimensions Table of camshaft dimensions If the diameters do not correspond to the val...

Page 50: ...nt oil to prevent them from rusting 3 Replace the camshaft see Assembling tha camshaft 6 3 4 Checking and replacing the fuel pump drive rod To check the drive rod it is necessary to disassemble the fuel pump See Disassembling the fuel pump for the correct procedure 1 Rotate the camshaft until the drive rod is at the most indented point 2 Check that the distance between the drive rod A and the cyli...

Page 51: ...he valve seats 6 Remove any debris clean the valve seat holder carefully and scrape the mouth 7 Lubricate the new valve seats and put them into the holder manually 6 3 5 Checking and overhaulimg the valves In order to carry out a control of the valves it is necessary to remove them from the cylinder head See Disassembling the valves for the correct procedure 1 Use a gauge to measure the length of ...

Page 52: ...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 other valves 6 3 7 Checking clearance volume 1 Position the pistons at the top dead centre 2 Measure the distance in four diametrically opposite points on the piston crown 3 Repeat the operation on all pistons The...

Page 53: ...eved the spring see Nozzle injector replacement must be replaced 7 After replacing the spring calibrate at 10 bars higher than the optimal operating calibration of 140 155 bars When the spring settles the calibration will level at the optimal value 8 Remove the tool 7107 1460 074 9 Replace the non return valve 10 Assemble the injection pump on the engine see Assemble injection pumps 6 3 9 Checking...

Page 54: ... zero 6 Rotate the crankshaft clockwise until the dial indicator moves away from zero 7 Measure the rotation angle of the crankshaft by using the magnetic goniometer The value registered indicates when the intake valve starts opening 8 Go on rotating the crankshaft clockwise until the dial indicator stops at point 0 9 Measure the rotation angle of the crankshaft by using the magnetic goniometer Th...

Page 55: ... centre γ γ γ γ γ 5 after I bottom dead centre δ δ δ δ δ 18 before S top ded centre 6 6 ADJUSTING STATIC INJECTION TIMING In order to adjust injection timing it is necessary to remove the rocker arm cover See Disassembling rocker arm cover for the correct procedure 1 Disassemble the injector pump fuel rail A 2 Select the cylinder on which the injection static advance adjustment will be carried out...

Page 56: ... the crankshaft clockwise until the injection cam acts on the rocker arm that controls the injector pump In these conditions the piston is near the compression top dead centre 11 Place the auxiliary tank at a height higher than that of the injectors 30 40 cm 12 Connect the tank to union H 13 Rotate slowly the crankshaft clockwise keeping the lever L lowered and the valve set on the piston crown un...

Page 57: ...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 operation the injection static advance must be as follows Engine with maximum speed up to 3000 rpm 13 1 Engine with maximum speed above 3000 rpm 15 1 Conversion table for establishing injection timing If the ...

Page 58: ...ws 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 Importante It is necessary to balance delivery whenever the injection pump is replaced In order to work on the injector it is necessary to remove the rocker arm cover See Disassembling the rocker arm cover for the correct proced...

Page 59: ... 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 Tighten the screws to a torque of 4Nm 3 Position the assembly 7107 1460 127 above the height of the injectors 4 Connect the outlet and intake pipes of the assembly to the test heads Important Be careful not to reverse the i...

Page 60: ...To decrease the rpm number tighten the screw whereas to increase it loosen the screw 6 8 ADJUSTING MINIMUM AND MAXIMUM IDLE SPEED RPMS 6 9 ADJUSTING INJECTION DELIVERY 6 9 1 Adjusting injection delivery without dyno break 1 Loosen locknut A 2 Firmly tighten the screw B of the flow limiter 3 Start the engine and bring it to the operating temperature 4 Bring the engine to maximim rpm allowed 5 Loose...

Page 61: ... B with the locknut A 9 Deactivate the dyno brake and take note of the stabilized engine speed 10 Switch off the engine and leave to cool 11 Check the valve rocker arm clearance see Adjusting valve rocker arm clearance 1 Remove the preassure switch A 2 Mount a union in the hole B and connect to a 10 bar pressure gauge C 3 Start the engine and bring it to the operating temperature 4 Start the engin...

Page 62: ... 62 service manual mod 051135 6 OVERHAULS AND TUNING ...

Page 63: ...fely 7 1 RECOMMENDATIONS FOR INSTALLING THE ASSEMBLIES 7 2 PRE ASSEMBLY OF SEALING RINGS PISTONS Thoroughly clean the pistons and lubricate the coupling areas 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 crown Keep the pistons together with their own connecting rods and wrist ...

Page 64: ...ecting rod B complete with cap 4 Insert the wrist pin completely and fasten with the lock ring Important Make sure the lock rings are positioned correctly in their seats Lubricate the coupling parts and those that are prone to oxidation 7 3 PRE ASSEMBLY OF CONNECTING RODS PISTONS 7 4 INSTALLING VALVES 7 4 1 Assembling the valves Important Make sure that the cylinder head is perfectly clean and dry...

Page 65: ...kcase 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 rod piston assembly B 4 Rotate the sealing rings so that the cuts have a displacement of about 120 between them Important In order not to damage the sealing rings and the contact areas while inserting the piston into the cyl...

Page 66: ...e screws 6 Tighten the connecting rod cap screws to a temporary torque of 25Nm 7 Tighten the connecting rod cap screws to a final torque of 30Nm 8 Assemble the crankcase see Assembling the crankcase 9 Measure the axial clearance of the crankshaft see Measuring crankshaft axial clearance 7 5 3 Assembling the crankcase Important Make sure that the contact surfaces and related pins are perfectly inta...

Page 67: ...g 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 uprated shoulder half rings and once again disassemble the crankcase see Dimensional check and overhaul of crankshaft 7 5 5 Assembling the crankshaft flange flywheel side 1 Clean the flange and the sealing ring seat N 2 Using the ...

Page 68: ...re 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 pump activation key into the crankshaft 3 Bring piston number one flywheel side to the top dead centre with the oil pump activation key in line with break in the flange in order to be able to assemble the pump 4 Install the pump B...

Page 69: ...n the screws 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 screws H 3 Tighten the screws temporarily in a crisscross pattern 4 Tighten the screws in a crisscross pattern to a final torque of 80Nm Important Turn the flywheel manually to check the movement of the mechanical parts oil pump...

Page 70: ...e 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 torque of 100Nm 6 Make sure that the precombustion chamber protrusion C is between 3 56 4 04 mm If the protrusion C exceeds the recommended value insert a shim D provied ad spare part beneath the precombustion chamber A 7 Tighten the r...

Page 71: ...en 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 clockwise rotating 90 8 Tighten the screws to their final torque rotating 90 Important If the screws H belong to 10 9 class the tightening torque is 60Nm and it is not necessary to tighten them further 7 6 3 Assembling the c...

Page 72: ...diagram when mounting 1 Mount the weights assembly H onto the camshaft Carry out this operation with the weights open so that they close on the flat part of the spacing collar 2 Check that all the components of the cover L are intact and if necessary replace them with original spares Important Make sure that the contact surfaces are perfectly intact and clean 3 Mount the new O ring on the cover L ...

Page 73: ...sket N and the oil O ring seals 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 Tighten the nuts to a final torque of 20 Nm 6 Hook the connecting rod R to the adjustment levers and fasten the injector pumps without fully tightening the screws 7 Tighten the screws to a final torque of 1 1 Nm 8 Hook the sprin...

Page 74: ...n 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 contact surfaces are perfectly clean and intact Make sure that the length of the drive rod is between 153 15 153 25 mm otherwise replace it 1 Insert the drive rod V 2 Mount a new O ring W 3 Install the fuel pump Z and fasten the ...

Page 75: ... 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 arm cover Important Make sure that the rocker arm cover is perfectly clean and dry Check that the contact surfaces are perfectly clean and intact 1 Slip on a new gasket C 2 Apply some silicone sealant on the fuel rail s...

Page 76: ...the timing belt 1 Insert the belt into the pulley C Keeping it taut insert into pulley A Important Keep the reference arrows G directed as shown in the diagram The timing belt must always be replaced with an original spare part whenever it is removed 2 Keep the belt inserted into the two pulleys and then mount it onto pulley E and the pulley nut F 3 Tighten the belt using the pulley nut F and fast...

Page 77: ...ion 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 again into the lever on the pulley nut support and repeat all the steps to check belt tension 13 Disassemble the pulley G1 7 7 3 Assembling the belt drive cover 1 Mount the guard G without tightening the screws completely 2 Tighten...

Page 78: ...e 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 Apply some anti seize product to the screw thread L Caution Warning The screw is left handed Turn anticlockwise to screw 6 Tighten the screw L to a torque of 180 Nm 7 Remove the tool M 8 Install the starter motor N and tighten...

Page 79: ...ernal alternator 1 Install the belt flange and the pulley hub R 2 Tighten the screws to a torque of 10 Nm 3 Carry out belt tension see Replacing alternator fan belt With external alternator 1 Install the flange and the pulley hub R 2 Tighten the screws to a torque of 10 Nm 3 Install the belt T 4 Tighten the belt T see Replacing the alternator fan belt With internal alternator With external alterna...

Page 80: ... 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 Assembling the intake manifold Panel dry air filter 1 Check that the contact surfaces are perfectly clean and intact 2 Eliminate any blockages in the ducts 3 Slip on a new gasket D 4 Bring the manifold C up to the cylinder head and ...

Page 81: ...t 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 the minimum maximum device 5 Install the manifold M without tightening the screws N completely 6 Tighten the screws in an alternating pattern to a final torque of 25Nm 7 Check the state of the filter cartridge If necessary remove the c...

Page 82: ... 82 service manual mod 051135 7 Notes INSTALLATION OF ASSEMBLIES ...

Page 83: ...he operator and any persons involved 8 2 REPLACING THE ALTERNATOR FAN BELT Important Replacement may be carried out with the engine installed on the machine The engine may have an external or internal alternator With external alternator 1 Switch off the engine and leave to cool 2 Loosen the nuts B B1 3 Loosen the belt by adjusting the alternator manually and tighten the nut B1 8 1 RACCOMMENDATIONS...

Page 84: ... 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 belt is fitted correctly 7 Tighten the screws to a torque of 10 Nm 8 Regolare la tensione della cinghia Important To check the belt tension follow the procedure explained in the figure The resultant R must be 10 15 mm If the belt ...

Page 85: ...d leave to cool 2 Prepare a receptacle to catch leaks 3 Remove the filter A using the special tool 4 Lubricate the new filter seal with engine oil 5 Install and tighten the filter manually Important Polluting substances should be disposed of properly in full compliance with the law 8 3 REPLACING THE TIMING BELT 4 Replace the timing belt with an original spare see Assembling the timing belt drive 5...

Page 86: ...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 place 8 5 REPLACING THE AIR FILTER Filtro a cartuccia 1 Switch off the engine and leave to cool 2 Remove the cover C 3 Extract the cover that is to be replaced D 4 Clean the cover with a jet of air 5 Replace the cartridge wit...

Page 87: ...acement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disconnect the electrical connectors 3 Remove the starter motor Important If in order to take care of the problem it is necessary to remove the motor please refer to an authorised BOSCH service centre 4 Install the starter motor A and tighten the screws 5 Tighten the screws to a final to...

Page 88: ...ear into its seat and place it carefully on the rim of the flywheel B Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disconnect the electrical connectors 3 Remove the thermostat Important The screw is left handed turn clockwise to unscrew 4 Install the new thermostat 5 Tighten the thermostat to a torque of 30 Nm Importa...

Page 89: ...ated in order to check weather it is functioning correctly Dip the thermostatic valve in a metal container of water Use a thermometer with a full scale of 150 C to monitor the temperature of the water in the container Heat the water and using the thermometer make sure that the temperature at which the valve begins to open is between 78 and 82 C If the thermostatic valve opens at a different temper...

Page 90: ...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 manifold see Disassembling the intake manifold 3 Disconnect the electric cable 4 Disconnect the preheating glow plugs 5 Install the new preheating glow plugs and tighten the screws to a torque of 20 Nm 6 Reconnect the electric cab...

Page 91: ...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 14 REPLACING INJECTOR PUMP PARTS Caption 1 Tension washer 2 Tappet 3 Stop collar 4 Plunger 5 Spring 6 Screw 7 Support 8 Lever 9 Ring nut 10 O ring 11 Barrel 12 Delivery valve 13 Gland 14 Spring 15 Filler 16 Pin 17 O ring 18 ...

Page 92: ...t 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 ring 1 16 Rotate the plunger 4 by means of the control blade 29 as shown in the figure 17 Insert the lever 8 and engage it in the plunger 4 Caution Warning Check that the position of both lever 8 and plunger control blade 29 is ...

Page 93: ...pump setting since it could be necessary to replace the adjusting shim 27 and the spring 26 Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disassemble the cooling fan belt drive see Removing the cooling fan belt drive 3 Remove the belt drive cover see Disassembling timing belt casing 4 Remove the support A 5 Install the...

Page 94: ... 94 service manual mod 051135 8 Notes REPLACING PARTS ...

Page 95: ...eplacing 88 Coolinf fan belt drive removing 30 Cooling fan belt drive installation 78 Cooling fan blet with external alternator disassembling 31 Cooling fan blet with internal alternator disassembling 31 Cooling fan support replacing 93 Cooling fan assembling 80 Cooling operating principle 15 Crank gear and crankcase removing 36 Crank gears and crankcase overhauling 41 Crankcase and crank gear rem...

Page 96: ...15 Operating principle for fuel injection 16 Operating principle for lubrification 15 O rings 41 Overhaul and dimensional check of connecting rods 45 Overhaul and dimensional check Cylinders 42 Overhaul and dimensional check pistons 42 Overhaul and dimensionalcheck crankshaft 44 Overhaul of cylinder head and components 47 Overhauling and checking the cylinder head 47 Overhauling and checking the f...

Page 97: ... Tabella classi e dimensioni cilindri pistoni 42 Table of cam dimensions 50 Table of camshaft dimensions 49 Table of connecting rod dimensions 45 Table of cylinder piston classes and dimensions 42 Table of diameters of connecting rods and half bearings 44 Table of dimensions for springs valve stems valve guides 51 Table of dimensions pin rocker arm 48 Table of head gasket and clearance volume valu...

Page 98: ...SERVICE MANUAL code 1 5302 727 ...

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