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

3.1 LOOKING FOR MALFUNCTIONS

MALFUNCTIONS

PROBABLE CAUSE

PROBLEM

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Clogged pipes
Clogged fuel filter
Air in the fuel circuit
Clogged tank breather
Faulty fuel pump
Blocked injector
Blocked injection pump valve
Injector not adjusted
Excess leaking in the plunger
Jammed injection pump delivery control
Wrong injection pump delivery setting

LUBR

IF

IC

AT

IO

N

High oil level
Blocked pressure relief valve
Worn oil pump
Air in the oil intake pipe
Faulty pressure gauge or switch
Clogged oil suction hose

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C

TRI

C

A

L

SY

S

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Burnt fuse on pre-heating glow plugs
Failure in glow plugs control unit
Discharged battery
Inefficient or wrong cable connection
Faulty ignition switch
Faulty starter motor

M

A

IN

TEN

A

N

C

E

Air filter clogged
Excessive idle operation
Incomplete running-in
Overloaded engine
Clogged cooling circuit
Slack or broken fan control belt

A

D

JU

S

TM

E

N

TS

/

R

E

P

A

IRS

Incorrect injection timing
Delayed injection
Incorrect governor linkage 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/injector delivery balancing

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Содержание Lombardini LDW FOCS 502 Euro 2

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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