LDW 502 LDW 602 LDW 903 LDW 1204 LDW
WORKSHOP
MANUAL
Focs series engines, code 1-5302-351
LDW 502
LDW 602
LDW 903
LDW 1204
LDW 1204/T
LDW 702
LDW 1003
LDW 1404
5st Edition
SERVICE
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
10.06.99
ENDORSED
1
FOREWORD
We have done all in our power to give up to date and accurate technical information in this manual. Lombardini
engines are, however, constantly developing thus the data in this publication may be liable to modification without
prior notice.
The information in this manual is the exclusive property of Lombardini. Neither partial nor total duplications or
reprints are therefore permitted without the express authorization of Lombardini.
The information in this manual is given on the assumption that:
1- the persons who service Lombardini engines have been adequately trained and outfitted to safely and
professionally carry out the necessary tasks;
2- the persons who service Lombardini engines possess the necessary skills and special Lombardini tools to
safely and professionally carry out the necessary tasks;
3- the persons who service Lombardini engines have read the specific information concerning the above
mentioned Service operations and that they have clearly understood the operations required.
GENERAL SERVICE NOTES
1 - Only use genuine Lombardini spare parts. Use of spurious spares may lead to incorrect performance and
shorten the life of the engines.
2 - The metric system is used to express all data, i.e. the dimensions are given in millimeters (mm), torque is
expressed in Newton-meters (Nm), weight in kilograms (Kg), volume in liters or cubic centimeters (cc) and
pressure in barometric units (bar).
SERVICE
WARRANTY CERTIFICATE
WARRANTY CERTIFICATE
Engine manufactured by Lombardini S.r.l., are warranted to be free of defects in workmanship or materials for 12
months from the date of delivery to the first purchaser or non more than two (2) years from date of engine delivery
to the Original Equipment Manufacturer as defined by Lombardini invoicing, whichever occurs firsts, except as
defined below.
Stationary applications, working at constant speed and/or slightly variable speeds, are excluded from the above
terms. Stationary/fixed speed applications will be warranted to be free of material/workmanship defects for a
maximum operational period of 1000 hours or 12months from the date of first purchase, whichever occurs first.
The two (2) year limitation from date of Lombardini invoice will remain intact as described above.
Modification of Lombardini products by the Original Equipement Manufacturer or the end user with respect to
cooling systems, filtration systems, induction systems, exhaust systems, lubrication system, fuel system, fuel
system settings, etc., will require special written warranty agreements. A test certificate/approval by the R&D/
Application engineering department of Lombardini or associated Lombardini companies concerning modified
Lombardini products will entitle Warranty as defined above. Warranty will not be granted on any modified
Lombardini product without special written approval by Lombardini.
Within the above stated periods Lombardini will replace and/or repair, at the option of Lombardini, any part or
component that, upon examination by Lombardini or an authorized Lombardini agent, is found to be defective in
workmanship or materials. Any other responsibility/obligation for different expenses, damages and direct/indirect
losses deriving from the engine use or from both the total or partial impossibility of use, is excluded.
The repair or replacemnt of any component will not extend or renew the warranty period. Direct labor required to
make repairs or to replace components found to be defective in materials or workmanship will be completed at no
cost to the end user. Lombardini in not responsible however for indirect costs of removing/installing the engine
assembly. Further, Lombardini is not responsible for the costs of transportation of the machine or components
requiring repair or for service supplies such as lubricating oils and filters.
Lombardini Warranty obligations will be cancelled if:
- Lombardini engines are applied to a given machine causing working engine parameters outside Lombardini
application guidelines.
- Lombardini engines are not serviced and maintained according to the "USE and MAINTENANCE" booklet.
- Any seal affixed to the engine by Lombardini has been tampered with or removed.
- Engines have been disassembled, repaired or altered by any party other than an authorized Lombardini agent.
- Spare parts used are not original Lombardini.
- Fuel injection system/component failures caused by the use of unauthorized fuel types or poor quality fuels
are not covered under the Lombardini warranty policy.
- Electrical system failures due to the modification of Lombardini supplied harnesses, modification of
Lombardini supplied control panels, OEM/end user supplied/installed relays, controls, etc. are not covered
under warranty.
Following expiration of the above stated warranty period(s) and limitations, Lombardini will have no further
responsibility for warranty and will consider our obligation for warranty complete.
The above warranty certificate will be in effect starting July 1, 1993 and cancels/replaces any and all explicit or
implicit warranty policies on the part of Lombardini. The above warranty conditions can from this date forward be
modified only in writing.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
3
INDEX
This manual contains pertinent information regarding the repair of LOMBARDINI water-cooled,
indirect injection Diesel engines type LDW 502-602-903-1204-124/T and LDW 702-10031404: updated November 15, 1999.
INDEX
TROUBLESHOOTING CHART - LDW FOCS SERIES
Pag.
9
SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS
"
10
I
GENERAL
POWER RATINGS FOR LDW-FOCS GENSET SPEC DIESEL ENGINES
LDW FOCS SERIES - TECHNICAL SPECIFICATIONS AND CAPACITIES LDW 502-602903-1204-1204/T
FLUID CAPACITIES (STANDARD) LDW 502-602-903-1204-1204/T
LDW FOCS SERIES - TECHNICAL SPECIFICATIONS AND CAPACITIES LDW 702-10031404
FLUID CAPACITIES (STANDARD) LDW 702-1003-1404
POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES LDW 502-602-903
POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES LDW 1204-1204/T
POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES LDW 702-1003-1404
GENERAL ENGINEERING DRAWINGS - LDW 502-602-903
GENERAL ENGINEERING DRAWINGS - LDW 1204-1204/T
GENERAL ENGINEERING DRAWINGS - LDW 702-1003-1404
LDW-FOCS SERIES MAINTENANCE SCHEDULE
RECOMMENDED OIL
DIESEL FUEL SPECIFICATIONS
ANTI-FREEZE / COOLANT SPECIFICATIONS / DETAILS - FOCS SERIES
DRIVING TORQUES FOR STANDARD SCREWS
SEALANT AND THREAD LOCK LOCATIONS/DETAILS
CRITICAL TORQUE SPECIFICATIONS
SPECIAL TOOLS
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DISASSEMBLY / REASSEMBLY
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25
II
Air filter support - (intake manifold)
Air restriction switch
Alternator / cooling fan drive belt
Camshaft journal / support bore specifications
Camshaft journal / support measurement
Camshaft lobe measurement procedure
Camshaft lobe specifications
Camshaft removal / replacement
Camshaft timing pulley
Connecting bearing / rod cap installation
Connecting rod / connecting rod bearings specifications
Connecting rod alignment
Connecting rod-piston assembly balance
Cooling fan
Cooling fan support
Crankcase breather - LDW 502
Crankcase vacuum regulator valve (602, 702, 903, 1003, 1204, 1204/t, 1404)
Crankshaft end play
Crankshaft journal inspection / measurement
Crankshaft journal specifications
Crankshaft lubrication drillings-typical
Crankshaft pulley
Crankshaft seals - front and rear
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4
COMPILER TECO/ATI
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REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
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REVISION
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DATE
15.11.99
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ENDORSED
Crankshaft timing pulley
Cylinder class
Cylinder head installation
Cylinder head removal
Cylinder head tightening procedure- LDW 1204, LDW 1404, LDW 1204/T
Cylinder head tightening procedure- LDW 502, 602, 702, 903 and 1003
Cylinder inspection / dimensional specifications
Cylinder surface finish
Dry type air filter- standard engine mounted
Exhaust manifold
Flywheel / ring gear
Front / rear main bearing caps / bearings
Fuel rail
Fuel tank - (optional accessory)
General piston notes
Governor fork
Governor springs
Head gasket selection/ installation
Hydraulic drive components- no. 3 pto
Hydraulic pump pto- (no. 3 pto)
Idler pulley
Injection pump control rod
Limiting speed governor
Main and connecting rod bearings
Main bearing caps / bearings- center
Main bearing clearance
No. 2 pto (crankshaft pulley) with “ringfeder”- LDW 1204, LDW 1204/T, LDW 1404
Oil bath air filter
Oil pan removal / installation
Oil pump assembly
Oil pump assembly to the engine
Oil pump inspection
Piston / connecting rod disassembly and piston inspection
Piston / connecting rod installation
Piston balance
Piston class, weight imbalance and genuine lombardini markings
Piston cooling jets- ldw 1204/t
Piston protrusion
Piston removal
Piston ring assembly location
Piston ring end gap
Piston ring to piston land clearance
Piston wrist pin installation / retaining snap ring
Precision speed governor -(gensets)
Pre-combustion chamber installation
Pre-combustion chamber removal
Pre-combustion chamber ring nut
Pre-combustion chamber-overview
Rocker arm assembly
Speed governor
Speed governor reassembly
Thrust bearings
Thrust surface specifications-crankshaft end play corrections
Timing belt / timing pulley arrangement
Timing belt cover
Timing belt installation- timing procedure
Timing belt removal
Timing belt tension procedure
Timing belt tensioning procedure- setup
Timing pulley - reference marks
Undersized bearings- rod and main
Unit injector check valve
Unit injector removal / installation
Valve / rocker cover
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COMPILER TECO/ATL
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REG. CODE
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MODEL N°
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50563
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DATE OF ISSUE
04.90
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REVISION
1-5302-351
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04
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DATE
15.11.99
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ENDORSED
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35
49
53
44
53
53
49
49
31
32
33
54
41
33
48
38
38
52
57
57
35
41
39
57
54
54
34
31
47
39
39
39
48
51
48
48
54
52
48
50
50
50
51
38
47
47
47
46
42
38
39
55
55
34
34
36
35
36
36
36
57
41
42
40
5
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
III
/ rocker cover gasket
adjustment
guide installation guidelines and post installation valve/valve guide specifications
guides / valve guide bore
recess and seat sealing width
removal
seats
specifications
springs
stem seal installation
timing angles
timing confirmation
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40
41
45
45
46
44
46
45
45
44
37
37
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"
TURBOCHARGER
Turbocharger
Turbocharger
Turbocharger
Turbocharger
IV
identification
components
pressure testing
waste gate adjustement-bench method
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58
58
58
59
"
LUBRICATION SYSTEM
Lubrication system
Oil pick-up screen and oil drain back tube
Oil pump specification
Oil filter
Oil pressure testing
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V
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"
COOLING SYSTEM
LDW-FOCS cooling system schematic
Cooling system pressure check/radiator cap inspection
Coolant pump details
Thermostat
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VI
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6
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COMPILER TECO/ATI
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REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
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REVISION
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04
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DATE
15.11.99
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63
63
64
64
64
FUEL SYSTEM
Barrel and plunger detail- (typical) current unit injectors (example- 6590-285)
Barrel and plunger detail- early unit injectors (typical)
Early unit injectors
Engine timing reference marks
Equalization tool installation, plumbing
Fuel filter assembly
Fuel rate adjustment details
Fuel system schematic
Fuel system special tools
Fuel transfer pump
Fuel transfer pump push rod protrusion
Injector
Injector nozzle protrusion
Late/ intermediate unit injectors
Static injection test instrumentation- early unit injectors
Static timing adjustment
Tdc determination and static injection timing checking
Unit injector
Unit injector components
Unit injector delivery equalization- preparation
Unit injector delivery equalization- preparation (cont.)
Unit injector fire ring
Unit injector plunger reassembly
Unit injector popping pressure testing and adjustment- low pressure procedure (current / intermediate
unit injectors)
60
60
61
61
62
62
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58
69
69
71
72
73
65
73
65
67
65
65
65
70
71
71
72
71
68
68
73
73
70
68
70
ENDORSED
65
Unit injector popping pressure testing and adjustment- high pressure procedure (early unit
injectors- all ref. No’s other than 272, 272-, 272-1, 235-3)
Unit injector reassembly (cont.)
Unit injector ring nut removal / replacement
Unit injector test stand specifications
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VII
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70
69
68
69
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ELECTRICAL SYSTEM
"
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TESTING-OPERATIONAL-ADJUSTEMENTS
"
Governor / unit injector rack adjustment
High (maximum) speed adjustment
Idle speed adjustment
Injection pump control rod stroke limit adjustment
Power, torque device and speed adjustments-dynamometer method
Torque device adjustment (without dynamometer)
Torque device details
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"
Storage
Storage - 1 to 6 months
Storage - in excess of 6 months
Preparing the engine for use after storage
COMPILER TECO/ATL
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84
85
84
84
85
85
84
84
STORAGE
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74
77
79
75
77
79
82
82
74
81
77
83
83
75
75
80
76
76
83
78
78
82
82
83
79
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IX
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12 electrical schematic-marelli 14V-33A
12V electrical schematic - 20/30 A flywheel alternator
12V electrical schematic-iskra 14V-33A
Battery sizing
Battery sizing
Bosch 12V/1.1 kW starter motor (DW 12V)
BOSCH 12V/1.6 kW starter motor (DW 12V)
Electrical system service precautions / warning
Engine side wiring harness for the Lombardini supplied control panel
Flywheel alternator - 12V
Glow plug
Glow plug controller / relay with coolant temp. Sensor
Iskra 14V/33A performance curve
Iskra alternator - 14V/33A
Lombardini supplied control panel
Marelli AA 125 R, 14V/45A performance curve
Marelli alternator (AA 125 R) - 14V-45A
Oil pressure (low) switch, coolant temperature (high) switch
Performance curve - 20A flywheel alternator
Performance curve - 30A flywheel alternator
Performance curve - BOSCH 12V/1.1 kW (DW 12V) starter
Performance curve - BOSCH 12V/1.6 kW (DW 12V) starter
Temperature sensor (thermistor)
Voltage regulator connection details (flywheel alternator only)
VIII
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REG. CODE
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MODEL N°
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DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
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04
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DATE
15.11.99
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ENDORSED
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86
86
86
86
86
7
NOTE
8
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
TROUBLESHOOTING CHART- LDW FOCS SERIES
TROUBLESHOOTING CHART- LDW FOCS SERIES
REG. CODE
MODEL N°
·
·
·
·
50563
Engine knocks
Excessive oil consumption
Oil level rising
Low oil pressure
Blue smoke
White smoke
·
·
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DATE OF ISSUE
REVISION
1-5302-351
Black smoke
·
·
·
Overheating
·
· ·
·
· ·
· · ·
·
·
·
·
·
·
·
Unsteady RPM
Poor acceleration
·
·
Wet exhaust
Low fuel level
Fuel supply/ return lines clogged
Clogged fuel tank vent
Fuel pump faulty
Fuel entrained with air
Unit injector(s) faulty/ worn
Unit injector settings incorrect
Injection pump rack sticking
Oil level too high
Improper oil viscosity
Oil diluted by fuel
Oil pressure relief valve faulty
Oil pick-up tube clogged
Oil pump air entrained at pick-up tube
Glow plugs faulty
Glow plug controller faulty
Glow plug relay inoperable
Starter defective
Battery voltage too low
Battery / battery cable connections corroded
Key switch defective
Air filter clogged
Excessive idle / light load operation
Incomplete engine run-in
Engine overloaded
Excessive parasitic load
Valve lash insufficient / excessive
Injection timing out of spec- advanced
Injection timing out of spec- retarded
Governor linkage adjustment incorrect
Governor spring fatigued or defective
Idle rpm too low
Piston rings worn or stuck
Piston worn or damaged
Cylinders worn or damaged
Valves / valve guides worn
Valves sticking
Bearings (main / rod) worn
Governor / governor linkage malfunction
Cylinder head gasket damaged
Thermostat stuck or malfunctioning
Engine seized
Radiator clogged (external or internal)
Coolant pump faulty
Turbocharger faulty
Engine starts, but stops
Engine will not crank
POSSIBLE CAUSE
COMPILER TECO/ATL
Engine does not start
SYMPTOM
04.90
·
·
04
DATE
15.11.99
ENDORSED
·
·
·
· ·
9
SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS
SAFETY AND WARNING DECALS
DANGER
CAUTION
Failure to comply with the
instructions could result in
damage to persons and
property
Failure to comply with the
instructions could lead to
technical damage to the
machine and/or system
SAFETY INSTRUCTIONS
· Lombardini Engines are built to supply their performances in a safe and long-lasting way. To obtain these results,
it is essential for users to comply with the servicing instructions given in the relative manual along with the safety
recommendations listed below.
· The engine has been made according to a machine manufacturer's specifications and all actions required to meet
the essential safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit.
All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the
use defined by Lombardini which thus declines all liability for any accidents deriving from such operations.
· The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning
engine operation in particular, along with the relative routine maintenance work.
· The user must read these instructions carefully and become familiar with the operations described. Failure to do
this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity
of the machine.
· The engine may only be used or assembled on a machine by technicians who are adequately trained about its
operation and the deriving dangers. This condition is also essential when it comes to routine and, above all,
extraordinary maintenance operations which, in the latter case, must only be carried out by persons specifically
trained by Lombardini and who work in compliance with the existing documentation.
· Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal
of seals, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized
personnel shall relieve Lombardini from all and every liability for deriving accidents or for failure to comply with the
laws in merit.
· On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the
case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or
dangerous objects, also considering the movements made by the operator. Pull-starting with a free cord (thus
excluding self-winding starting only), is not permitted even in an emergency.
· Make sure that the machine is stable to prevent the risk of overturning.
· Become familiar with how to adjust the rotation speed and stop the engine.
· Never start the engine in a closed place or where there is insufficient ventilation. Combustion creates carbon
monoxide, an odourless and highly poisonous gas. Lengthy stays in places where the engine freely exhausts this
gas can lead to unconsciousness and death.
10
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS
· The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is
dust that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have
been certified for the machine.
· To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.
· Children and animals must be kept at a due distance from operating machines in order to prevent hazards
deriving from their operation.
· Fuel is inflammable. The tank must only be filled when the engine is off. Thoroughly dry any spilt fuel and move
the fuel container away along with any rags soaked in fuel or oil. Make sure that no soundproofing panels made
of porous material are soaked in fuel or oil. Make sure that the ground or floor on which the machine is standing
has not soaked up any fuel or oil.
· Fully tighten the tank plug each time after refuelling. Do not fill the tank right to the top but leave an adequate
space for the fuel to expand.
· Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place.
· Do not smoke or use naked flames when refuelling.
· The engine must be started in compliance with the specific instructions in the operation manual of the engine
and/or machine itself. Do not use auxiliary starting aids that were not installed on the original machine (e.g.
Startpilot’).
· Before starting, remove any tools that were used to service the engine and/or machine. Make sure that all guards
have been refitted.
· During operation, the surface of the engine can become dangerously hot. Avoid touching the exhaust system in
particular.
· Before proceeding with any operation on the engine, stop it and allow it to cool. Never carry out any operation
whilst the engine is running.
· The coolant fluid circuit is under pressure. Never carry out any inspections until the engine has cooled and even
in this case, only open the radiator plug or expansion chamber with the utmost caution, wearing protective
garments and goggles. If there is an electric fan, do not approach the engine whilst it is still hot as the fan could
also start operating when the engine is at a standstill. Only clean the coolant system when the engine is at a
standstill.
· When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to
safeguard the environment. The spongy filtering material in oil-cooled air filters must not be soaked in oil. The
reservoir of the separator pre-filter must not be filled with oil.
· The oil must be drained whilst the engine is hot (oil T ~ 80°C). Particular care is required to prevent burns. Do
not allow the oil to come into contact with the skin.
· Make sure that the drained oil, the oil filter and the oil it contains are disposed of in the correct way in order to
safeguard the environment.
· Pay attention to the temperature of the oil filter when the filter itself is replaced.
· Only check, top up and change the coolant fluid when the engine is off and cold. Take care to prevent fluids
containing nitrites from being mixed with others that do not contain these substances since "Nitrosamine",
dangerous for the health, can form. The coolant fluid is polluting and must therefore be disposed of in the correct
way to safeguard the environment.
· During operations that involve access to moving parts of the engine and/or removal of rotating guards,
disconnect and insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter
motor from being energized.
· Only check belt tension when the engine is off.
· Only use the eyebolts installed by Lombardini to move the engine. These lifting points are not suitable for the
entire machine; in this case, the eyebolts installed by the manufacturer should be used.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
11
I
GENERAL
All pertinent information needed for engine identification and spare parts ordering can be accessed from the engine data plate.
Additionally, the maximum engine speed, “K’ number and approval codes are included on the engine data plate. The location
of the data plate, as shown below, is identical for all LOMBARDINI LDW-FOCS industrial engines. Please supply the engine
data plate information to your Authorized LOMBARDINI Distributor or Dealer when ordering replacement parts or when
making technical inquiries.
No. of Cylinders
Displacement / 10 (cc)
Water Cooled
Diesel Engine
LOMBARDINI
12
COMPILER TECO/ATI
r/min
Customer Code (‘K’ No.)
Approval Code (Internal)
Serial Number
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
POWER RATINGS FOR LDW-FOCS GENSET SPEC
DIESEL ENGINES
CONTINUOUS (NA) RATING- kW
ENGINE
MODEL
1500
r/min
1800
r/min
3000
r/min
3600
r/min
LDW 602
4.5
5.4
9.0
9.9
LDW 903
6.7
8.1
14.0
14.9
LDW 1204
9.0
10.8
18.9
19.9
LDW 1204/T
11.7
14.0
24.8
25.8
LDW 702
5.0
5.9
9.9
10.6
LDW 1003
7.7
9.0
14.9
16.3
LDW 1404
9.9
11.7
19.8
22.8
NOTE: THE ABOVE RATINGS ARE FLYWHEEL OUTPUT, NOT ELECTRICAL GENSET OUTPUT
INTERMITTENT (NB) RATING- kW
ENGINE
MODEL
1500
r/min
1800
r/min
3000
r/min
3600
r/min
LDW 602
5.0
6.0
10.0
11.0
LDW 903
7.5
9.0
15.5
16.5
LDW 1204
10.0
12.0
21.0
22.0
LDW 1204/T
13.0
15.5
27.5
28.5
LDW 702
5.5
6.5
11.0
11.7
LDW 1003
8.5
10.0
16.5
18
LDW 1404
11.0
13.0
22.0
25
NOTE: THE ABOVE RATINGS ARE FLYWHEEL OUTPUT, NOT ELECTRICAL GENSET OUTPUT
POWER RATING STANDARDS
NB- ISO 3046/1-IFN - Maximum intermittent rating with no overload capacity; operation with constant speed and variable load.
NA- ISO 3046/1-ICXN- Continuous rating with 10% intermittent overload allowed; operation with constant speed and constant load.
Standard Rating Conditions: 25°C, 100kPa Total Barometric Pressure, 30% Relative Humidity.
Standard Production Power Tolerance = +/- 5%
Standard/ General Derations: 2% per 5°C increase in temperature over 25°C; 1% per 100m over mean sea level
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
13
I
GENERAL
LDW FOCS SERIES- TECHNICAL SPECIFICATIONS AND CAPACITIES
TECHNICAL SPECIFICATIONS
LDW 502 LDW 602
No. of Cylinders
Firing Order
Cylinder Bore (mm)
LDW 903
LDW 1204
2
2
3
4
LDW 1204/T
4
1-2
1-2
1-3-2
1-3-4-2
1-3-4-2
72
72
72
72
72
Cylinder Stroke (mm)
62
75
75
75
Displacement (cc)
505
611
916
1222
1222
Aspiration Type
75
Natural
Natural
Natural
Natural
Turbo
22.8:1
22.8:1
22.8:1
22.8:1
22.8:1
3600
3600
3600
3600
Compression Ratio
RPM- maximum
3600
Power- (N)- ISO 1585- KW(CV)[email protected] r/min
9.8(13.4) 11.8(16.0) 17.2(23.4) 24.4(33.2)
31.0(42.0)
Power- (Nb)- ISO 3046-1 IFN- KW(CV)[email protected] r/min
9.1(12.4) 10.3(14.0) 15.6(21.2) 22.0(30.0)
28.5(38.7)
Power- (Na)- ISO 3046-1 ICXN- KW(CV)[email protected] r/min 8.2(11.2) 9.2(12.5)
13.7(18.6) 19.9(27.0)
25.8(35.0)
Torque(MAX)/rpm @Nb output, (Nm)
28.7/2400 34.5/2200 53.5/2000 75.1/2200
98/2400
Maximum Torque Available @ N0. 3 PTO (Nm)
37/1800
Fuel Consumption (Nb)@3600 rpm- (g/KWh)
37/1800
37/1800
37/1800
37/1800
326
282
300
290
305
0.007
0.007
0.012
0.017
0.019
Dry Weight- (Kg)
60
65
85
96
101
Inclination (max)- (30 seconds)
35°
35°
35°
35°
35°
Inclination (max)- (60 seconds)
30°
30°
30°
30°
30°
Inclination (continuous)- APPLICATION DEPENDENT
****
****
****
****
****
Axial Load (max) on Crankshaft (both directions)- (Kg)
300
300
300
300
300
Radial (side) Load - APPLICATION DEPENDENT
****
****
****
****
****
Oil Consumption (Na)- (Kg/hr)
**** - CONTACT LOMBARDINI APPLICATION ENGINEERING DEPARTMENT FOR DETAILS
FLUID CAPACITIES (STANDARD)
Oil Capacity (including oil filter)- (liters)
1.6
1.6
2.4
3.2
4.3
Oil Capacity (less oil filter)- (liters)
1.5
1.5
2.3
3.0
4.1
Coolant Capacity (including std. radiator)- (liters)
2.3
4.0
4.9
6.0
7.5
Coolant Capacity (engine only)- (liters)
0.8
0.9
1.3
1.8
2.0
Fuel Tank-standard (OPTIONAL)- (liters)
4.3
4.3
10.0
15.0
15.0
NOTE: The above cooling system capacities (including radiator) assume that the radiator fitted to your Lombardini
FOCS series diesel engine is the standard Lombardini radiator. Different OEM machines may or may not be fitted with
a standard Lombardini radiator. Always refer to your equipment documentation for capacity details.
14
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
LDW 502/602
LDW 903
LDW 1204
LDW 1204/T
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
15
I
GENERAL
LDW FOCS SERIES- TECHNICAL SPECIFICATIONS AND CAPACITIES
TECHNICAL SPECIFICATIONS
LDW 702 LDW 1003
No. of Cylinders
Firing Order
Cylinder Bore (mm)
LDW 1404
2
3
4
1-2
1-3-2
1-3-4-2
75
75
75
Cylinder Stroke (mm)
77.6
77.6
77.6
Displacement (cc)
686
1028
1372
Aspiration Type
Natural
Natural
Natural
Compression Ratio
22.8:1
22.8:1
22.8:1
RPM- maximum
3600
3600
3600
Power- (N)- ISO 1585- KW(CV)[email protected] r/min
13(17.7)
20(27.2)
27.2(36.7)
Power- (Nb)- ISO 3046-1 IFN- KW(CV)[email protected] r/min
11.7(16)
18(24.5)
25(34)
Power- (Na)- ISO 3046-1 ICXN- KW(CV)[email protected] r/min 10.6(14.4)
16.3(22.2)
22.8(31)
Torque(MAX)/rpm @Nb output, (Nm)
40/2200
59/2200
82.5/2200
Maximum Torque Available @ N0. 3 PTO (Nm)
37/1800
37/1800
37/1800
Fuel Consumption (Nb)@3600 rpm- (g/KWh)
Oil Consumption (Na)- (Kg/hr)
320
300
325
0.009
0.013
0.019
Dry Weight- (Kg)
66
87
98
Inclination (max)- (30 seconds)
35°
35°
35°
Inclination (max)- (60 seconds)
30°
30°
30°
Inclination (continuous)- APPLICATION DEPENDENT
****
****
****
Axial Load (max) on Crankshaft (both directions)- (Kg)
300
300
300
Radial (side) Load - APPLICATION DEPENDENT
****
****
****
**** - CONTACT LOMBARDINI APPLICATION ENGINEERING DEPARTMENT FOR DETAILS
FLUID CAPACITIES (STANDARD)
Oil Capacity (including oil filter)- (liters)
1.6
2.4
3.2
Oil Capacity (less oil filter)- (liters)
1.5
2.3
3.0
Coolant Capacity (including std. radiator)- (liters)
2.3
4.9
6.0
Coolant Capacity (engine only)- (liters)
0.9
1.3
1.7
Fuel Tank-standard (OPTIONAL)- (liters)
4.3
4.3
10.0
NOTE: The above cooling system capacities (including radiator) assume that the radiator
fitted to your Lombardini FOCS series diesel engine is the standard Lombardini radiator.
Different OEM machines may or may not be fitted with a standard Lombardini radiator. Always
refer to your equipment documentation for capacity details.
16
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
LDW 702
LDW 1003
LDW 1404
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
17
I
GENERAL
POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES
LDW 502 FOCS, LDW 602 FOCS, LDW 903 FOCS
N - 80/1269/CEE- ISO 1585, Gross automotive rating- intermittent operation with variable speed and variable load.
NB- ISO 3046/1-IFN - Maximum intermittent rating with no overload capacity; operation with constant speed and variable load.
NA- ISO 3046/1-ICXN- Continuous rating with 10% intermittent overload allowed; operation with constant speed and constant load.
M(X)- Torque at N, NB and NA ratings respectively.
C- Specific fuel consumption at NB rating.
Standard Rating Conditions: 25°C, 100kPa Total Barometric Pressure, 30% Relative Humidity.
Standard Production Power Tolerance = +/- 5%
Standard/ General Derations: 2% per 5°C increase in temperature over 25°C; 1% per 100m over mean sea level
18
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES
LDW 1204 FOCS and LDW 1204/T FOCS
N - 80/1269/CEE- ISO 1585, Gross automotive rating- intermittent operation with variable speed and variable load.
NB- ISO 3046/1-IFN - Maximum intermittent rating with no overload capacity; operation with constant speed and variable load.
NA- ISO 3046/1-ICXN- Continuous rating with 10% intermittent overload allowed; operation with constant speed and constant load.
M(X)- Torque at N, NB and NA ratings respectively.
C- Specific fuel consumption at NB rating.
Standard Rating Conditions: 25°C, 100kPa Total Barometric Pressure, 30% Relative Humidity.
Standard Production Power Tolerance = +/- 5%
Standard/ General Derations: 2% per 5°C increase in temperature over 25°C; 1% per 100m over mean sea level
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
19
I
GENERAL
POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES
LDW 702 FOCS, LDW 1003 FOCS, LDW 1404 FOCS
N - 80/1269/CEE- ISO 1585, Gross automotive rating- intermittent operation with variable speed and variable load.
NB- ISO 3046/1-IFN - Maximum intermittent rating with no overload capacity; operation with constant speed and variable load.
NA- ISO 3046/1-ICXN- Continuous rating with 10% intermittent overload allowed; operation with constant speed and constant load.
M(X)- Torque at N, NB and NA ratings respectively.
C- Specific fuel consumption at NB rating.
Standard Rating Conditions: 25°C, 100kPa Total Barometric Pressure, 30% Relative Humidity.
Standard Production Power Tolerance = +/- 5%
Standard/ General Derations: 2% per 5°C increase in temperature over 25°C; 1% per 100m over mean sea level
20
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
GENERAL ENGINEERING DRAWINGS- LDW 502 FOCS, LDW 602 FOCS, LDW 903 FOCS
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
21
I
GENERAL
GENERAL ENGINEERING DRAWINGS- LDW 1204 FOCS, LDW 1204/T FOCS
22
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
GENERAL ENGINEERING DRAWINGS- LDW 702 FOCS, LDW 1003 FOCS, LDW 1404 FOCS
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
23
GENERAL
I
Failure to carry out the operations described in the table may lead to technical damage to the machine
and/or system
LDW- FOCS SERIES MAINTENANCE SCHEDULE
MAINTENANCE INTERVAL
10
hours
or
DAILY
MAINTENANCE OPERATION
50
hours
125
hours
250
hours
500
hours
1000
hours
·
·
·
OIL LEVEL CHECK (D)
COOLANT LEVEL CHECK (D)
FAN/ ALTERNATOR BELT INSPECTION (•)
AIR FILTER ELEMENT CHECK (DRY TYPE) (*)
see note
·
·
·
·
AIR FILTER CHECK (OIL BATH TYPE) (**)
RADIATOR CORE INSPECTION (ž)
FLUID LEAK INSPECTION- GENERAL (•)
SAFETY GUARD INSPECTION (•)
OIL REPLACEMENT- INITIAL ONLY-(see RECOMMENDED OIL TYPE)
OIL FILTER REPLACEMENT - INITIAL ONLY
·
·
·
OIL REPLACEMENT- (see RECOMMENDED OIL TYPE)
OIL FILTER REPLACEMENT
FUEL FILTER REPLACEMENT
·
·
·
·
COOLANT HOSE INSPECTION
FAN/ ALTERNATOR BELT TENSION ADJUSTMENT
·
·
·
VALVE ADJUSTMENT
FAN/ ALTERNATOR BELT REPLACEMENT
FUEL INJECTION SYSTEM ADJUSTMENT
CLEAN FUEL TANK (ž)
·
·
COOLANT REPLACEMENT (***)
REPLACE TIMING BELT
·
(D)
(•)
(ž)
(*)
Add fluid(s) as required
After inspection, adjust, repair or replace as required
Clean as often as required
Replace air filter after air filter restriction switch indication or one(1) year. Lombardini does not
recommend the removal of air filter elements for purposes of inspection.
(**) Service oil bath filter element (upper and lower) as required. Replace reservoir oil as required.
NOTE: In dusty conditions, service the oil bath air filter every four(4) hours.
(***) Replace coolant every 1000 hours or 2 years
NOTES:
24
1. USE ONLY GENUINE LOMBARDINI REPLACEMENT PARTS.
2. USE ONLY LOMBARDINI APPROVED FLUIDS.
COMPILER TECO/ATI
2500
hours
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its
combustion could sharply increase the rotation speed.
Use a suitable oil in order to protect the engine.
The lubrication oil influences the performances and life of the engine in an incredible way.
Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, may make the
compression rings jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine life
will also be notably reduced.
Oil viscosity must suit the ambient temperature in which the engine operates.
Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil
is inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible.
Appropriate protective gloves etc should be wore during this operation.
Old oil is highly polluting and must be disposed of in the correct way. Do not litter.
RECOMMENDED OIL
AGIP SINT 2000 5W40 specification API SJ/CF ACEA A3-96 B3-96
MIL-L-46152 D/E.
ESSO ULTRA 10W40 specification API SJ/CF ACEA A3-96 MIL-L46152 D/E.
In countries where AGIP and ESSO products are not available, use
API SJ/CF oil for gasoline-fuelled engines or oil that complies with
military specification MIL-L-46152 D/E.
GRADE
- - - - - - - + + + + + + + + + +
40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50
SAE 10W
SAE 20W
SAE 30
OIL SUPPLY ( liters ) 502 - 602 - 702
Standard oil sump
filter included
1.6
filter excluded
1.5
SAE 40
SAE 10W-30
SAE 10W-40
SAE 10W-60
OIL SUPPLY ( liters ) 903 - 1003
Standard oil sump
filter included
2.4
filter excluded
2.3
SAE 15W-40 mineral based
SAE 15W-40 semi-synthetic based
SAE 20W-60 semi-synthetic based
SAE 5W-30 synthetic based
OIL SUPPLY ( liters ) 1204 -1404
Standard oil sump
filter included
3.2
filter excluded
3.0
SAE 5W-40 synthetic based
SAE 0W-30 synthetic based
OIL SUPPLY ( liters ) 1204/T
Standard oil sump
API CF
filter included
4.3
filter excluded
4.1
CE
ACEA SEQUENCES
D- 4
A = Gasoline (Petrol)
B = Light Diesel fuels
E = Heavy Diesel fuels
D- 5
CD CC CB
CA
SA SB
SC
SD
SE
CCMC G- 2
CCMC G- 3
CCMC PD - 1 / PD - 2
CCMC D- 2
CCMC D- 3
SF
SG SH SJ
G- 4
G- 5
MIL - L - 2104 D
MIL - L - 2104 E
Required levels :
MIL - L -46152 C
MIL - L- 46152 D/E
A1-96
A2-96
A3-96
MB 226.1
MB 227.1
228.3
B1-96
B2-96
B3-96
MB 226.5
MB 227.5
MB 228.1
VW 500.00
VW 501.01
VW 505.00
VOLVO VDS
E1-96
E2-96
E3-96
COMPILER TECO/ATL
BENZINA - ESSENCE - PETROL
BENZIN - GASOLINA -
DIESEL
MAN QC 13-017
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
25
I
GENERAL
DIESEL FUEL SPECIFICATIONS
Diesel fuel must be clean, fresh, meet Lombardini fuel specifications and be sourced from a known and reputable
supplier. Clean, fresh and properly specified diesel fuel will provide assurances of maximum engine performance
and maximum fuel injection system longevity. The use of out-of-spec, dirty or questionable quality diesel fuel will
result in engine performance and start ability problems as well as reductions in engine and fuel injection system
life.
Lombardini diesel engines are designed to operate on No. 2 diesel fuel. However, some geographical areas, by
virtue of cold winter temperatures, change the diesel fuel supply depot to No. 1 diesel fuel in winter months. No. 2
diesel fuel provides maximum viscosity and lubricity but can have “waxing” problems at lower temperature.
Lombardini expressly recommends the use of No. 2 diesel fuels when temperatures are above -10°C (14°F).
Lombardini recommends that No. 1 diesel fuel be used when temperatures are at or below -10°C (14°F).
Lombardini allows the use of either EPA- High Sulfur, off-highway diesel fuel or EPA- Low Sulfur, on-highway fuel
for non-CARB certified engines. CARB certified engines must consume only EPA- low sulfur diesel fuels
conforming to EPA 40 CFR 86-113-94. For general non-CARB certified engines, Lombardini highly recommends
that either low sulfur or high sulfur fuel be used on a continuous basis. Mixing the usage of low sulfur and high
sulfur fuels can cause complications within the fuel injection system and thus is not recommended.
Lombardini does not recommend the use of “heating oil”, blended fuel/ waste engine oil, or low grade diesel fuel of
any kind. The use of aviation fuels- JP4, JP5 or JP8 must be approved on an application basis and is not
recommended for broad range commercial applications.
EPA FUEL SPECIFICATIONS (No. 2 DIESEL FUEL):
ASTM
TEST
CETANE NUMBER
DISTILLATION RANGE
BP
10% point
50% point
90% point
EP
GRAVITY (API)
TOTAL SULFUR (pct.)
EPA 40CFR 86.113-90
(OFF-HIGHWAY FUEL)
D613
D86
D86
D86
D86
D86
HYDROCARBONS
AROMATICS (min. pct.)
PARAFFINS, OLEFINS,
NAPHTHENES (pct.)
FLASHPOINT
VISCOSITY (CSt)
EPA 40CFR 86.113-94
(ON-HIGHWAY FUEL)
42-50
40-48
340-400°F (171.1-204.4°C)
400-460°F (204.4-237.8°C)
470-540°F (243.3-282.2°C)
550-610°F (287.8-321.1°C)
580-660°F (304.4-348.9°C)
D287
33-37
D129
0.2-0.5
D2622
D1319
D1319
D93
D445
340-400°F (171.1-204.4°C)
400-460°F (204.4-237.8°C)
470-540°F (243.3-282.2°C)
560-630°F (287.8-321.1°C)
610-690°F (304.4-348.9°C)
33-37
0.03-0.05
27
73
27
73
130°F (54.4°C)
2.0-3.2
130°F (54.4°C)
2.0-3.2
NOTE: BY LAW, EPA 40CFR 86.113-90 FUEL MUST BE DYED RED.
FUEL QUALITY/ STORAGE:
No. 1 and No. 2 Diesel fuel degrades with time. No. 2 diesel fuel has a storage life of approximately one(1) year.
No. 1 diesel fuel has a maximum storage life of two(2) years. Further, storage of diesel fuel in contaminated
storage tanks can lead to excessive impurities within the stored fuel. As such, aged or contaminated diesel fuel
should not be consumed by Lombardini diesel engines. Aside from the specifications listed above, fuel measured
to have total insolubles > 1mg/100mg, organic matter > 1mg/100ml or rust/mineral matter > 2mg/ml should not be
consumed by Lombardini diesel engines.
26
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
ANTI-FREEZE / COOLANT SPECIFICATIONS/ DETAILS- FOCS SERIES
Ethylene Glycol based Anti-freeze / coolant usage is required for all Lombardini LDW-FOCS series engines. Never operate a
LDW-FOCS engine with the cooling system filled with water only. The purpose of the anti-freeze/coolant is three-fold. First the
anti-freeze/coolant mixture prevents or reduces the potential for corrosion within the cooling system. Secondly, the anti-freeze/
coolant increases the boiling point of the cooling fluid, reducing the potential for localized boiling within the engine and engine
overheat in general. Lastly, the anti-freeze/coolant reduces the freezing point of the engine coolant, thereby reducing or
preventing potential engine damage caused by freezing.
Many different brands and types of anti-freeze are available in the market. Some anti-freeze/coolants are designed exclusively
for automotive type cooling systems with aluminum cooling system components. Other anti-freeze/coolants are designed
exclusively for use within heavy-duty, predominately cast iron cooling systems and require that the coolant solution be
“charged” with a Supplemental Coolant Additive (SCA). Other anti-freeze solutions are designed for long life and are
sometimes designated “permanent”.
Lombardini recommends only those anti-freeze/coolants which are ethylene glycol based and designed to protect aluminum
coolant components- thus, automotive anti-freeze/coolant. Long life anti-freeze/coolants may be used so long as the antifreeze/coolant is changed at least every two(2) years as is required by the Lombardini maintenance schedule. Lombardini
does not recommend the use of low silicate heavy duty anti-freeze/coolants which may or may not require the use of SCA’s.
The following provides guidelines for the selection of acceptable anti-freeze/coolants for LDW-FOCS series diesel engines.
ANTI-FREEZE/COOLANT CONCENTRATION
Lombardini recommends that the minimum anti-freeze/coolant concentration be 30% when mixed with distilled water.
Concentrations below 30% will not provide adequate corrosion protection. Lombardini further recommends that the maximum
allowable anti-freeze/coolant concentration be 60% when mixed with distilled water. Concentrations of anti-freeze/coolant in
excess of 60% provide no appreciable additional freeze protection and can actually reduce the heat rejection capability of the
cooling system. As such, Lombardini recommends that an anti-freeze / coolant mixture of 50% anti-freeze/coolant and 50%
distilled water be used for most general applications. In general terms the freezing points of anti-freeze/coolant solutions
(ethylene glycol based) with respect to concentration is 30%/ -15°C(5°F); 40%/ -24°C(-12°F); 50%/ -37°C(-34°F); 60%/ 52°C(-62°F). Please refer to the details regarding freezing points as supplied from your anti-freeze/coolant supplier for more
exact information.
WATER SPECIFICATIONS
Lombardini recommends that the engine cooling fluid solution be made up of the ethylene glycol based anti-freeze/coolant
and distilled water. Further, we realize that the use of distilled water is not always practical. The quality of the base water does
play a large role in the overall chemical composition of the coolant solution and the corrosion prevention characteristics of the
solution. As such, tap water may be used as long as the water meets the following specifications with reference to SAE j1941:
PROPERTY
SPECIFICATION
TEST METHOD
Total Solids (max.)
Total Hardness (max. CaCO3)
Chloride (max.)
Sulfate (max. SO4)
pH
340ppm
170ppm
40ppm
100ppm
5.5-9.0
ASTM
ASTM
ASTM
ASTM
ASTM
D1888
D1126
D512
D516
1293
ANTI-FREEZE COOLANT MINIMUM RECOMMENDATIONS/ SPECIFICATIONS
Lombardini recommends that only automotive type anti-freeze/coolants be used in LDW-FOCS series diesel engines. These
anti-freeze/coolants are typically “High Silicate” , although not always, and are designed to prevent corrosion in cooling
systems with aluminum components. The chosen coolant should meet or exceed ASTM 3306 and SAE j1034. Further, the
chosen anti-freeze/coolant should pass ASTM D4340, ASTM D1384 and ASTM D2570 corrosion tests as detailed within SAE
j1034.
NOTE: Many brands/ products meet the specifications presented above and may be used within Lombardini LDW-FOCS
series diesel engines. The engine owner is responsible for determining the suitability of any given anti-freeze/coolant to the
minimum specifications provided. Failure to follow the above coolant guidelines may impact the engine warranty.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
27
I
GENERAL
DRIVING TORQUES FOR STANDARD SCREWS
DENOMINATION
Diameter x pitch
(mm)
R ³ 1000 N/mm²
R ³ 800 N/mm²
R ³ 1200 N/mm²
Nm
Kgm
Nm
Kgm
Nm
Kgm
4x0.70
3.6
0.37
5.1
0.52
6
0.62
5x0.80
7
0.72
9.9
1.01
11.9
1.22
6x1.00
12
1.23
17
1.73
20.4
2.08
7x1.00
19.8
2.02
27.8
2.84
33
3.40
8x1.25
29.6
3.02
41.6
4.25
50
5.10
9x1.25
38
3.88
53.4
5.45
64.2
6.55
10x1.50
52.5
5.36
73.8
7.54
88.7
9.05
13x1.75
89
9.09
125
12.80
150
15.30
14x2.00
135
13.80
190
19.40
228
23.30
16x2.00
205
21.00
289
29.50
347
35.40
18x2.50
257
26.30
362
37.00
435
44.40
20x2.50
358
36.60
504
51.50
605
61.80
22x2.50
435
44.40
611
62.40
734
74.90
24x3.00
557
56.90
784
80.00
940
96.00
SEALANT and THREAD LOCK LOCATIONS/ DETAILS
LOCATION
DETAIL
Valve / Rocker Cover
Oil Filter Nipple
Camshaft Bearing Retainer Bolts
Timing Belt Idler Stud to Crankcase
Crankcase
Cylinder Head
Cylinder Head
Crankcase and Cylinder Head
12mm Crankcase Vent Tube
M20x1.5 Hollow Nipple
M6
M10
M12x1.5 Plug
18mm Plug
M6x1.0 Stud
Welch Plugs (30mm)
28
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
SEALANT / THREAD LOCK
(LOCTITE BRAND)
638
601
270
601
242
510
601
510
REVISION
04
DATE
15.11.99
ENDORSED
GENERAL
I
CRITICAL TORQUE SPECIFICATIONS
POSITION/ LOCATION
Page No. Ref.
Diameter/ Pitch
(mm)
TORQUE
(Nm)
Injection Pump Control Rod (Rack Adjustment)
78
M3 (special)
1.1
Injection Pump Control Rod to Unit Injector Rack Bolt
34
M3 (special)
1.2
Fuel Rail
34
M4x0.7
4
Connecting Rod (***)
44
M8x1.00
40
Piston Cooling Jet (LDW 1204/T)
M8X1.5
12
Glow Plugs
M12x1.25
25
Valve / Rocker Cover
33
M6x1.00
9
Main Bearing Cap
47
M10
60
Oil Pan
40
M6
10
M6
10
Camshaft Roller Bearing Retainer
Glow Plug Wire Nut
Timing Belt Idler
28
Stop Lever Nut
M5x0.8
5
M10
40
M8x1.25
8
Unit Injector Retainer Nut
30
M8
20 (*)
Rocker Arm Support
35
M10
40
Fuel Pump Eccentric
34
M10x1.25
80
M6
12
M30x1.5
(**)
M6x1.00
7
Oil Seal Support (Flywheel Side)
Pre-chamber Ring Nut
40
Governor Fork Pivot
Crankshaft Pulley (V)
26
Camshaft Timing Pulley
27
M16x1.5 (Left Hand)
360
M10x1.25
80
Oil Pressure Switch
M12x1.5
25
Oil Pan Plug
M12x1.5
40
Cylinder Head
46
Flywheel
26
SEE MANUAL FOR DETAILS
M10x1.5
80
(*) Torque the unit injector retaining nuts alternately in 5 Nm steps
(**) Torque the pre-chamber ring nut to 100 Nm first, then torque to 180 Nm.
(***) Torque aluminum connecting rods to 35 Nm.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
29
I
GENERAL
SPECIAL TOOLS
30
COMPILER TECO/ATI
PART No.
DESCRIPTION
Fuel delivery equalization tool. Allows the
adjustment of individual unit injector fuel
delivery.
7107-1460-090
Pre-chamber removal tool.
7107-1460-030
Static timing tool
7107-1460-024
Main bearing cap lateral seal installation tool.
7107-1460-053
Unit injector ring nut tool.
7107-1460-029
Pre-chamber ring nut tool.
7107-1460-027
Pre-chamber index.
7107-1460-031
Union for static timing adjustment/ testing.
7107-1460-028
Valve guide seal installation tool.
7107-1460-047
T.D.C. determination fixture.
7107-1460-048
Timing Belt tension tool.
7107-1460-049
Flywheel/ Ring gear engine locking tool.
7107-1460-051
Static timing kit for “low pressure” testing/
adjustment.
7107-1460-074
7107-1460-056
(See pg. 55 for details)
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
WARNING: Always exercise extreme care when performing engine service work. Refer to and understand the
safety guidelines presented on page 3. Additionally, some engine components have sharp edges which could
cause cuts if not handled properly. Wear hand protection. Further, some engine components are heavy. As such,
wear foot protection to protect from accidental drops of engine components. Always use proper form and
procedures when lifting engine components. Ask for help or assistance if in doubt concerning the lifting or
manipulation of the engine or engine components. The use of compressed air is required for some operations.
Compressed air can be dangerous. Do not direct compressed air towards yourself or others. Do not allow bearings
to spin while drying with compressed air. The use of cleaning solvents is also required for certain service
operations. When “SOLVENT” is recommended, a commercially available, low-toxicity, degreasing solvent such
as “SAFETY-KLEEN” should be used. Wear hand and eye protection and avoid direct contact with solvents.
DRY TYPE AIR FILTER- STANDARD ENGINE MOUNTED
Components:
1
Cover
2
Filter Element
3
Support
Air Filter Specifications: Filtration Level
13-14 micron
Filtration Area
4470 cm2- 502, 602, 702, 903, 1003
Filtration Area
7150 cm2- 1204, 1404
INSPECTION: Inspect the air filter cover for cracks, heat damage or warpage.
Replace as required.
AIR RESTRICTION SWITCH
LDW FOCS diesel engines that are supplied with engine mounted, panel type air
filters as shown above, are fitted with an air filter restriction switch. The purpose of
the air restriction switch is to signal the engine operator, via a lamp or otherwise, of
a high air filter restriction condition. The electrical connections for the signal is
provided at (2) as shown. Following a signal from the restriction switch, the switch
must be reset. Reset the switch by pushing button (1) until the button latches. The
restriction switch is set to 600/650 mm-H2O.
After the restriction signal, the air filter should be replaced at once. Do not clean
the air filter element. Operation in a high restriction condition could cause
excessive oil consumption, low power output, engine overheating and potentially
engine damage.
Components:
1
Reset Button
2
.25” Tab Connection
OIL BATH AIR FILTER
1
Upper Housing
6 Oil level reference mark (on 7)
2
Diaphragm Seat
7 Reservoir bowl
3
Diaphragm
8 Outer seal ring
4
Polyurethane upper element
9 Inner seal ring
5
Metal wool lower element
Service Instructions: Check the sealing rings regularly. Replace the sealing rings if
hardening or damage is noted. Inspect the air filter housing and bowl- replace if
damaged. Carefully clean the reservoir bowl and both elements with clean diesel
fuel. Blow the lower element dry with compressed air. Dry the upper element by
squeezing out excess diesel fuel, then drying with suitable cloths. Fill the reservoir
with clean engine oil to the reference mark. DO NOT OVERFILL.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
31
II
DISASSEMBLY/REASSEMBLY
AIR FILTER SUPPORT- (INTAKE MANIFOLD)
REMOVAL: Disassemble the air filter cover and air filter element.
Loosen the crankcase ventilation hose (see page 29) and pull the
hose from the air filter support. Remove all bolts that secure the air
filter support (1) to the cylinder head. Carefully pull the air filter
support from the cylinder head. Using suitable pliers, release the
governor spring (2) from the air filter support assembly.
INSPECTION: Carefully clean the gasket (3) from the air filter
support and the cylinder head. Clean the air filter support with
solvent. Dry with compressed air. Inspect the air filter support for
cracks or warpage. Replace as required.
INSTALLATION: Using a new gasket, install the air filter support by
reversing the procedure detailed above. Torque the air filter support
in three(3) steps to 29.6 Nm.
EXHAUST MANIFOLD
REMOVAL: Disconnect the equipment exhaust system. Remove the
nuts that affix the exhaust manifold to the cylinder head.
INSPECTION: Carefully clean all gasket material form the exhaust
manifold and the cylinder head. Remove all carbon deposits. Check
the exhaust manifold mounting flange for warpage and flatness.
Inspect the exhaust manifold for cracks and heat stress. Replace as
necessary.
INSTALLATION: Using new gaskets, install the exhaust manifold to
the cylinder head by reversing the removal procedure. Torque the
exhaust manifold nuts to 24.5 Nm.
COOLING FAN
REMOVAL: Loosen and remove the four(4) bolts and the stress plate
attaching the cooling fan to the cooling fan support.
INSPECTION: Inspect the entire cooling fan for cracks, stress
damage, indications of contact with the shroud and brittleness.
Replace the cooling fan if ANY damage is noted.
INSTALLATION: Install the stress plate and bolts. Torque the bolts to
20.0 Nm.
ALTERNATOR / COOLING FAN DRIVE BELT
REMOVAL: Loosen bolts (1) and (2). Pivot the alternator so that the
belt can be removed. Remove the belt.
INSPECTION: Inspect the belt for brittleness, cracks and general
appearance. Replace the belt if any irregularities are noted.
INSTALLATION / ADJUSTMENT: Install the belt over the cooling fan
support, crankshaft pulley and alternator pulley. Pivot the alternator,
thus tensioning the belt. Adjust the belt tension so that a 100N force
at the midpoint of the belt center (as shown) results in a 10-15mm
deflection. Tighten bolts (1) and (2). DO NOT OVER TIGHTEN THE
BELT.
32
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
FUEL TANK - (OPTIONAL ACCESSORY)
A fuel tank may be fitted the the LDW-FOCS engine as shown on an
optional basis. Any fuel tank whether engine mounted or not must be
maintained. Extreme care must be taken to make sure that only high
quality, clean and properly specified fuel is consumed by the LDWFOCS engine. In general terms, service the engine fuel tank as
follows: Carefully drain all fuel from the tank in a suitable container.
Inspect the fuel cap to make sure that the vent is open and that a
good seal is present at the fill neck. Replace the fuel cap as
necessary. Flush the fuel tank to remove all scale, rust and
impurities. After cleaning, fill the fuel tank with sufficient fuel to allow
a thorough rinsing. Drain the rinse fuel from the tank. Dispose of the
drained and rinse fuel according to local and national laws. Replace
the fuel tank if adequate cleanliness cannot be attained. Always
replace the engine fuel filter following fuel tank service and prior to
initial start-up.
FLYWHEEL / RING GEAR
REMOVAL: Remove the engine starter. (See page 63 for warnings).
Install the flywheel fixture tool 1460-051 in place of the starter.
Remove the flywheel bolts. WARNING: The flywheel is heavy. Do
not remove the final flywheel bolt until the flywheel is secured from
accidentally falling.
INSPECTION: Clean the flywheel and flywheel bolts in solvent. Dry
with compressed air. Inspect the flywheel for cracks, indications of
loose operation and general damage. Inspect the ring gear for
damaged teeth. Replace as required. Clean the crankshaft flywheel
pilot as required.
RING GEAR REPLACEMENT: Secure the engine flywheel in a soft
jawed vise. Carefully drive the ring gear from the flywheel. Remove
the flywheel from the vise and lie on a secure flat surface- ring gear
side up. Heat the new ring gear to 300°C for 20 minutes in a suitable
oven. Using insulated hand protection and suitable hooks, place the
heated ring gear on the flywheel ring gear pilot. Tap the ring gear
down onto the seat as required. Allow to completely cool.
INSTALLATION: Carefully place the flywheel onto the crankshaft.
Align the dowel index. Install the flywheel bolts and torque to 80Nm.
COOLING FAN SUPPORT
REMOVAL: Remove the center bolt (1) and slide the fan support
assembly from the engine.
Components:
1 Bolt
2 Washer
3 Spacer
4 Pulley
5 Snap Ring
6 Bearing
7 Spacer
8 Bearing
9 Snap Ring
INSPECTION: Disassemble the support assembly. Clean all
components. Inspect the pulley for wear. Inspect the bearings for
wear. Replace as required.
INSTALLATION: Install the support assembly onto the engine. Using
Locktite 270 on bolt (1), torque to 25 Nm.
CRANKSHAFT PULLEY
REMOVAL: Secure the engine from rotation by removing the engine
starter (see warnings on page 62) and installing the fixture tool 1460051. Remove the four(4) M6 bolts, then remove the center bolt (1).
NOTE: THE CENTER BOLT(1) IS LEFT-HANDED.
INSPECTION: Clean the pulley removing all oil residue and dirt.
Inspect the pulley for cracks, warpage and V-groove wear or
damage. Replace as required.
INSTALLATION: Align the crankshaft pulley with the index pin on the
crankshaft. Hand tighten the M6 bolts. Using Locktite on the center
bolt thread, torque the center bolt to 360 Nm. Torque the M6 bolts
to 12 Nm.
NOTE: When pulley reference mark (A) aligns with the timing cover
reference mark (B), the flywheel side piston is at TDC.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
33
II
DISASSEMBLY/REASSEMBLY
No. 2 PTO (CRANKSHAFT PULLEY) with “RINGFEDER”- LDW
1204, LDW 1204/T, LDW 1404
The maximum allowable power to be taken from the LDW 1204 and
LDW 1204/T and LDW 1404 standard No. 2 PTO is 75% of the
speed specific output (see page 10). In order provide 100% of the
available power, a “RINGFEDER” coupling must be fitted to the
engine.
Components:
1 Pulley- Special
2 M6 Bolt
3 M16x1.5 Bolt
4 RINGFEDER
Internal Ring
5 M8 Bolt
6 RINGFEDER
External Ring
7 Spacer Flange
8 Shoulder Plate
9 Crankshaft
INSTALLATION: Clean the crankshaft of all nicks, rust, dirt and oil.
Clean all components of the RINGFEDER in solvent and dry with
compressed air. Saturate all RINGFEDER components with clean
engine oil. Lock the engine by removing the engine starter and
installing the 1460-051 fixture (see page 62 for warnings). With
reference to the diagram at the left, insert into pulley (1) -internal ring
(4), external ring (6) and flange (7). The protruding portion of flange
(7) must be oriented toward the external ring (6). Install the plate (8)
onto the crankshaft. Install the (1), (4), (6), (7) subassembly onto the
crankshaft. Loosely install the M6 bolts(2) through the pulley
assembly, through the plate (8) and into the crankshaft timing pulley.
Install the M8 bolts (5) loosely.
Torque (crossing pattern) the M6 bolts (2) to 10 Nm.
Torque the M16 bolt (3) to 360 Nm. (Note: Left Hand thread.)
Torque (crossing pattern) the M8 bolts (5) to 15 Nm.
Torque (crossing pattern) the M8 bolts (5) to 35 Nm.
Torque (crossing pattern) the M8 bolts (5) to 35 Nm (confirmation
step).
TIMING BELT COVER
REMOVAL: Remove and note position of the five(5) allen head
screws attaching the timing cover to the engine. The attachment
screws are of differing lengths.
INSPECTION: Clean the cover (inside and out) with a solvent soaked
rag. DO NOT SOAK THE TIMING COVER IN SOLVENT. Inspect the
cover for cracks and warpage. For engines equipped with a sealed
timing cover, inspect the integrity of the exterior perimeter seal and
the condition of the lip seals at the fan support and crankshaft pulley.
Replace the cover and/or seals as required.
INSTALLATION: Fit the timing cover to the engine. Install the five(5)
allen head screws in the exact location as removed. Torque the
screws to 10 Nm.
TIMING BELT / TIMING PULLEY ARRANGEMENT
COMPONENT IDENTIFICATION:
1 Camshaft Pulley
2 Timing Belt
3 Crankshaft Pulley
4 Coolant Pump Pulley
5 Belt Tensioner Pulley
34
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
TIMING BELT REMOVAL
REMOVAL: Loosen nut (1). Slide the timing belt off of the pulleys.
NOTE 1.: Timing belt refitting can be greatly simplified if the engine
is rotated until the timing marks align prior to removing the timing
belt.
NOTE 2.: Discard the timing belt after removal irrespective of
operational hours. Timing belts take a “set” during operation and
subsequent reinstallations will not allow replacement in the identical
position as prior.
IDLER PULLEY
REMOVAL: Remove nut (1) and washer (2). Remove the idler pulley
assembly from the engine.
INSPECTION: Inspect the pulley idler surface for chips, wear,
degradation, etc. Check the bearing for radial run-out and smooth
operation. Replace the bearing, pulley or assembly as required.
Components:
1 Nut
4 Bearing
2 Washer
5 Shaft/ Support
3 Pulley
6 Mounting Plate
CRANKSHAFT TIMING PULLEY
REMOVAL: Slide pulley from the crankshaft.
INSPECTION: Clean the pulley in solvent. Dry with compressed air.
Inspect the pulley for chips, tooth profile wear and cracks. Inspect
the keyway for fretting or indications of loose operation. Inspect the
crankshaft for signs of fretting at the keyway. Inspect the key
condition. Replace components as required. Remove all rust and
deposits from the crankshaft.
INSTALLATION: Slide the clean timing pulley onto the crankshaft
aligning the keyway in the pulley with the key on the crankshaft.
NOTE: Reference mark (1) on the crankshaft timing pulley and
reference mark (2) on the oil pump housing are timing marks. When
aligned, No. 1 piston (flywheel side) is at TDC.
CAMSHAFT TIMING PULLEY
REMOVAL: Loosen and remove bolt(1) and washer(2). Slide the
camshaft pulley from the camshaft.
INSPECTION: Clean the pulley in solvent. Dry with compressed air.
Inspect the pulley for chips, tooth profile wear and cracks. Inspect
the keyway for fretting or indications of loose operation. Inspect the
seal race on the backside of the pulley for excessive grooving,
erosion or roughness. Replace as required.
INSTALLATION: Coat the seal race of the camshaft pulley with clean
engine oil. Install the camshaft pulley onto the camshaft taking care
not to damage the camshaft seal. Install the washer (2) onto the bolt
(1). Torque the camshaft retaining bolt to 80 Nm.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
35
II
DISASSEMBLY/REASSEMBLY
TIMING PULLEY - REFERENCE MARKS
All LDW-FOCS engines (502, 602, 903, 1204 and 1204/T) utilize the
same camshaft timing pulley. The cam timing of the LDW 502
however, differs from the other LDW-FOCS engines. Carefully review
the diagram to the left and the chart below to assure the correct
timing marks are used with respect to the engine model.
1 Timing Reference Mark on Cylinder Head.
2 Camshaft Pulley Timing Mark- LDW 502 Only.
3 Camshaft Pulley Timing Mark- LDW602,702,903,1003,1204,1404 and 1204/T
TIMING BELT INSTALLATION- TIMING PROCEDURE
With reference to the Crankshaft Timing Pulley section on the
previous page, align the crankshaft timing pulley mark with the TDC
reference mark on the oil pump housing. Align the camshaft timing
pulley with the timing reference mark as detailed above.
Loosen the timing belt idler pulley (see page 24). Orient the new
timing belt with the directional marks(A) as shown. Install the timing
belt onto the engine routing the timing belt over the crankshaft pulley,
over the camshaft pulley, over the coolant pump pulley and finally
around the idler. Push the timing belt against the back of the
crankshaft pulley and align the timing belt on all other pulleys. Pivot
the timing belt idler by hand and slightly tension the belt. Hand
tighten the tensioner nut, then loosen the nut by 1/2 turn.
TIMING BELT TENSIONING PROCEDURE- SETUP
Position belt preload tool 1460-049 (1) over the timing belt idler
adjustment ear (2). The tool should be oriented so that parallelism
with axis (B) is attained.
TIMING BELT TENSION PROCEDURE
Position a torque wrench as shown, engaging the 1460-049 tension
tool. The torque wrench axis (A) should be 90° from axis (B) as
shown above. Tension the belt by applying a torque of 30 Nm. While
holding the torque at 20 Nm, tighten the idler nut (3) securely. Torque
nut (3) to 40 Nm.
Rotate the engine in the normal direction of rotation (CW when
viewed from fan end of engine) three(3) complete revolutions to allow
the timing belt to “seat” and to align perfectly.
Repeat the above procedure two(2) times, including rotating the
engine to allow complete and confident tensioning.
36
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
VALVE TIMING CONFIRMATION
A
B
Intake Valve
Exhaust Valve
Rotate the engine in the normal direction of rotation until the No. 1
piston (flywheel side) approaches TDC- compression stroke. Setup
dial indicators on the intake and exhaust valve caps as shown.
Locate the dial indicators so that the full valve travel will be indicated
by needle movement. Rotate the engine (normal direction) until the
valves are on “rocking point”. Rocking point is defined as the
condition at which any small movement of the crankshaft results in
opposing valve movements. That is, a movement of the crankshaft
CW with result in one valve tending to open and the other valve
tending to close. Further, a movement of the crankshaft CCW will
result in the opposite valve behavior. Position the crankshaft so that
both valves are at the highest point possible with reference to the
dial indicator movements- thus TDC. Zero the dial indicators. Rotate
the engine 360° so that the engine is at TDC- exhaust stroke. Check
the valve timing angles as detailed below.
VALVE TIMING ANGLES
With the engine setup as above and positioned at TDC- exhaust
stroke as determined above, fit the engine crankshaft with a suitable
“degree wheel” and pointer. Set the pointer to 0°. Adjust valve
clearance to 0.25mm at the camshaft to rocker arm roller interface.
Zero the dial indicators. Rotate the engine clockwise (when facing
the crankshaft pulley end of the engine) and check conformance to
the chart to the left and the data below.
S
I
= TDC (Top Dead Center)
= BDC (Bottom Dead Center)
a
b
g
d
=
=
=
=
Intake Valve Opening Angle
Intake Valve Closing Angle
Exhaust Valve Opening Angle
Exhaust Valve Closing Angle
LDW 502, 602, 903 and 1204:
a
b
g
d
=
=
=
=
16°
36°
36°
16°
BTDC
ABDC
BBDC
ATDC
LDW 1204/ T
a
b
g
d
COMPILER TECO/ATL
REG. CODE
MODEL N°
=
=
=
=
10°
42°
56°
16°
BTDC
ABDC
BBDC
ATDC
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
37
II
DISASSEMBLY/REASSEMBLY
SPEED GOVERNOR
The FOCS speed governor is driven by the camshaft and is housed
within the cylinder head. Access to the speed governor is gained by
removing the camshaft front support as shown. Disassemble the
front camshaft support by first loosening and removing three(3)
securing bolts holding the camshaft support to the cylinder head,
then pulling the support from the cylinder head. Following removal of
the camshaft support, the governor assembly may be removed from
the engine.
Components (Speed Governor)
(see figure directly at left)
1
2
3
Thrust Washer
Spool
Flyweight Assy.
Components (Governor / Camshaft Support Assembly)
1
2
3
4
Oil Seal
Bolt
Support
O-Ring
5
6
7
8
Bearing
Retainer
Bolt
Flyweight Assy.
9 Spool
10 Thrust Bearing
NOTE: The flyweight assembly has four(4) weights up to 4000 r/min
and two(2) weights over 4000 r/min. Further, the flyweight mass is
reduced by 25% for limiting speed governors.
INSPECTION: Remove the bearing(5) from the support by removing
the bolts(7) and retainer(6). Clean the camshaft support and
governor components in solvent then blow dry with compressed air.
Inspect the spool(3) (thrust surfaces and internal bushing), thrust
bearing(10), bearing(5) and flyweights(8) for wear. Replace as
required.
GOVERNOR FORK
After removal of the intake manifold/ air filter support (page 20) and
the governor/ camshaft support assembly, remove the governor fork
pivot pin (not shown) located on top of the cylinder head in the area
of the governor. Remove the fork assembly as shown making sure
that the governor spring(C) does not drop off. Clean the fork
assembly in solvent and dry using compressed air. Inspect the for
wear at points(B) and make sure that the contact areas at points(B)
are parallel within 0.05mm. Replace the fork if the contact points(B)
show evidence of flat spots or if the assembly does not operate
freely and smoothly. Check dimension(A) to make sure that the
distance is 45/46mm.
GOVERNOR SPRINGS
Governor springs are fitted within FOCS series engines as a function
of the intended operating speed. Springs are available in the
following ranges: 3600 r/min, 3000 r/min, 2400-2600 r/min, 1800 r/
min and 1500 r/min. Additionally, a special spring is available for the
limiting speed governor.
PRECISION SPEED GOVERNOR -(GENSETS)
FOCS engines ordered and specified for genset applications at 1500
or 1800 r/min are supplied with a modified governor fork assembly
with respect to standard. The governor fork for genset applications
utilizes qty(4) bearings as shown at (A). The additional bearings
reduce friction, there by providing better governor regulation at 1500
or 1800 r/min.
INSPECTION: Clean the governor fork assembly using solvent. Dry
with compressed air. Inspect the fork wear surfaces and actuating
pin height as described above for the standard fork assembly. Test
the fork assembly for smooth operation. Replace as required. Coat
with clean engine oil before installation.
38
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
LIMITING SPEED GOVERNOR
Applications requiring true operator “foot” control, such as vehicles,
are specified with a limiting speed or “MIN-MAX” governor. The
limiting speed governor spring is designed as a singular unit but
comprises two(2) separate springs- an idle spring and a high speed
spring. The spring assemblies are speed specific and are identified
by color code as detailed below.
Components
1 Nut- Adjustment
5 Register
2 Idle Spring
6 Seat- Elastomeric
3 High Speed Spring 7 Actuation Rod
4 Case
Ref. Color
red
(none)
black
orange
white
brown
green
Speed
3000
3200
3600
3750
4200
4500
4300
SPEED GOVERNOR REASSEMBLY
Install the governor fork assembly (with governor spring). After
coating with oil, install the governor fork pivot bolt (use new -o-ring
on pivot bolt). Torque the pivot bolt to 7 Nm. With reference to the
previous page (Governor / Camshaft Support Assembly), install the
governor assembly using a new O-Ring(4) and Seal(1). Coat all
components with clean engine oil. Subassemble the camshaft
support by installing the bearing(5), retainer(6) and bolts(7). Torque
the retainer bolts(7) to 10 Nm. Install the governor assembly onto the
camshaft as shown in the diagram, beginning with the thrust
bearing(10), then the spool(9), then the flyweight assembly(8),
making sure that the needle bearing side of the thrust bearing faces
the spool. Install the camshaft support. Torque the camshaft support
bolts to 10 Nm.
NOTE: After assembly, check the camshaft end play. If end play is
noted, replace the camshaft support bearing.
OIL PUMP ASSEMBLY
The FOCS oil pump is supplied as an assembly. Lombardini
therefore recommends that the oil pump be handled as an assembly
from a service standpoint. Lombardini does not recommend that the
oil pump be disassembled, then reassembled for purposes of
installation on the engine except during emergency situations.
REMOVAL: Rotate the crankshaft until the crankshaft timing pulley
keyway is vertical as shown. Remove the oil pump assembly
retaining bolts. When the crankshaft timing pulley keyway is vertical,
the oil pump drive keyway(A) will be at 3:00 o’clock allowing removal
of the oil pump assembly via relief(B).
OIL PUMP INSPECTION:
Tear down analysis and failure analysis regarding the FOCS oil
pump is facilitated by removing the oil pump back plate. Cleanliness
is very important. Do not wipe the oil pump housing or rotors with a
rag. Clean the oil pump rotor and housing using clean solvent. Dry
with compressed air. When reassembling the oil pump, coat all
components with clean engine oil and align timing marks(2) and (3).
Replace O-ring(1) before installing the back plate. Torque the back
plate bolts to 10 Nm. Replace the crankshaft oil seal if any indication
of seal degradation or wear is noted (see page 45).
OIL PUMP ASSEMBLY TO THE ENGINE:
Thoroughly clean the crankshaft to remove dirt, rust and residue.
Coat the oil seal with clean engine oil. Install the oil pump assembly
onto the crankshaft taking care not to damage the crankshaft oil seal.
Torque the oil pump retaining
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
39
II
DISASSEMBLY/REASSEMBLY
VALVE / ROCKER COVER: All critical engine adjustments require
the removal of the valve/ rocker cover. Remove the valve / rocker
cover by removing the crankcase vacuum regulator valve (see
below), removing the retaining bolts, then lifting the valve / rocker
cover assembly.The engine crankcase breather system is integrally
contained by the valve / rocker cover. Additionally, the valve / rocker
cover facilitates oil pressure measurement and camshaft/ rocker
arm lubrication via oil ports.
Components:
1 Oil Pressure Switch
2 Camshaft Lubrication Port
3 Rocker Arm Lubrication Port
4 Boot/ Tube for oil return to the Oil Sump
5 Crankcase Ventilation Chamber
INSPECTION / CLEANING: Inspect the valve/ rocker cover for
clogged oil ports, varnish deposits, cracks and lack of parallelism at
the mounting flange. Remove boot(4) ,clean in solvent and dry
(COMPLETELY) with compressed air. Replace the boot (4) if
swelling, cracking or degradation is noted.
CRANKCASE VACUUM REGULATOR VALVE (602, 702, 903,
1003, 1204, 1204/T, 1404)
The LDW-FOCS crankcase breather system is closed loop design.
Therefore, all crankcase vapors are induced into the intake manifold
and consumed by the engine. As such, a crankcase vacuum
regulator is required so that in conditions of high air filter restriction,
excessive oil is prevented from entering the engine potentially
causing speed regulation problems.
Components:
1
2
3
4
5
Gland Nut
Bushing
Body
Diaphragm
Cap/ Cover
6
7
8
9
10
Clip / Lock
O-Ring
Washer
O-Ring
Valve
11 Spring
12 Tube
13 Hose
CRANKCASE BREATHER - LDW 502
The crankcase breather system of the LDW 502 is not integral with
the valve/ rocker cover as described above. The LDW 502 breather
system includes a breather assembly(1), which includes a vapor
separation, condensate drain and vacuum regulator. A hose (not
shown) connects the breather assembly to the intake manifold.
VALVE / ROCKER COVER GASKET
The FOCS valve/ rocker cover gasket (A) is a critical part of the
lubricating system. Always replace the valve / rocker cover gasket
when reinstalling the valve / rocker cover.
Thoroughly clean all gasket material from the cylinder head and
valve / rocker cover. Place a small bead of RTV Silicone at positions
(1) and (2). Install the valve / rocker cover gently, inserting the drain
boot (see top diagram, No. 4) into the cylinder head. Torque the
valve / rocker cover bolts to 9 Nm.
40
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
VALVE ADJUSTMENT
Valve adjustments should be performed on a cold engine. Remove
the engine valve / rocker cover. Rotate the engine to TDCcompression stroke before adjusting the valves on each respective
cylinder.
Loosen the adjustment lock nut and adjust the clearance at (A) to
0.20mm or 0.15mm at (B) for both intake and exhaust valves.
While holding the adjustment screw with a suitable screwdriver,
tighten the adjustment lock nut. Re-check the valve clearance and readjust as required. Repeat the procedure for each cylinder.
After adjusting the valves, replace the valve / rocker cover using a
new gasket and following the instructions from the previous page.
INJECTION PUMP CONTROL ROD
Depending on the engine model, the injection pump control rod will
link two(2), three(3), or four(4) injectors to the engine governor.
REMOVAL: Carefully remove spring(3). Carefully remove bolts (1),(2)
at point (B) of each unit injector. Do not loosen the bolts at (A).
NOTE: Each unit injector has a pivot bolt identical to bolts (1),(2). For
purposes of illustration, a LDW 602 engine is shown, thus, two(2)
pivot bolts. Disengage the control rod from the unit injectors and the
governor fork. Remove the control rod.
INSPECTION: Clean the control rod with solvent and dry with
compressed air. Inspect the actuation slot at the the point the control
rod attaches to the governor for wear, bending, galling, etc. Inspect
the control rod for bending or general degradation. Replace as
required.
INSTALLATION: Install the control rod by reversing the removal
procedure detailed above. Coat the control rod with clean engine oil.
Torque bolts (1), (2) to 1.1 Nm. NOTE: Adjustment of the control rod
is covered on page 74.
FUEL RAIL
Fuel supply to the unit injectors and the return of excess fuel from the
unit injectors to the fuel tank is facilitated by the fuel rail.
REMOVAL: Remove the supply and return lines from the end of the
fuel rail. Remove the bolts securing the fuel rail to the unit injectors
(two(2) bolts per unit injector). Carefully lift fuel rail (A) from the unit
injectors making sure that the sealing O-rings (C) do not fall into the
engine.
INSPECTION: Clean the fuel rail in clean diesel fuel. Inspect the fuel
rail for welded joint fatigue or cracks, degradation and flatness at the
O-ring joint. Inspect the fuel rail grommet joint (located at the fuel rail
/ cylinder head interface on the rear of the cylinder head). Replace the
grommet if brittleness or evidence of oil leakage is evident. Replace
the fuel rail as required.
INSTALLATION: Remove all O-rings(C) and clean the seats of all Orings. Replace the O-rings(C). Lightly coat the grommet seat on the
cylinder head with RTV silicone. Carefully lower the fuel rail onto the
unit injectors. Torque the retaining bolts to 4 Nm. WARNING: Do not
use any type of sealing compound at the O-ring joints.
UNIT INJECTOR CHECK VALVE
The unit injector check valve(A) allows an instantaneous engine
shutdown via a simple fuel shut-off valve. With reference to the unit
injector identification chart on page 55, remove the unit injector check
valve. Please note that unit injector reference no.’s 231-2, 235-2 and
272-o are equipped with push-in check valves, while all other unit
injector reference no’s are equipped with screw-in check valves.
INSPECTION: Inspect the check valves for general condition,
indication of loose operation within the unit injectors, loose or
damaged check valve balls/retaining pins and erosion. Replace as
required. Reassemble the check valves into the unit injectors.
Measure the and confirm the following dimensions as shown on the
diagram: B= 1,0/1,85mm; D= 5.5/6.0mm; E= 7.0/7.1mm (502-602903-1204) and B= 0.5/1.15mm; D= 5.95/6.5mm; E=7.0/7.1mm.
Special spacer washers are available to increase the height of the
check valve to specifications.
NOTE: The sealing of the fuel rail and check valves is critical to
prevent fuel from entering the oil sump. The sealing mechanisms are
O-rings (C). If in doubt, always replace the O-rings.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
41
II
DISASSEMBLY/REASSEMBLY
UNIT INJECTOR REMOVAL / INSTALLATION
Unit injectors may require removal for either service on the unit
injector, or for purposes of allowing other service operations. If unit
injector service is required, a static timing and fuel delivery
equalization procedure will be required (see FUEL SYSTEM).
If unit injector service is not required, the following procedure may be
used to allow unit injector removal and replacement without the need
for other adjustments.
1. Remove the valve/rocker cover(page 29).
2. Remove the control rod(page 30).
3. Remove the fuel rail(page 30).
4. Label all injectors with respect to cylinder number.
5. DO NOT LOOSEN THE UNIT INJECTOR ADJUSTMENT
SCREW(4).
6. Rotate the engine until the unit injector cam lobe(2) forces the cam
follower (1) to the highest position.
7. Insert a suitable sized (hardened) pin into the hole (3).
8. Rotate the engine until the cam follower(1) is at the lowest
position.
9. Loosen and remove the two(2) M8 unit injector retainer nuts and
washers.
10. Remove the unit injector from the cylinder head while making
sure that the push rod(5) does not fall into the engine. Set aside the
“labeled” unit injector, keeping the push rod(5) from each cylinder
with the respective unit injector.
ASSEMBLY: Inspect the unit injector O-rings for damage and replace
as required. Using a new fire ring (see page 59), reassemble the unit
injectors and unit injector push rods into the exact cylinder from with
they were removed. Install the unit injectors using a procedure
reverse from the removal procedure. Torque the unit injector
retaining nuts in 5 Nm steps to 20 Nm.
ROCKER ARM ASSEMBLY
NOTE: The rocker arm assembly may be removed without removal
of the unit injectors. If unit injector removal is not required, follow
steps 1, 5, 6, 7 and 8. Upon reinstallation of the rocker arm
assembly, follow steps 8, 7, 6, 5 and 1 as detailed above.
REMOVAL: Remove the nuts and washers attaching the rocker arm
assembly to the cylinder head. Lift the rocker arm assembly from the
engine as shown in the diagram. Take measures to insure that the
unit injector push rods do not fall into the engine when lifting the
rocker arm assembly.
INSPECTION: Clean the rocker arm assembly in solvent and dry
with compressed air. Inspect the rocker arm to valve stem contact
areas, inspect the unit injector actuation balls, inspect the rocker
arms for signs of looseness or galling and fractures. If complete
disassembly and dimensional analysis of the rocker arm assembly is
required or desired, refer to the lower diagram.
DISASSEMBLY: Label all rocker arms so that the rocker arms may
be reinstalled in the same position. Using a 4mm drill bit and a
suitable drill and vise, drill out the pin(3). Remove the support
blocks(2) and the rocker arms. Remove plug (4) and thoroughly
clean shaft (1). with solvent.
SPECIFICATIONS
A
B
C
0-1.00mm
17.989/18.000mm
18.015/18.030
C-B = 0.015/0.041mm (USEABLE Limit= 0.090mm)
INSTALLATION: Reassemble the rocker arm assembly installing the
rocker arms in identical positions as removed (if reused), coating all
components with clean engine oil. Reassemble the rocker arm
assembly onto the engine taking
42
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
CAMSHAFT REMOVAL/ REPLACEMENT
PREPARATION: Remove the rocker arm assembly, remove the
camshaft end cover(1), remove the camshaft timing pulley, remove
the governor assembly, remove the fuel lift pump, remove the fuel lift
pump push rod.
REMOVAL: Gently and slowly, slide the camshaft toward the
flywheel end of the engine. Slight rotation(s) may be required to
prevent binding of the camshaft lobes against the camshaft bearing
surface bores.
INSPECTION: Clean the camshaft with solvent and dry with
compressed air. Inspect all lobes and journals for wear, seizure,
pitting, etc. Refer to the data presented in the following for
dimensional analysis of the camshaft. Replace the camshaft as
required.
INSTALLATION: Liberally oil the cylinder head camshaft supprt
bores and the camshaft journals. Install the camshaft into the
cylinder head, gently rotating the camshaft as required to allow
installation. Replace O-ring(2) and replace the camshaft cover(1).
NOTE: The flywheel end of the camshaft includes a bolt-on
eccentric(3) for purposes of lift pump drive. Torque the eccentric(3)
to 80 Nm.
CAMSHAFT JOURNAL / SUPPORT MEASUREMENT
After thoroughly cleaning the camshaft and cylinder head bores,
measure the critical diameters with calibrated micrometers as
shown.
CAMSHAFT JOURNAL / SUPPORT BORE SPECIFICATIONS
A
B
37.035/37.060mm
36.975/37.000mm
A-B= 0.035/0.085mm (USEABLE Limit= 0.170mm)
NOTE: The camshaft journal and cylinder head camshaft bore
dimensions are identical for all LDW-FOCS series engines- LDW
502, LDW 602, LDW 702, LDW 903, LDW 1003, LDW 1204, LDW
1404, LDW 1204/T.
CAMSHAFT LOBE MEASUREMENT PROCEDURE
After thoroughly cleaning the camshaft, measure the camshaft lobes
from the circle base to the top of the lobe (maximum possible
dimension) using a calibrated micrometer.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
43
II
DISASSEMBLY/REASSEMBLY
CAMSHAFT LOBE SPECIFICATIONS
NOTE: The camshaft shown in the figure is reflective of a LDW 903.
However, the cam lobes are identical for the LDW 502, LDW 602,
LDW 903 and LDW 1204 diesel engines. The cam lobes are slightly
different for the LDW 1204/T as is shown in the data below.
H- (502, 602, 903, 1204)= Valve Lobe (intake/ exhaust)= 29.598/
29.650mm
H- 1204/T, Intake Lobe= 29.438/29.490mm
H- 1204/T, Exhaust Lobe= 29.778/29.830mm
H- USEABLE Limit (All Models)= Minimum Value minus(-) 0.1mm
H1- Injection Lobe (All Models)= 28.948/29.00mm
H1- Injection Lobe USEABLE Limit= 28.848mm
LOBE IDENTIFICATION:
A1 No. 1 Intake A2 No. 2 Intake
S1 No. 1 Exhaust S2 No. 2 Exhaust
I1 No. 1 Injection I2 No. 2 Injection
A3 No. 3 Intake
S3 No. 3 Exhaust
I3 No. 3 Injection
CYLINDER HEAD REMOVAL
Remove all cylinder head bolts, then lift the cylinder head from the
crankcase. Do not pry excessively, lever or strike the cylinder head
with a hammer in attempts to break the cylinder head loose from the
head gasket. Do not damage the pre-combustion chambers during
the handling process.
INSPECTION: Thoroughly clean the cylinder head in a non-caustic
solvent. Dry with compressed air. Inspect for cracks and warpage.
Check cylinder head warpage using a high quality straight edge and
precision feeler gauges. Hold the straight edge on the cylinder head
deck and check corner-to-corner and side to side in at least four(4)
equidistant zones. The maximum allowable warpage is 0.10mm. If
warpage exceeds 0.10mm, the cylinder head may be planed a
maximum of 0.20mm. NOTE: Remove pre-combustion chambers
before planing.
VALVE REMOVAL
Components:
1 Valve Stem
2 Valve Seal
3 Spring Seat
4 Spring
5 Spring Cap
6 Collets
Place the cylinder head on suitable wood spacers so that the prechambers do not touch the top of the work bench when the cylinder
head is oriented as shown. Using a suitable valve spring
compression tool and acting on the spring cap(5), compress the
valve springs so that the collets(6) can be removed while the spring
is being held in the compressed state. WARNING: Valve springs can
store a considerable amount of energy while under compression.
Compress and hold valve springs under compression with care- wear
suitable eye protection. After the collets are removed from all valves,
turn the cylinder head 90° so that the cylinder head is resting on the
intake or exhaust planes. Remove the valves. If valves are to be
reused, label each valve according to cylinder number so that the
valves can be reinstalled in the identical position as removed.
VALVE STEM SEAL INSTALLATION
Following cleaning of the cylinder head and machining or lapping of
the valves/ valve seats, install the valves into the cylinder head.
Using wooden spacers to prevent pre-chamber damage, orient the
cylinder head as shown. Soak new valve stem seals in clean engine
oil for five(5) minutes. Liberally lubricate the valve stems with clean
engine oil. Using special tool 1460-047, place the valve stem seals in
the end of the 1460-047 tool. Carefully push the valve stem onto the
valve stem and over the valve guide. Do not force the seal or use a
hammer to drive the seals into place. The hand force applied must be
parallel to the valve
44
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
VALVE SPRINGS
INSPECTION:
Clean all valve springs in solvent and dry with compressed air.
Inspect the springs for surface cracks and fractures. Orient the
spring in normal direction of operation with one end of the spring
resting on a flat surface. Make sure that both planes of the spring are
parallel. If the springs seats are not parallel, discard the spring.
Measure the free height of the spring as shown in the diagram. The
free height should be 45.6mm (nominal). If the free height is less
than 43.5mm, discard the spring.
VALVE SPECIFICATIONS:
INTAKE VALVE:
Base Material: X 45 Cr Si 8 UNI 3992
Zone 1 - Chrome Plated
C= 33.00mm (LDW 502-602-903-1204-1204/T)
C= 34.40mm (LDW 702-1003-1404)
a 1= 60° 30’ / 60° 45’
EXHAUST VALVE: Zone 2 - Weld Joint
Zone 3- Chrome Plated
Zone 4- Base Material: X 45 Cr Si 8 UNI 3992
Zone 5- Base Material: X 70 Cr Mn NI N 216
UNI 3992
D= 29.00mm (LDW 502-602-903-1204-1204/T)
D= 30.20mm (LDW 702-1003-1404)
a= 45° 30’ / 45° 45’
VALVE CLEANING: The face and lower shank of the valves may be
power cleaned via an electric brush. DO NOT POWER BRUSH THE
VALVE STEM!
VALVE GUIDES / VALVE GUIDE BORE
Both intake and exhaust valve guides are identical dimensionally and
are made from phosphoric gray iron with a pearlitic matrix. The
dimensional specifications are as follows:
A
B
C
D
E
36.4/36.6mm
11.045/11.054mm
11.000/11.018mm
5.80/6.20mm
9.75/9.85mm
Valve guides are supplied in finished form. No further machining of
standard valve guides is required or recommended. NOTE: 0.50mm
oversized valves guides (OD) are available. If oversized valve guides
are used, dimension (C) from above must be increased by 0.50mm.
VALVE GUIDE INSTALLATION GUIDELINES AND POST
INSTALLATION VALVE/VALVE GUIDE SPECIFICATIONS
Lombardini does not provide installation tools for valve guides.
Lombardini recommends that valve guide replacement be done by a
suitable shop specializing in cylinder head work.
Whether newly installed or existing, the valve guides should conform
to the following:
A 39.5/40.0mm
B 7.005/7.020mm
C 6.960/6.990mm
B-C= 0.015/0.050mm; USAGE Limit= 0.10mm
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
45
II
DISASSEMBLY/REASSEMBLY
VALVE SEATS
Valve seats are supplied fully finished. No further machining of the
valve seats is required or recommended except for a final lapping
operation as part of valve installation. Lombardini does not provide
installation tools for valve seats. Lombardini recommends that valve
seat replacement be done by a suitable shop specializing in cylinder
head work. Whether newly installed or existing, the valve seat to
cylinder head interface must conform to the following:
For LDW 502-602-903-1204-1204/T
EXHAUST VALVE SEAT: A = 34.020 / 34.045mm
B = 34.106 / 34.115mm
a1=59° 53’ / 60°
INTAKE VALVE SEAT:
For LDW 702-1003-1404
EXHAUST VALVE SEAT:
INTAKE VALVE SEAT:
C = 30.020 / 30.041mm
D = 30.108 / 30.116mm
a = 44° 53’ / 45°
A = 35.220 / 35.245mm
B = 35.306 / 35.315mm
a1=59° 53’ / 60°
C = 31.220 / 31.241mm
D = 31.308 / 31.316mm
a = 44° 53’ / 45°
VALVE RECESS and SEAT SEALING WIDTH
Invert the cylinder head as shown with the cylinder head resting on
suitable supports. Install the valves, but not the valve springs.
Lubricate the valve stems with clean engine oil and perform the final
lapping on the valve to valve seat interface using ‘fine’ lapping
compound. Wipe off all excess lapping compound. Remove each
valve following lapping and measure the width of the sealing band
(S) as shown by the gray lap line.
For LDW 502-602-903-1204-1204/T
SEALING WIDTH (S) = 1.6 / 1.7mm; USEABLE Limit= 2.0mm
VALVE RECESS (D) = 0.5 / 0.8mm; USEABLE Limit= 1.1mm
With the valve resting in the cylinder head, use a depth micrometer
to determine the recess (D) that the valve face drops below the
cylinder head deck.
If valve recess or valve sealing area does not meet the above
specifications, replace the valves/ valve seats as required.
For LDW 702-1003-1404
SEALING WIDTH (S) = 1.6mm; USEABLE Limit= 2.0mm
VALVE RECESS (D) = 0.7 / 1.0mm; USEABLE Limit= 1.3mm
PRE-COMBUSTION CHAMBER-OVERVIEW
Components of the Pre-combustion chamber configuration
1
2
3
4
Pre-combustion Chamber
Glow Plug
Pre-combustion Chamber Ring Nut
Cylinder Head
NOTE: Pre-combustion chambers are identical for the LDW 602,
LDW 903, LDW 1204 and LDW 1204/T. The LDW 502 has a slightly
different design than the other FOCS models.
46
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
NOTE: THE PRE-COMBUSTION CHAMBER DOES NOT
NORMALLY REQUIRE REMOVAL OR SERVICE AND SHOULD
NOT BE DISTURBED UNLESS ABSOLUTELY NECESSARY. DO
NOT REMOVE PRE-COMBUSTION CHAMBERS AS PART OF A
NORMAL REBUILD OR VALVE JOB. FURTHER, LOMBARDINI
RECOMMENDS THAT NEW PRE-COMBUSTION CHAMBERS BE
INSTALLED IF REMOVAL OF THE EXISTING PRE-CHAMBERS IS
REQUIRED. THE FOLLOWING PROCEDURES DETAIL PRECHAMBER REMOVAL AND INSTALLATION SHOULD SERVICE BE
REQUIRED.
PRE-COMBUSTION CHAMBER RING NUT:
As shown in the diagram at the bottom of page 35, the precombustion chamber is secured to the cylinder head by a ring nut.
The ring nut(2) may be removed by securing the cylinder head in a
safe and suitable manner- resting on wooden blocks to protect the
pre-combustion chambers, then using special tool 1460-027 and a
breaker bar to loosen and remove the ring nut(2).
PRE-COMBUSTION CHAMBER REMOVAL
Remove the glow plug(s) from the cylinder head. Screw special tool
1460-030 into the pre-combustion chamber. Special tool 1460-030 is
comprised of shaft/end (1) and slide hammer(2). Make sure that the
shaft/end (1) portion of the special tool is completely screwed into
the pre-combustion chamber. Carefully, but sharply, slide the slide
hammer(2) up the special tool shaft until contact is made with the
end of the tool. The hammer effect of the special tool will extract the
pre-combustion chamber. Following extraction of the pre-combustion
chamber, unscrew the pre-combustion chamber(3) from the special
tool.
WARNING: SPECIAL TOOL 1460-030 IS AN IMPACT DEVICE.
EYE PROTECTION SHOULD BE WORN DURING OPERATION.
GREAT CARE SHOULD BE TAKEN TO PREVENT THE PINCHING
OF YOUR HAND OR FINGERS AS THE SLIDE HAMMER IMPACTS
THE TOP OF THE TOOL.
PRE-COMBUSTION CHAMBER INSTALLATION:
Carefully clean all carbon from the pre-combustion chamber pocket
in the cylinder head. Do not use sharp edges or abrasive means to
clean the pre-combustion chamber pocket. Non-caustic solvents
may be used to assist in carbon removal.
Introduce a new pre-combustion chamber into the cylinder head so
that the side hole of the pre-combustion chamber approximately
aligns with the glow plug hole (see diagram at left). Screw the prechamber alignment tool 1460-031 fully into the glow plug threaded
hole, through the pre-chamber side hole. Using the pre-combustion
chamber ring nut tool- 1460-027 as shown above, install and tighten
the pre-combustion chamber ring nut. Torque the ring nut in two(2)
steps- 100 Nm, then 180 Nm.
Reinstall the glow plug. Torque the glow plug to 25 Nm.
OIL PAN REMOVAL / INSTALLATION
REMOVAL: Drain the oil from the oil pan. Remove all oil pan bolts.
Gently, without deforming the pan, pry the pan from the crankcase
using a small bar(1). Numerous attempts at several different
locations around the perimeter of the pan may be required before the
pan releases from the crankcase.
INSPECTION/ CLEANING: Thoroughly clean the oil pan in solvent
and dry with compressed air. Remove all traces of the oil pan gasket
from the oil pan and crankcase. Inspect the oil pan for warpage,
cracks, dents, etc.. Inspect the oil pick-up screen for tears and/or
clogging. Inspect the oil drain plug holes for thread integrity. Lay the
oil pan mounting flange on a flat surface and check for flatness.
Repair or replace as required.
INSTALLATION: Install a new oil pick-up O-ring. Apply Dow Corning
7091 Silicone around the perimeter of the sealing surface of the pan
as shown. Allow the silicone to “skin”. Install the oil pan to the
engine. Torque the oil pan bolts to 10 Nm. Torque the oil drain plug
to 40 Nm.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
47
II
DISASSEMBLY/REASSEMBLY
PISTON REMOVAL: Rotate the engine to BDC. Clean all carbon
from the top of the cylinder bore. If a wear ridge is present at the top
of the cylinder bore, remove the ridge with a suitable “ridge reamer”.
Remove the connecting rod cap as shown. Using a soft, wood rod,
carefully and slowly push on the connecting rod- forcing the piston
upward. Do not allow the connecting rod to hit the crankshaft. Note:
Slight crankshaft rotation may be required to gain adequate access
to the connecting rod for purposes of pushing. Push the connecting
rod until the piston oil ring is outside of the cylinder bore. Lift the
piston from the cylinder bore as shown. Mark the top of the piston
and the connecting rod with respect to cylinder number. Loosely reattach the connecting rod cap to the connecting rod.
GENERAL PISTON NOTES: FOCS Series pistons are identical for
the 602, 903, 1204. The 502 piston is slightly different and carries a
separate part no.. The 1204/T piston is identical to the 602, 903 and
1204, but is fitted with a special top compression ring individual to
the 1204/T.
PISTON / CONNECTING ROD DISASSEMBLY and PISTON
INSPECTION
Carefully remove and retain the piston pin snap ring (one(1) side
only) using a suitable awl and a small screwdriver as required(see
diagram). Do not damage the snap ring seat during the removal
process. Push the piston wrist pin far enough to allow the piston and
connecting rod to be separated. NOTE: If required, the wrist pin
may be tapped with a soft faced drift to assist wrist pin movement. If
tapping is required, place the piston on a protected surface so that
the skirt of the piston is not damaged during the tapping process. Do
not allow the drift to contact the piston pin bore.
INSPECTION: Clean the piston and piston pin in solvent. Dry with
compressed air. Inspect the piston for scoring, galling and signs of
localized overheating. Carefully remove the piston rings. Remove all
carbon from the piston top. Clean the carbon from the ring grooves
using a suitable ring groove cleaning tool.
MEASUREMENT: Measure the diameter(Q) of the piston skirt a
distance(A)-9mm from the bottom of the piston skirt. Measure piston
ring land/ ring clearance as detailed on page 39.
PISTON CLASS, WEIGHT IMBALANCE and GENUINE
LOMBARDINI MARKINGS
As part of the high quality standards of Lombardini, pistons are fitted
within FOCS engines as a function of finished cylinder size. Four(3)
piston classes exist- A,B,C. The piston class is stamped into the
bottom of the piston as shown in the diagram (at arrow). The
Lombardini logo on the bottom of the piston crown is your assurance
that the piston is GENUINE Lombardini.
PISTON CLASS DETAILS (502-602-903-1204-1204/T):
CLASS
A
B
C
Ø Cylinder (mm)
71.990 / 72.000
72.000 / 72.010
72.010 / 72.020
Ø Piston (mm)
71.930 / 71.940
71.940 / 71.950
71.950 / 71.960
Clearance (mm)
0.050 / 0.070
PISTON CLASS DETAILS (702-1003-1404):
CLASS
A
B
C
Ø Cylinder (mm)
74.990 / 75.000
75.000 / 75.010
75.010 / 75.020
Ø Piston (mm)
74.930 / 74.940
74.940 / 74.950
74.950 / 74.960
Clearance (mm)
0.050 / 0.070
REPLACEMENT PISTONS (SPARE PARTS): Replacement pistons
are supplied with piston rings reflective of the piston class.
Replacement pistons are supplied as class A. Piston classes B and
C are reserved for production engines. Oversized pistons are
available as 0.50mm and 1.00mm and are supplied with piston rings
reflective of the oversized diameter. DO NOT FIT PISTON RINGS
FOR STANDARD PISTONS ON OVERSIZED PISTONS. DO NOT
FIT RINGS FOR OVERSIZED PISTONS ON STANDARD PISTONS.
PISTON BALANCE: Weigh all pistons to be installed within a single
engine. The total difference in weight between the lightest and
heaviest piston should not exceed 4 grams.
48
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
CYLINDER INSPECTION / DIMENSIONAL SPECIFICATIONS
Thoroughly clean the cylinders and upper deck of the crankcase.
Alternately, completely clean the crankcase with solvent and dry with
compressed air. Remove all carbon deposits from the cylinder and
carefully remove any excessive ridge at the upper portion of the
cylinder using a suitable “RIDGE REAMER” tool. Inspect the
cylinders for general wear, scoring, galling and discoloration.
Using a calibrated bore gauge, measure the cylinder diameter at
four(4) positions in 45° intervals at each of the depths (1), (2) and (3)
as shown. The piston ring contact zone is shown as (X), while the
piston skirt only contact area is shown as (Z). Dimensional analysis
is as follows:
D= 71.990 / 72.000mm, CLASS A- (All FOCS Models)
If the cylinder is found to be 72.050mm or greater at any
measurement point, bore the cylinder by 0.50 or 1.00mm. Further, if
the cylinder is found to be in specification, but the bore is tapered or
bell-mouthed, boring is suggested. NOTE: To determine the piston
running clearance, measure the piston skirt as detailed on page 37,
then measure the cylinder bore in zone (Z). The piston running
clearance will be the difference between the two (2) dimensions.
CYLINDER CLASS
The cylinder class (at time of manufacture) is stamped on the upper
deck of the crankcase as shown in the diagram. Cylinders are
classed as A,B,C depending on the exact cylinder diameter.
NOTE: Replacement pistons are available in class A. If upon
disassembly, the existing pistons cannot be reused, replace the
piston with class A depending on the cylinder diameters found.
NOTE 2: The LDW 502 aluminum version is designed with an
aluminum crankcase and non-replaceable cast iron cylinders. The
cylinders may be machined 0.500 and 1.000mm identically to
standard crankcase versions of the LDW-FOCS.
CYLINDER SURFACE FINISH
Proper cylinder surface finish is critical for low oil consumption and
optimal engine performance. Therefore, the success of an engine
rebuild is greatly affected by the preparation of the cylinders with
respect to surface finish.
After inspection of the cylinders as detailed above, the cylinders
should be power honed. A “BEAD” type hone is preferred for engines
that do not require boring. Engines that require boring, should be
power honed as part of the boring operation. Since honing removes
material, the diameter of the cylinder should be re-checked as
detailed above following honing.
The honing operation should produce a pattern oriented at 45-55° as
shown in the diagram. The final surface roughness should be 0.51.0mm.
POST HONING CLEANING: Lombardini strongly recommends that
the cylinders be washed with hot water and a strong degreasing soap
following honing. Finish the cleaning operation with a thorough
rinsing with clean water, then dry the crankcase with compressed air.
Coat all exposed surfaces, especially the cylinders and upper
crankcase deck with clean engine oil to prevent corrosion.
NOTE: DO NOT USE EMERY CLOTH, SAND PAPER, ETC. ON
THE CYLINDER IN ATTEMPTS TO CREATE A CROSS-HATCH
PATTERN BY HAND MOTION.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
49
II
DISASSEMBLY/REASSEMBLY
PISTON RING END GAP
Prior to installing piston rings on each piston, install the rings within
the cylinder bore, approximately 25mm from the top of the crankcase
deck as shown. A piston turned upside down should be used to push
the rings to the 25mm depth so that assurances of proper orientation
can be had. Use a feeler gage(A) to measure the ring end gap. The
specifications are as follows:
1st piston ring(compression) = 0.25-0.45mm,(USEABLE Limit =
1.00mm)
2nd piston ring(compression) = 0.25-0.45mm,(USEABLE Limit =
1.00mm)
3rd piston ring(oil scraper) = 0.25-0.45mm,(USEABLE Limit =
1.00mm)
NOTE: If the ring gap is less than the minimum value shown, gently
secure the ring in a soft jaw vise and file (small amount) the ends of
the ring, re-checking the end gap periodically until the required
clearance is achieved. Remove all burrs from the piston ring ends
before installation.
PISTON RING TO PISTON LAND CLEARANCE
With reference to the diagrams, measure the piston ring to piston
land clearance using a feeler gage. If the piston has previously been
operated within and engine, the piston should be inspected and
cleaned as described on page 36.
The specifications for piston ring to piston land clearance are as
follow:
A
B
C
= 0.090-0.125mm
= 0.050-0.085mm
= 0.040-0.075mm
Replace the piston and/or piston rings if the piston ring to piston ring
land clearance exceeds the specification.
PISTON RING ASSEMBLY LOCATION
With reference to the diagram, carefully install the piston rings onto
the piston.
A
B
C
D
E
Top Compression Ring (Tapered / Torsional)
No. 2 Compression Ring (Tapered / Torsional)
Oil Control Ring (Internal Spring, 2 piece Ring)
Chrome Plated Portion of Top Compression Ring
Chrome Plated Portion of Oil Control Ring
NOTE: As shown on the diagram, install the rings so that the word
“top”, “UP” or any other markings faces up.
CONNECTING
ROD
/
CONNECTING
ROD
BEARINGS
SPECIFICATIONS
INSPECTION / SET-UP: Remove the connecting rod cap. Remove
the connecting rod bearing inserts. Clean the connecting rod and
bearings in solvent, then dry with compressed air. Inspect the
connecting rod for nicks, gouges and potential stress risers. Inspect
the wrist pin bushing for scratches and indications of galling or
overheating. Discard the connecting rod if any doubt concerning the
general condition of the connecting rod exists. Inspect the
connecting rod bearings for wear, dis-coloration, scatches and
grooves. Discard the connecting rod bearings if any doubt exists.
Install the connecting rod bearing inserts (whether new or existing)
into the connecting rod, then torque the connecting rod cap. See
page 41 for connecting rod cap orientation and torque specifications.
The following provides dimensional specifications for a fully
assembled (with bearings) and torque connecting rod. Replace the
connecting rod and/or connecting rod bearings if dimension
conformance to the following is not shown.
Dim. SPECIFICATION
NOTES
A
126.48÷126.520mm LDW 502=106.98 / 107.02mm
B
18.015÷18.025mm LDW 1204/T= 20.015 / 20.025
C
40.021÷40.050mm (Cap Torqued to 40 Nm)
D
17.996÷18.000mm LDW 1204/T= 19.996 / 20.000mm
E
50.900÷51.100mm LDW 1204/T= 54.000 / 55.100mm
B-D = 0.015÷0.039mm; USEABLITY Limit = 0.060
NOTE: If the small end bushing is replaced, the lubrication hole must
be aligned
50
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
CONNECTING ROD ALIGNMENT
Check the alignment of the connecting rod wrist pin bore with
respect to the connecting rod journal diameter by fitting the
connecting rod to a suitable fixture as shown or by placing the
connecting rod on a mandrel in V-blocks as shown. If the V-block
and dial indicator method is used, center the wrist pin in the
connecting rod wrist pin bore so that an equal amount of the wrist
pin protrudes from each side of the connecting rod. While holding
the wrist pin down and seated in the wrist pin bushing, measure the
height of the wrist pin on both sides of the connecting rod. If the
fixture method is used, press down on the wrist pin as shown and
measure the any axial offset.
Maximum Axial Mis-alignment = .015mm (USEABILITY Limit =
0.030mm)
Minor mis-alignment may be corrected by skillfully and gradually
working the connecting rod between centers on a press. DO NOT
ATTEMPT TO CORRECT MIS-ALIGNMENT UNLESS PROPERLY
TRAINED AND EXPERIENCED.
PISTON WRIST PIN INSTALLATION / RETAINING SNAP RING
After thoroughly cleaning and checking the connecting rod as
described in the previous, liberally coat the wrist pin , piston wrist pin
bore and wrist pin bushing with clean engine oil. While holding the
piston and connecting rod as shown, insert the wrist pin into the
piston and through the connecting rod. Do not force the wrist pin or
use a hammer or drift pin to install the wrist pin. If hand force cannot
install the wrist pin, investigate the cause of the problem.
Install the piston pin retaining pin so that the open ends of the snap
ring are oriented as shown in the diagram. The radial distance
between the piston centerline and the open ends of the snap ring
should be equal on both sides. The snap ring may be moved into
proper position after installation by carefully acting on the snap ring
with a suitable awl at point(A).
CONNECTING ROD- PISTON ASSEMBLY BALANCE
Weigh the connecting rod / piston assemblies to be installed with a
given engine. The maximum allowable weight difference between the
lightest and heaviest assembly is 10 grams.
If the 10 gram differential in weight cannot be achieved, exchange
pistons and/ or connecting rods until the maximum differential is 10
grams or less.
PISTON / CONNECTING ROD INSTALLATION
With reference to the cylinder bore and preparation specifications on
page 38 and the information presented prior regarding pistons,
piston rings and connecting rods, install the piston / connecting rod
assembly.
Rotate the engine so that the respective cylinder for piston/
connecting rod installation is at BDC. Clean the crankshaft rod
journal. Coat the rod journal with clean engine oil. Remove the
connecting rod cap. Install the upper and lower connecting rod
bearings (see page 41). Liberally coat the connecting rod bearings,
cylinder, piston and piston rings with clean engine oil. Rotate the
piston rings to insure that no ring end gap is located on the thrust
side of the piston (90° ± 10° from the wrist pin axis) and that all ring
end gaps are spaced approximately 120° relative to each other.
Compress the piston rings with a suitable tool as shown. Orient the
piston so that the turbulence chamber(A) in the top of the piston will
correspond to the pre-combustion chamber in the cylinder head.
Gently lower the piston / connecting rod assembly into the cylinder
taking extreme care not to cock the piston in the bore and preventing
the connecting rod from contacting the crankshaft. Gently tap the
center of the piston with the wooden end of a light hammer while
guiding the connecting rod over the crankshaft journal.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
51
II
DISASSEMBLY/REASSEMBLY
CONNECTING BEARING / ROD CAP INSTALLATION
Install the connecting rod bearing inserts into the connecting rod and
connecting rod cap. Make sure that the back of the bearing insert and
the connecting rod and connecting rod cap bore is free of dirt, rust,
oil etc. Insert the bearing inserts so that the tab on the bearing aligns
with the slot in the connecting rod or connecting rod cap. Push the
bearing completely into the connecting rod and connecting rod cap.
Liberally oil the bearings with clean engine oil. Install the connecting
rod cap onto the connecting rod making sure that the respective
tang/slot locks on the connecting rod cap aligns with the tang/ slot
lock on the connecting rod.
Torque the connecting rod bolts to 40 Nm in 5 Nm steps.
PISTON PROTRUSION
Rotate each cylinder to exact TDC. TDC may be determined by the
use of a dial indicator mounted to the cylinder deck and indicating
piston height as a function of crankshaft rotation.
After TDC is established, measure the protrusion of the piston (A)
from the cylinder deck plane using a calibrated depth micrometer.
The height should be measured on a line corresponding to the wrist
pin axis as shown. Record the protrusion. Repeat the TDC
establishment and piston protrusion procedure for each cylinder,
recording the value for each cylinder. The HIGHEST protrusion
measured will be used to establish the proper head gasket selection
as presented below.
HEAD GASKET SELECTION/ INSTALLATION
Three(3) separate head gasket thickness’ are available for FOCS
engines depending on the measured piston protrusion as measured
above. The head gaskets are identified by notches cut in the edge
located at point (B) as detailed below. Head gaskets are provided
with “0 notch”, “1 notch” or “2 notches” to
For 502,602,903,1204,1204/T
A (mm)
(PISTON PROTRUSION)
Head Clearance (mm)
0.97/1.06
1.07/1.16
1.17/1.25
Match the piston protrusion dimension determined
above with dimension(A) from the chart. Install the
corresponding head gasket. If a head gasket cannot
be chosen based upon the piston protrusion
measured, check the connecting rod length, rod
bearings, wrist pin bushing, etc. for the cause of the
problem.
Completely clean the deck surface of oil, old gasket
material, varnish, coolant, etc. Remove all traces of
fluid from the cylinder head bolt bores. Install the
head gasket so that the gasket aligns with the deck
dowels and the brand name or “TOP” printed on the
gasket faces up.
No. of hole
Piston to Cylinder
0
0.39/0.48
1
0.40/0.48
2
For 702,1003
A (mm)
(PISTON PROTRUSION)
Head Clearance (mm)
No. of hole
0.82/0.91
0
0.92/1.01
1
Piston to Cylinder
0.54/0.63
1.02/1.10
0.55/0.63
2
For 1404
A (mm)
(PISTON PROTRUSION)
Head Clearance (mm)
No. of Notches
0.82/0.91
1
0.92/1.01
2
Piston to Cylinder
0.52/0.61
1.02/1.10
0.53/0.61
3
assist in the identification of the different gaskets.
52
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
CYLINDER HEAD INSTALLATION
FOCS cylinder head bolts are tightened/ torqued using a constant
tension method as opposed to the traditional simple torque method.
In short, the bolts are pre-loaded, then rotated in two(2) steps to
ensure all bolts are tensioned exactly the same. The additional
rotation after the initial pre-load stretches the bolts.
PREPARATION: Clean the cylinder deck thread holes of all liquid,
gasket material, rust, etc. Clean the cylinder head sealing surface of
all gasket material, deposits, etc. Clean the head bolt threads.
Measure the length of the head bolts. The nominal length (new) is
89.5 / 90.5mm. Each time the bolts are tightened, the bolt stretches
slightly. DO NOT USE HEAD BOLTS WITH MEASURED LENGTHS
OF 92mm OR GREATER. In general terms, head bolts may be
tightened three(3) times before replacement. Liberally oil the cylinder
head bolt thread, bolt head thrust area and washer. Install the head
gasket according to the instructions on page 41. Gently place the
cylinder head on the crankcase aligning the index dowels. Fit a
suitably sized torque wrench with a dividing head as shown.
CYLINDER HEAD TIGHTENING PROCEDURE- LDW 502, 602,
702, 903 and 1003:
FIGURE A = LDW 502, LDW 602, LDW 702
FIGURE B = LDW 903, LDW 1003
STEP 1: Torque the head bolts to 50 Nm in 10 Nm steps in the order
shown.
STEP 2: Rotate each head bolt, in the order shown, 90° (clockwise)
STEP 3: Rotate each head bolt, in the order shown, 90° (clockwise)
NOTE: NO POST OPERATION RE-TORQUE OF THE CYLINDER
HEAD IS REQUIRED OR RECOMMENDED.
CYLINDER HEAD TIGHTENING PROCEDURE- LDW 1204, LDW
1404, LDW 1204/T
STEP 1: Torque the head bolts to 50 Nm in 10 Nm steps in the order
shown.
STEP 2: Rotate each head bolt, in the order shown, 90° (clockwise)
STEP 3: Rotate each head bolt, in the order shown, 90° (clockwise)
NOTE: NO POST OPERATION RE-TORQUE OF THE CYLINDER
HEAD IS REQUIRED OR RECOMMENDED.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
53
II
DISASSEMBLY/REASSEMBLY
MAIN BEARING CAPS / BEARINGS- CENTER
The center main caps are referenced on the actual cap and on the
crankcase as shown to allow replacement of the caps in the identical
position of removal. The reference number locations are shown in the
figure at the left. Always reposition main caps in the original position.
NOTE: If main bearings are intended to be re-used following
disassembly, mark the bearing position using a permanent marker.
INSPECTION / CLEANING: Clean the main bearing caps in solvent
and dry with compressed air. Remove all dirt, oil and deposits from
the bearing seats. Check/ clean all oil passages and remove any and
all impurities. Flush the oil passages with clean solvent before
assembling the crankshaft. Inspect the main bearing caps and
crankcase for cracks, signs of overheating, nicks, etc. Inspect the
main bearings for wear and signs of oil starvation, pitting, scoring,
etc. Thoroughly scrub, but do not damage the non-bearing surface
(back side) of the main bearings if re-use is intended. Replace the
main bearings if any doubt exists.
BEARING INSTALLATION / TORQUE SPECIFICATION. Install the
main bearings (upper and lower) into the respective bearing seats/
caps aligning the “tang” on the bearing with the “slot” in the seat or
cap. Liberally oil the bearing surface with clean engine oil. Install the
main bearing caps with reference to original position (see above).
Torque the main bearing caps to 60 Nm in 10 Nm steps.
FRONT / REAR MAIN BEARING CAPS / BEARINGS
The front and rear main bearings of the FOCS engine are designed
with lateral seals (2) installed between the sides of the main bearing
cap and the crankcase saddle. The lateral seals MUST be replaced
each time the main bearing caps are removed. Thoroughly clean the
main bearing cap and crankcase as described above. Install and
lubricate the main bearings as described above. Install the thrust
bearings (rear main only) as described on page 43. Install the lateral
seals onto the main bearing cap(1). Liberally lubricate the exterior of
the seals. Place the special shims (part no. 1460-053) as shown in
the figure between the crankcase and the main bearing. Push the
main bearing into place. Remove the shims (part no. 1460-053).
Torque the front and rear main bearing caps to 60 Nm in 10 Nm
steps. Following installation, the lateral seal must extended 0.51.0mm past the crankcase planes(A) at the front and rear face of the
crankcase and 0.5-1.0mm past the oil pan plane(B) to allow
complete sealing. Trim material in excess of 1.00mm with a razor
knife. NOTE: Prior to installation of the rear seal support, oil pump or
the oil pan, apply a small amount of RTV Silicone to the lateral seal
extended area.
MAIN BEARING CLEARANCE
Ideally, main bearing clearance is determined following actual
measurement of the main bearing journals and the main bearing
diameters. “PLASTIGAGE” however, can provide a quick and
reasonably accurate determination of main bearing clearance.
Review and understand the instructions provided with the
“PLASTIGAGE” kit. Invert (if possible) the engine so that the
crankshaft weight is directed away from the main bearing cap.
Remove the main bearing cap in question. Clean all oil from the
main bearing and crankshaft using a spray solvent. Place a small
strip of PLASTIGAGE across the main bearing as shown at (A).
Install and torque the main bearing to 60 Nm. DO NOT ROTATE
THE ENGINE!. Remove the main bearing cap and compare the width
of the compressed PLASTIGAGE strip to the “KEY” provided with the
PLASTIGAGE (as shown) to determine the bearing clearance.
PISTON COOLING JETS- LDW 1204/T: The LDW 1204/T engine is
equipped with cooling jets which spray engine oil on the underside of
the piston providing additional engine cooling. The cooling jets attach
to the crankcase directly adjacent to the lower cylinder.
COMPONENTS:
SPECIFICATIONS:
1 Washer
A = 0.80 / 0.85mm
2 Nozzle
B = 34mm
3 Washer
C = 150mm
4 Banjo Bolt
D = 16mm
5 Check Ball
a = 5°
6 Spring
INSPECTION / CLEANING / INSTALLATION: Inspect the spray jets
for damage and clogging. Using new washers(1),(3), affix the
nozzle(2) to the crankcase with bolt(4). Slowly rotate the engine to
BDC (each cylinder). Adjust the position of the nozzle(2) so that no
contact is made with the piston at BDC and the nozzle is pointed at
the center of the piston bottom. Torque the bolt (4)
54
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
THRUST BEARINGS
Thrust bearings on the FOCS engine are supported by the rear main
bearing cap and the crankcase. The thrust bearing assembly consists
of four(4) separate thrust bearing segments. Two(2) of the segments
are supported by the crankcase and the remaining two(2) are
supported by the rear main bearing cap. All four(4) of the thrust
bearing segments act upon the crankshaft thrust surfaces.
INSPECTION: Thoroughly clean the rear main bearing cap thrust
bearing socket and the crankcase side thrust bearing socket. Inspect
the thrust bearings for indications of high wear, scuffing, scratches
and general condition. Inspect the crankshaft thrust surfaces for
galling, scratches, pitting, etc..
INSTALLATION: Liberally coat the crankcase side thrust bearings
with clean engine oil and install by “rolling” the segments between
the crankcase thrust bearing socket and the crankshaft thrust
surface. The bearings must be installed so that the bearing surface,
as indicated by oil grooves(A) is oriented toward the crankshaft thrust
surface. The main bearing cap thrust bearings are simply placed on
the thrust bearing reliefs and indexed with location “ears” as shown in
the diagram. The thrust bearings must be oriented so that the oil
grooves(A) face the crankshaft thrust surfaces. Liberally coat the
thrust bearings with clean engine oil, then install the rear main
bearing following the instructions presented on page 43. NOTE: The
upper thrust bearings (crankcase side) do not include the locator
“ears” for purposes of locational index.
CRANKSHAFT END PLAY
After installing all main bearings and the thrust bearings, the
crankshaft end play may be measured.
1. Push the crankshaft toward the crankshaft pulley end of the
engine.
2. Using a feeler gage, measure the clearance between the thrust
bearing wear surface and the crankshaft thrust surface.
SPECIFICATIONS:
A = 0.130 / 0.313mm (Wear Limit = 0.5mm)
B = 23.05 / 23.10mm (Wear Limit = 23.50mm)
If the crankshaft end play exceeds the specifications above, fit the
engine with oversize thrust bearing segments and/or grind the
crankshaft thrust surfaces. The following provides guidelines for the
application of oversize bearings and for grinding the crankshaft thrust
surfaces.
THRUST SURFACE SPECIFICATIONS- CRANKSHAFT END PLAY
CORRECTIONS
Depending on the condition/ width of the crankshaft thrust
surfaces(B)(above figure) and the width(C) of of the main bearing
cap thrust bearing socket/ thrust bearing width combination,
crankshaft end play can be corrected in several ways. Std, 0.1mm
oversized and 0.2mm oversized thrust bearings can be fitted on
side(1), side(2) or both. The following table provides details of the
combinations of thrust bearing width, thrust surface width(main
bearing cap / crankcase) and crankshaft thrust surface width.
TABLE KEY:
A = Crankshaft End Play (resultant)
B = Width of crankshaft thrust surface
THRUST BEARING
COMBINATION
Standard
0.1mm (both sides)
0.1mm (one side)
0.2mm (one side)
0.2mm (both sides)
COMPILER TECO/ATL
REG. CODE
MODEL N°
C (mm)
B (mm)
A (mm)
22.787÷22.920
22.987÷23.120
23.050÷23.100
23.250÷23.300
0.130÷0.313
0.130÷0.313
23.087÷23.220
23.187÷23.320
23.350÷23.400
23.450÷23.500
0.130÷0.313
0.130÷0.313
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
55
II
DISASSEMBLY/REASSEMBLY
CRANKSHAFT SEALS - FRONT and REAR
The front seal for the FOCS diesel engine is housed within the oil
pump assembly. The rear oil seal is supported by the rear oil seal
support. Lombardini recommends that oil seals be replaced if
removed from the supporting bores. The oil seals should also be
replaced if upon inspection, signs of hardening, stress cracks,
dampness on the exterior or dry rot is noted.
Front Crankshaft Seal
Rear Crankshaft Seal
SEAL DETAILS:
A Seal Support
B Seal
1 Installation depth plane (initial), front
2 Installation depth plane (initial), rear
3 Crankshaft wear surface- front
4 Crankshaft wear surface- rear
INSTALLATION: Remove the oil pump or seal support depending
upon front or rear seal replacement. Gently, without deforming the
seal supporting bore, pry the seal from the bore. Carefully clean, in a
non abrasive manner, the wear surface of the crankshaft. Soak the
oil seal in clean engine oil for approximately 1/2 hour. Coat the
crankshaft with clean engine oil. Using a suitable mandrel, evenly
and squarely push the seal into the bore until the outer seal plane
coincides with planes (1) or (2). Reinstall the oil pump or seal
support using new gaskets as required. Torque the rear seal support
retaining bolts to 12 Nm. Torque the oil pump retaining bolts to 25
Nm.
NOTE: If the wear surface of the crankshaft showed signs of
grooving at the initial installation depth reference (1) or (2), push the
seal into the bore an additional 2mm using a suitable mandrel.
CRANKSHAFT LUBRICATION DRILLINGS- TYPICAL
The lubrication drillings for the LDW 502(A) and LDW 602-702(B)
are shown in the diagram. The lubrication drillings for the LDW 903,
LDW 1204 and LDW 1204T are very similar to the LDW 602-702.
CLEANING: Remove plugs at (1) and (4) by suitable means. Soak
the crankshaft in solvent to loosen any deposits within the drillings.
Clean the drillings (1), (2), (3), and (4) by blowing with compressed
air, using stem brushes, etc.. Cap the drillings at (1) and (4) with new
plugs.
CRANKSHAFT JOURNAL INSPECTION / MEASUREMENT
INSPECTION: Inspect each journal (main and rod) for scratches,
scoring, grooves and general wear. Replace the crankshaft or
machine as required. See page 456for dimensional specifications.
MEASUREMENT: With reference to the diagram, measure each
journal with a calibrated micrometer. Each journal should be
measured at 45° intervals around the circumference of each journal
beginning at the position shown on the left most diagram. At each
interval, measure two seperate parts of the given diameter- once
near the center of the journal and once near the fillet of the journal.
56
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
DISASSEMBLY/REASSEMBLY
II
CRANKSHAFT JOURNAL SPECIFICATIONS
For LDW 502,602,903,1204,1204/T
A = Main Journals= 47.984 / 48.000mm (WEAR Limit = 47.900mm)
For LDW 702,1003,1404
A = Main Journals= 50,981 / 51.000mm (WEAR Limit = 50.900mm)
For LDW 502,602,702,903,1003,1204,1204/T,1404
B = Rod Journals = 39.984 / 40.000mm (WEAR Limit = 39.900mm)
NOTE 2: THE CRANKSHAFTS IN THE ALUMINUM AND CAST
IRON
VERSIONS
OF
THE
LDW
502
ARE
NOT
INTERCHANGEABLE.
UNDERSIZED BEARINGS- ROD and MAIN
Undersized connecting rod and main bearings are available in sizes
0.25 and 0.50mm. Use of the undersized bearings will require the
nominal size of the rod/ main journals to be reduced by 0.25 or
0.50mm respectively.
MAIN and CONNECTING ROD BEARINGS
The dimensions shown reflect clean, installed and torqued bearing
inserts.
For LDW 502,602,903,1204,1204/T
C = Main Bearings =47.984 / 48.016mm (WEAR Limit = 48.055mm)
C-A = 0.022 / 0.074mm (WEAR Limit = 0.200mm)
For LDW 702,1003,1404
C = Main Bearings =51,023 / 51,059mm (WEAR Limit = 51,098mm)
C-A = 0.023 / 0.078mm (WEAR Limit = 0.200mm)
For LDW 502,602,702,903,1003,1204,1204/T,1404
D = Rod Bearings =40.021 / 40.050mm (WEAR Limit = 40.100mm)
D-B = 0.021 / 0.066mm (WEAR Limit = 0.130mm)
HYDRAULIC PUMP PTO- (No. 3 PTO)
All FOCS diesel engines may be fitted with a hydraulic pump
drive(A) as shown. The hydraulic drive takes power from the back of
the engine camshaft.
Hydraulic pump adaptations for DIN size 2PD, DIN size 1P and
BOSCH pumps are available.
DRIVE SPECIFICATIONS:
Speed Ratio: 1 : 2, or 1/2 engine speed.
Maximum Torque = 37 Nm, irrespective of engine speed.
NOTE: 37 Nm @ 3600 r/min corresponds to 7 kW.
HYDRAULIC DRIVE COMPONENTS- No. 3 PTO
1
2
3
4
5
Splined Drive- (Bolts to Camshaft)
Pump Drive Gear (Attaches to Pump Input Shaft)
O-Ring
Pump Support (Bolts to Cylinder Head)
O-Ring
The splined drive(1) also includes the eccentric for the fuel lift pump.
The splined drive must be bolted to the camshaft end and torqued to
80 Nm. The pump drive gear(2) must be torqued to the hydraulic
pump input shaft. Check with the pump manufacturer for torque
specifications at the input shaft.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
57
III
TURBOCHARGER
TURBOCHARGER IDENTIFICATION
Only the LDW 1204/T is supplied with a turbocharger. The LDW
1204/T is available in two(2) versions with respect to no-load speed.
A version operating up to 3000 rpm and a version operating up to
3600 rpm is offered. The two(2) engine versions are fitted with
different turbocharger models with respect to the engine speed. The
turbocharger can be identified by the manufacturing ID numbers on
the data plate of the turbocharger.
TD 025 03C 2.8TD 025 03C 2.0-
3600r/min
3000r/min
TURBOCHARGER COMPONENTS
1 Waste gate tube
10 Turbine wheel
19 O-ring
2 Waste gate actuator 11 Ring-oil
20 Thrust bearing
3 Band clamp
12 Fire ring
21 Thrust ring
4 Turbine housing
13 Bearing
22 Bearing
5 Ring
14 Band clamp
23 Ring
6 Compressor scroll
15 Shim
24 Ring
7 Shim
16 Ring-oil
25 Bearing support
8 Nut
17 Oil shield
9 Lock nut
18 Thrust bearing
TURBOCHARGER PRESSURE TESTING
Install a 0-2bar pressure gauge at position(A) after removing the
existing plug.
Start the engine and operate at low idle for five(5) minutes to allow
warm-up. Increase the engine speed to 3000 r/min or 3600 r/min
(depending on engine specification while applying full Nb load to the
engine). See page 10 for the power output curve.
The gauge pressure, at full speed, full load, should be 0.87-0.91 bar.
If the pressure setting does not reach specification, adjust the
turbocharger waste gate as is defined on page 48.
58
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
TURBOCHARGER
III
TURBOCHARGER WASTE GATE ADJUSTMENT- BENCH
METHOD
The adjustment of the turbocharger wastegate is a critical
adjustment that should be carried out with the utmost care.
Prepare the following group of tools/ materials.
1
2
3
4
Calibrated, liquid filled pressure gauge with a mid-range
scale of 1.2 bar.
Dial indicator with suitable magnetic base.
Regulated compressed air supply.
Suitable “TEE” fitting for gauge.
PROCEDURE:
1 Disconnect wastegate tube (7) from the turbocharger
compressor side.
2 Drill a 1.5 mm hole (B) in the gauge side of the “TEE”
fitting. The relief hole will be required to allow stable
pressure readings.
3 Sub-assemble the gauge onto the “TEE” fitting.
4 Using a suitable barb fitting, connect the gauge subassembly to the tube (7).
5 Fit the remaining open port of the “TEE” with a suitable
regulated compressed air supply.
6 Set-up a magnetic based dial indicator so as to accurately
measure the horizontal travel of actuation rod (8). The dial
indicator should act upon rod end (2). Zero the dial
indicator.
7 Slowly charge the tube(7) with air by gradually increasing
air pressure from the regulated air supply(5). Continue to
allow air flow until the dial indicator shows a total and
accurate rod(8) movement of 1.00mm.
8 Note the gauge(4) pressure when the rod movement is
1.00mm(A).
9 The gauge pressure should be 1.11-1.19 bar.
10 If the proper gauge reading is not observed, remove
pin(9), loosen nut(1), and adjust the rod end(2) position
until the proper pressure reading is observed. Repeat the
above procedure as required.
NOTE: When reassemblting the rod end(2) onto the waste
gate, take care not to position rod end (2) so as to impede free
motion. DO NOT LOAD THE WASTEGATE LEVER.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
59
IV
LUBRICATION SYSTEM
The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because its
combustion may lead to a sharp increase in the rotation speed.
Use suitable oil in order to protect the engine.
Nothing more than lubrication oil can influence the performances and life of an engine.
Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, will cause the piston
rings to jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine life will also
be notably reduced.
The oil viscosity must suit the ambient temperature in which the engine operates.
Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with
the oil is unavoidable, you are advised to wash your hands with soap and water as soon as possible.
Dispose of old oil in the correct way as it is highly polluting.
1
2
3
4
5
Oil pressure Switch
Rocker Arm Shaft
Connecting Rod Journal
Oil Filter
Main Bearing Journal
6
7
8
9
10
Oil Drain Plug
Oil Dipstick
Crankcase Breather
Oil Fill Cap
Camshaft
11
12
13
14
15
Oil Pressure Relief Valve
Oil pump
Crankshaft
Oil Pick-up Screen
Turbocharger
NOTE : Only the LDW 1204/T is equipped with a turbocharger (item 15) and turbocharger lubrication circuit.
60
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
LUBRICATION SYSTEM
IV
OIL PICK-UP SCREEN AND OIL DRAIN BACK TUBE
After oil pan removal, remove the oil drain back tube(2) from the
engine crankcase. Clean both the oil pan and drain back tube in
solvent. Dry the oil pan and oil drain back tube with compressed air.
Inspection: Inspect the oil pick-up tube for dents, holes, corrosion
and cracks. The oil pick-up screen must be free of obstructions.
Inspect the oil pick-up tube O-ring seat for any damage or dents.
Replace as required. Inspect the oil drain back tube for crimps, dents
and cracks. Inspect the oil drain back tube O-ring seat for any
damage. Replace as required.
Installation: Always replace O-rings (3) and (4) and oil pan gasket
(5).
NOTE: The oil pan gasket may be replaced by Dow Cornkn 7091.
See pag 40
OIL PUMP SPECIFICATION:
Oil pump delivery (average figures) at 1000 r/min and oil temperature
of 120°C
ENGINE MODEL
DELIVERY (I/min)
Pressure (Bar)
LDW 502,602,702,903,1003
4.0-4.3
3.0-3.5
LDW 1204,1204/T,1404
6.0-6.5
3.0-4.5
Oil pump delivery (average figures) at 3600 r/min and oil temperature
of 120°C
ENGINE MODEL
DELIVERY (Ilmin)
Pressure (Bar)
LDW 502,602,702,903,1003
19.3
4.0-4.5
LDW 1204,1204/T,1404
28.5
4.0-4.5
OIL PUMIP ROTOR INSPECTION
NOTE: Seee page 28, «OIL PUMP ASSEMBLY» for additional
comments.
The oli pump rotor set should be replaced as part of the oil pump
assembly. The condition of the oil pump can be ascertained by
carefully disassembling the oil pump noting the thrust surface
position of the rotor sets. The rotor set should be refitted in the
original position. Remove the oil pressure relief valve (see below).
Carefully clean the oil pump rotor and oil pump body in clean solvent.
Dry the components with compressed air.DO NOT DRY OR WIPE
THE OIL PUMP COMPONENTS WITH A RAG. Coat the rotor the
assembly and oil pump body with clean engine oil. Reassembly the
rotor assembly as exp'lained above. Using a tapered feeler guage,
gently determine the the rotor tip cIearance. DO NOT FORCE THE
MEASUREMENT.
MAXIMUM CLEARANCE = 0.174 mm
OIL PRESSURE RELIEF VALVE
Components:
1
Plunger Valve
2
Spring
3
Gasket
4
Plug
Inspect the plunger (1) for scoring or galling. Replace the oil pump
assembly if any damage is noted. Measure the lenght of the pressure
relief spring. The spring lenght tolerance is 27.50 - 27.75 mm.
By-pass pressure setting (opening threshold)= 4.5 - 5.5 Bar.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
61
IV
LUBRICATION SYSTEM
OIL FILTER
Components:
1 GASKET
2 HEAD PLATE
3 GASKET
4 SPRING
5 FILTRATION MEDIA
6 BYPASS VALVE
7 SPRING-BYPASS
Oil filter Specifications : Max. operating pressure :7 Bar
Max. rupture pressure : 20 Bar
Filtration level : 20µm
By-pass valve setting: 1,5 - 1,7 Bar
Total filter area (502,602,903): 730 cm²
Total filter area (1204): 1450 cm²
NOTE: Always use genuine Lombardini replacement oil filters. Apply
a coating of clean engine oil to the oil filter gasket before installation.
Hand tighten the oil filter onto the engine.
OIL PRESSURE TESTING
Remove the standard oil pressure switch from the engine valve
cover. Replace the oil pressure switch with a calibrated oil pressure
gauge arrangement as shown.
The following describes the proper procedure to measure engine oil
pressure.
1 Check and top off all engine fluid levels.
2 Start the engine and allow a five (5) minute warm-up period at low
idle.
3 Increase the engine speed to high idle.
4 Allow the engine to reach operating temperature
5 Record the oil pressure at high idle and at low idle only after the
engine is at operating temperature.
NOTE: The minimum allowable oil pressure is 1.1 Bar at an oil
temperature of 120° C and operating at 900 r/min.
62
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
COOLING SYSTEM
V
The cooling circuit contains fluid under pressure. Do not carry out any inspections until the engine has cooled and even
then, open the plug of the radiator or expansion chamber with caution.
Keep well away from a hot engine if an electric fan is installed since this could start up even when the engine is at a
standstill.
Coolant fluid is polluting. It must therefore be disposed of correctly. Do not litter.
LDW- FOCS COOLING SYSTEM SCHEMATIC
1 Pressure cap
6
Coolant Pump
2 Expansion Tank
7
Cooling Fan
3 Thermostat
8
Radiator (Heat Exchanger)
4 Cylinder Block Coolant Jacket
9
Oil Cooler
5 High Temperature Switch
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
63
V
COOLING SYSTEM
COOLING SYSTEM PRESSURE CHECK / RADIATOR CAP
INSPECTION
Pressure checking the cooling system is the only reliable method of
determining the source of coolant leaks and the condition of the
radiator, hoses and coolant pump seals. The radiator cap controls
operating cooling system pressure and thus must be inspected
regularly. The illustration shown depicts a cross flow type radiator
with a remote expansion tank. The proceedures / inspection criterion
below is applicable to both cross flow and top tank radiators.
Radiator Cap: Inspect the vacuum valve (1) and the relief valve (2).
Fit the radiator cap onto a suitable radiator cap testing fixture.
Pressurize to 0.7 bar to insure the radiator cap holds rated pressure.
Replace the cap if 0.7 bar cannot be reached before pressure relief.
Replace the radiator cap if any degradation is seen on the vacuum
valve seal or the pressure relief seal or if the cap is bent, deformed or
damaged.
Radiator Seat: The sealing ability of the radiator cap is a function of
the radiator or expansion tank seat. Inspect the radiator cap seat and
replace/ repair as needed.
Cooling System Pressure Test: Fill the cooling system completely
with a 50/50% solution- water/ ethylene glycol. Fit a cooling system
pressurizing device to the cooling system fill port. Pressurize the
cooling system to 0.7 bar. The pressure should hold steady. If the
pressure does not hold steady at 0.7 bar, a malfunction in the
pressure device exists or a leak in the cooling system exists. Inspect
the cooling system for signs of liquid at all joints, hoses and at the
coolant pump. Tighten, repair or replace as required.
NOTE: Lombardini recommends a radiator cap pressure relief setting
of 0.7 bar. Do not operate the engine with a pressure cap of higher or
lower setting installed.
COOLANT PUMP DETAILS
The design of all LDW-FOCS coolant pumps is similiar. However, the
impeller(1) size and seal assembly (2) are larger for the LDW 1204
,LDW 1204/T and 1404, allowing for greater coolant flow.
Components:
1
2
3
4
5
6
7
Impeller
Seal assembly
Pump body
Weep hole
Bearing
Pulley
Shaft
THERMOSTAT
Removal: Drain the engine coolant in a suitable container. Remove
the two(2) capcrews retaining the coolant outlet to the thermostat
housing. Remove the thermostat from the thermostat housing.
Inspection: Inspect the the thermostat for deposits, corrosion and
deformation. Clean or replace as required.
Components:
1 Thermostat body- stainless steel, brass or thermoplastic.
2 Expansion bulb
3 Bleed vent
NOTE: Metalic thermostats require a O-ring gasket- replace as
required.
64
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
FUEL SYSTEM
VI
FUEL SYSTEM SCHEMATIC
1
2
3
4
5
6
7
8
9
10
Fuel Tank
Fuel Filter
Supply Hose
Fuel Pump
Injector
Injection Pump
Fuel Rail Grommet
Return Hose
Fuel Tank Fill Cap (Vented)
Fuel Shut-off Valve (Electric)
FUEL FILTER ASSEMBLY
1
2
3
4
5
Air Bleed Plug
Filter Head(Base)
Spin-on Fuel Filter
Gasket
Filter Media
Fuel Filter Specifications:
Media Type
Filtration Area
Filtration Level
Max. Pressure
PF 905
2400 cm3
2-3µm
4 bar
FUEL TRANSFER PUMP
Components:
1
2
3
Fuel Transfer Pump Assembly
Push Rod
Sealing O-Ring
The fuel transfer pump is a diaphragm type pump actuated by the
camshaft driven push rod. Manual fuel system bleeding is facilitated
by operating the pumping bail lever.
Performance: At an engine speed of 3000 r/min, the fuel transfer
pump delivers 60 l/h at a self-regulated pressure of 4.5 / 5.5 m H2O.
FUEL TRANSFER PUMP PUSH ROD PROTRUSION
With the engine rotated to position the camshaft eccentric (1) as
shown, resulting in the lowest possible push rod (2) position with
respect to the cylinder head plain, dimension ‘A’ should be 0.961.48mm.
If the proper clearance cannot be attained, measure the push rod (2)
length. The push rod (2) should be 152.45-152.65mm in length.
Replace the push rod as required. No other adjustments can be
made to change fuel pump push rod protrusion.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
65
VI
FUEL SYSTEM
LOMBARDINI CONTINUALLY DEVELOPS THE FOCS DIESEL LINE. CONSTANT RESEARCH AND DEVELOPMENT IS CARRIED OUT TO
IMPROVE OVERALL PERFORMANCE OF FOCS PRODUCTS. AS SUCH, THE DESIGN OF THE FOCS UNIT INJECTOR HAS CHANGED
DURING THE DEVELOPMENT PROCESS. THE FIGURE ABOVE PROVIDES A REFERENCE FOR THE THREE(3) DIFFERENT VERSIONS
OF THE FOCS UNIT INJECTOR TO DATE.
EARLY UNIT INJECTORS ARE CHARACTERIZED BY THE HIGH PRESSURE PORT AS SHOWN.
INTERMEDIATE UNIT INJECTORS ARE CHARACTERIZED BY THE LACK OF A DRILLED HIGH PRESSURE PORT (HIGH PRESSURE
PLUG MAY BE PRESENT, BUT IS NOT FUNCTIONAL) AND THE ADDITIONAL INDEX PIN AS SHOWN.
CURRENT UNIT INJECTORS ARE CHARACTERIZED BY OFFSET FUEL PORTS, NO HIGH PRESSURE PORT AND RELATIVELY LARGER
PORT SIZES.
THE FOLLOWING CHART MAY BE USED AS A GENERAL REFERENCE FOR UNIT INJECTOR IDENTIFICATION, SPECIAL TOOL
REQUIREMENTS AND CRITICAL ADJUSTMENT SPECIFICATIONS. WHEN SERVICING FOCS UNIT INJECTORS, ALWAYS REFERENCE
THE ENGINE MODEL, ENGINE SERIAL NUMBER, APPLICATION AND UNIT INJECTOR REFERENCE NUMBER.
REFERENCE
NUMBER
PART
NUMBER
APPLICATION
231-2
6590.262
502, 602, 903, 1204
272-0
6590.283
235-2
6590.235
272
6590.272
502, 602, 903, 1204
272-1
6590.285
502, 602, 903, 1204
272272+
235-4
235-3
235-4
6590.286
6590.307
6590.290
6590.287
6590.290
66
COMPILER TECO/ATI
STATIC TIMING
METHOD
SPECIAL TOOLS
FOR TDC, TIMING AND
PRESSURE TESTING
11-13
HIGH PRESSURE
502 MINI CAR
11-13
HIGH PRESSURE
1204/T
4-6
HIGH PRESSURE
8-10
LOW PRESSURE
TIMING- 1460.028 + 1460.024
PRESSURE- 1460.028
TDC- 1460.048
TIMING- 1460.028 + 1460.024
PRESSURE- 1460.028
TDC- 1460.048
TIMING- 1460.028 + 1460.024
PRESSURE- 1460.028
TDC- 1460.048
TIMING/PRESSURE-1460.056
1460.028 / TDC -1460.048
TIMING/PRESSURE-1460.074
TDC- 1460.048
TIMING/PRESSURE-1460.074
TDC- 1460.048
TIMING/PRESSURE-1460.074
TDC- 1460.048
TIMING/PRESSURE-1460.074
TDC- 1460.048
502 MINI CAR
STATIC TIMING
(°BTDC)
8-10 > 2999 rpm
12-14 < 3000 rpm
11-13
1204/T
702, 1003, 1404
LOW PRESSURE
LOW PRESSURE
6-8
LOW PRESSURE
8-10
LOW PRESSURE
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
FUEL SYSTEM
VI
FUEL SYSTEM SPECIAL TOOLS
UNION- 1460.028
FUNCTION: Allows high pressure testing of unit injectors. Use for
both static timing and pressure testing of early unit injectors. The
1460.028 union screws directly into the unit injector after removal of
the high pressure plug.
Application: 6590.262, 6590.283, 6590.235 unit injectors.
TIMING TOOL- 1460.024
FUNCTION: Allows high pressure static timing of early unit injectors.
Use with the 1460.028 union.
Application: 6590.262, 6590.283, 6590.235 unit injectors.
LOW PRESSURE TEST SET
Includes adapter block, union, plug, drip tube, eccentric washers and
fill tube for low pressure static timing and allows pressure testing for
intermediate and current unit injectors.
PART No. 1460.056- Only for 6590.272 unit injectors
PART No. 1460.074-Use with 6590.285, 6590.286, 6590.287 and
6590.290 Unit Injectors.
TDC DETERMINATION / TIMING FIXTURE- 1460.048
FUNCTION: Determination of exact TDC for purposes of static
injection timing. After exact TDC is found, the static injection point
may be determined as a function of piston position as measured by
the TDC fixture. Refer to the following pages for more detail.
EQUALIZATION TOOL
FUNCTION: Allows each individual cylinder fuel consumption to be
measured. Thus, the individual delivery rates can be adjusted to
insure equivalent fuel delivery to all cylinders. The equalization tool
set includes fuel rail blocks to allow attachment to the unit injectors.
Three(3) different equalization tools have been issued reflective of
improvements in the tool and changes to the unit injectors. Aside
from the fuel rail blocks included with the equalization tool, the
equalization tool will work on all unit injector types. Fuel rail blocks
as detailed below can be ordered to allow complete interchangability
with all unit injector styles.
Equalization Part No.’s: 1460.020(early),1460.050(intermediate) and
1460.090 (current).
Fuel Block Part No.’s: 1460.081 (early / intermediate) with in-line fuel
ports. 1460.089 (current) with offset fuel ports.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
67
VI
FUEL SYSTEM
UNIT INJECTOR: The unit injectors fitted within Lombardini FOCS
diesel engines are designed by Lombardini. One unit injector is
required for each cylinder.
In the continuing development of the
FOCS diesel engine, design changes have been made to the unit
Injector resulting in less that total interchangability between older and
newer FOCS engines. Please refer to the previous pages for details
regarding the identification, special tool requirement, testing method
and application of unit injectors. Always use the utmost cleanliness
and care when servicing fuel injection equipment.
UNIT INJECTOR COMPONENTS
1 Circlip
12 Delivery Valve
2 Tappet
13 Shim/ Gasket
A Cup
B O-Ring
3 Retainer
14 Spring
C Nozzle
4 Plunger
15 Filler
D Spacer
5 Spring
16 Pin
E Spring Seat
6 Bolt
17 O-Ring
F Spring
7 Support
18 Check Valve
G Shim
8 Rack Lever
19 O-Ring
I Unit Inj. Body
9 Ring Nut
20 Plug
L Helix
10 O-Ring
21 Gasket
M Index
11 Barrel
Note: Cup (A) torque = 70 Nm.
UNIT INJECTOR RING NUT REMOVAL / REPLACEMENT
When disassembling or reassembling the unit injector, follow the
numerical order presented above, then proceed through the
alphabetical order A-I.
After disassembling items one(1) through seven (7) (see above), fit
the injector into a suitable vice with soft jaws. Use special tool (A)
1460-029 to remove the ring nut (9) as shown.
When reassembling the unit injector, torque the ring nut to 34 Nm.
UNIT INJECTOR PLUNGER REASSEMBLY
When reassembling the unit injector, refer to the above exploded
diagram. Assemble in the following order: I-A, then 21-1.
When refitting the plunger, orient the plunger helix (L) to align with
the check valve(18). See also the figure and explanation on the next
page.
68
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
FUEL SYSTEM
VI
UNIT INJECTOR REASSEMBLY (CONT.)
With reference to the previous frame, and the exploded view of the
unit injector on the previous page, continue to introduce the plunger
into the unit injector, while gently rotating rack lever (8) back and
forth until index (M) can be engaged with the rack lever (8).
NOTE: If the plunger is accidentally installed incorrectly positioned
with respect to the helix location, the engine will not operate.
BARREL AND PLUNGER DETAIL- EARLY UNIT INJECTORS
(TYPICAL)
Component
Details
Dimensional
Details
1 Plunger
2 Plunger End View
3 Barrel
4 Retardation Notch
5 Helix
A = 5.5 mm (nominal)
B = 2.00/2.03 mm (Inlet Port)
C = 1.50/1.53 mm (Bypass)
D = 10.00 mm
E = 9.6 mm
F = 0.7 mm
BARREL AND PLUNGER DETAIL- (TYPICAL) CURRENT UNIT
INJECTORS (EXAMPLE- 6590-285)
Component
Details
Dimensional
Details
1 Plunger
2 Plunger End View
3 Barrel
4 Retardation Notch
5 Helix
A = 6.0 mm (nominal)
B = 1.50/1.53 mm (Inlet Port)
C = 1.50/1.53 mm (Bypass)
D = 9.965/10.035 mm
E = 9.565/9.635 mm
F = 0.9 mm
For LDW 702,1003,1204/T,1404 CURRENT UNIT INJECTORS
(EXAMPLE- 6590-290)
A = 6.5 mm (nominal)
UNIT INJECTOR TEST STAND SPECIFICATIONS
1
2
COMPILER TECO/ATL
REG. CODE
MODEL N°
Rack lever in stop or no delivery position
Rack lever in maximum delivery position
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
69
VI
FUEL SYSTEM
WARNING: THE TESTING AND SERVICE OF FUEL INJECTION EQUIPMENT SUCH AS DETAILED BELOW INCLUDES
HIGH PRESSURE AND SPRAYING FLUIDS. WEAR PROPER EYE AND HAND PROTECTION. DO NOT ALLOW ANY
PART OF YOUR BODY TO COME INTO CONTACT WITH HIGH PRESSURE FUEL OR TESTING FLUID. FURTHER, HIGH
PRESSURE FUEL IS VERY FLAMMABLE. DO NOT TEST FUEL INJECTION EQUIPMENT NEAR ANY OPEN FLAME,
SPARKS OR LIT CIGARETTES.
UNIT INJECTOR POPPING PRESSURE TESTING AND ADJUSTMENTHIGH PRESSURE PROCEDURE (EARLY UNIT INJECTORS- ALL REF.
NO’s OTHER THAN 272, 272-, 272-1, 235-3)
With reference to the exploded view from page 57, remove the high pressure
plug(20). Fit to the injector, in place of plug(20), union 1460-028. Install the
injector onto a hand pop test machine. Using extreme care and proper eye
and hand protection, cycle the injector several times until all air is out of the
injector. Operate the popping tester taking note of the injection pressure. The
injector should require 130-140 bar before injection. If the pressure is not to
specification, again refer to the exploded view as above. The pressure can be
increased by adding shims(G) or reduced by removing shims(G). Shims are
available ranging from 1 to 2 mm in eleven steps. When servicing the unit
injector, initial pressure settings should be 10 bar higher than specified to
allow for seating during operation.
Injector nozzle leakage may be checked by holding a pressure of 130 bar on
the injector for 10 seconds. The nozzle should be replaced if leakage is
noted.
UNIT INJECTOR POPPING PRESSURE TESTING AND ADJUSTMENTLOW PRESSURE PROCEDURE (CURRENT / INTERMEDIATE UNIT
INJECTORS)
Unit injectors having codes 272, 272-, 272-1, 235-3, 235-4 are not equipped
with a high pressure port drilling as above. With reference to the exploded
view on page 57, pressure checks of the unit injector are facilitated by
removing the check valve(18) , then installing the plug, eccentric gasket and
block (1) which are supplied as components within part no. 1460-074. Fit the
block (1) onto the injector making sure that the rack lever is held in the
maximum deliver position as is shown. Fit the supplied union (2)(part of
1460-074) onto the block. Using extreme care and proper eye and hand
protection, test the injector on a hand popping pressure testing machine as is
detailed above. Pressure settings, nozzle leakage testing and pressure
adjustments are carried out as explained above. The new style injector
should require 140 / 150 bar of pressure before injection. If service is
required to increase the injection pressure, set the injector to 10 bar higher
than nominal to allow for seating.
NOTE: 6590-272 (ref. no. 272) unit injectors will require the block(1) as
supplied within part no. 1460-056.
INJECTOR NOZZLE PROTRUSION
Injector nozzle protrusion (B) should be 6.80 / 7.05 mm
If the injector nozzle protrusion exceeds the above dimension, additional 0.25
mm copper washers(2) may be placed on the injector nozzle, resting against
the cup (1) to supplement the thickness of the standard copper washer(3)
and offset any injector nozzle protrusion problems.
The 0.25 mm supplemental washers are available as special spare parts.
Contact your local distributor for details.
UNIT INJECTOR FIRE RING
The unit injector fire ring should be replaced following unit injector removal.
DO NOT REUSE fire rings.
Clean the fire ring sealing surface in the cylinder head and injection nozzle.
(Do not damage the injector nozzle or pre-cup ring nut.
Orient the fire ring so that plane (A) will face the unit injector nozzle.
Reinstall the injector, tightening the unit injector securing nuts to 20 Nm
alternately and in 5 Nm steps.
70
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
FUEL SYSTEM
STATIC INJECTION
INJECTORS
TEST
INSTRUMENTATION-
VI
EARLY
UNIT
Carefully remove the engine valve cover. With reference to the exploded unit
injector diagram on page 57, remove plug (20). Replace plug(20) with
union(1)- 1460-028.
Install Injection timing tool (2)- 1460-024 onto the 1460-028 union.
NOTE 1: When refitting the plug(20), carefully check the sealing properties
of the plug.
NOTE 2: Later versions of the unit injector are not equipped with the
plug(20). Therefore, static timing adjustments require alternative approaches
than those shown. Please see page 56 for details of the static injection timing
instrumentation for later versions of the FOCS unit injector.
TDC DETERMINATION and STATIC INJECTION TIMING CHECKING
With the static injection timing instrumentation installed as described above,
fit the engine with the timing fixture(1), part no. 1460-048 as shown. The dial
indicator support should be oriented over the engine valve spring cap.
Remove the injection pump rack assembly starting aid spring. Adjust and
secure the injection pump rack at 1/2 stroke.
Rotate the engine until the cylinder being static timed approaches TDC,
compression stroke. Alternately, rotate the crankshaft toward TDC and press
down on the timing fixture lever(2) until minimum dial indicator travel is
established. At minimum dial indicator travel, TDC is established. Zero the
dial indicator at the TDC position.
Insure that a good supply of clean diesel fuel is available to the engine,
preferable from an external fuel tank elevated above the level of the engine.
a
LDW 502
(mm)
13°
12°
11°
10°
9°
8°
7°
6°
5°
4°
1.022
0.871
0.733
0.606
0.491
0.388
0.297
0.218
0.152
0.097
LDW 602, 903,
1204,1204/T
(mm)
1.242
1.059
0.891
0.737
0.597
0.472
0.362
0.266
0.185
0.118
LDW 702
1003,1404
(mm)
1.296
1.105
0.930
0.769
0.623
0.493
0.378
0.277
0.193
0.123
EARLY UNIT INJECTORS (Ref No’s: 231-2, 235-2, 272o)-With reference to
the upper figure, bleed the injection the injection timing tool by bringing the
engine to such as position as the injection pump is being acted upon via the
camshaft. Alternately rotate the engine back and forth until fuel is injected out
of the injection timing tool and free of air.
Rotate the engine in opposite normal direction approximately 90°. Rotate the
engine in normal direction of rotation until a fuel movement is noted in the
static timing sight glass. Stop rotation IMMEDIATELY upon any notice of fuel
movement. Depress the timing fixture lever and note the dial indicator
reading. Check the corresponding dimension listed in the chart to the leftdetermine static injection timing from the chart. Correct, if needed, the
injection timing by turning screw(E)- see next page. Refer to the chart on
page 55 for static timing specifications with respect to the injector reference
number. See the following page for static timing adjustment procedures.
LATE/ INTERMEDIATE UNIT INJECTORS- (6590-272, 6590-285, 6590286, 6590-287, 6590-290) Remove the check valve from all injectors, remove
the check valve side o-ring from all injectors, replace the o-ring with special
eccentric gasket supplied within 1460-074. With reference to the lower
diagram, fit the unit injectors with a special tool block(1), bleed fitting(2),
union(3), supply fitting(4) and nylon bleed tube(5) as supplied within 1460074. Note: 6590-272 unit injectors do not require the eccentric gaskets
as detailed above but do require a special block(1) as supplied under
part no. 1460-056.
Place a small cup beneath the nylon bleed tube, rotate the engine in the
normal direction of rotation until fuel stops flowing from the bleed tube. At the
very instant of fuel flow stoppage, stop rotating the engine. The fuel flow
stoppage indicates the beginning of injection. Depress the timing fixture lever
and note the dial indicator reading. Check the corresponding dimension listed
in the chart to the left- determine static injection timing from the chart.
Correct, if needed, the injection timing by turning screw(E)- see next page.
Refer to page 64 for the static timing specification with respect to the unit
injector reference number. See the following page for static timing adjust
procedures.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
71
VI
FUEL SYSTEM
STATIC TIMING ADJUSTMENT
Should the static timing testing procedures as presented on the
previous page show the need for static timing adjustment, proceed as
follows.
1. Locate timing adjustment screw (E), loosen the locking nut.
2. Rotate the adjustment screw(E) clockwise to advance the static
timing, or rotate the adjustment screw counterclockwise to delay the
static timing.
3. Tighten the timing adjustment screw lock nut.
4. Repeat the static timing test procedure.
NOTE: 1/2 turn equates to approximately a 5° change in static
timing.
ENGINE TIMING REFERENCE MARKS
Although not as accurate as the procedure presented in the previous
section, TDC for FOCS diesel engines may be determined via timing
marks on the timing cover and crankshaft pulley. Further, the timing
marks on the timing cover can greatly assist the static timing test due
to outside confirmation of TDC with respect to the findings of the
timing fixture assembly- 1460-048. Lombardini strongly recommends
the use of the 1460-048 timing fixture for purposes of static timing
adjustments.
With reference to the figure to the left, Pulley mark (D) corresponds
to the No. 1 piston (flywheel side piston). Timing cover mark (C)
corresponds to approximately 11°-13° BTDC.
With reference to the figure below, note the following:
D aligns with A-
TDC No. 1 cyl. and No. 4 cyl.,1204,1204/T,1404
TDC No. 1 and No. 2 cyl., 502
E aligns with A-
TDC No. 2 cyl., 903,1003
F aligns with A-
TDC No. 2 cyl., 602,702
TDC No. 2 cyl. and No. 3 cyl.,1204,1204/T,1404
G aligns with A-
TDC No. 3 cyl., 903, 1003
NOTE 1: The firing order of the LDW 903, 1003 is 1-3-2, thus on the
crankshaft pulley, D,G,E.
NOTE 2: The firing order of the LDW 1204 and LDW 1204/T,1404 is
1-3-4-2, thus on the crankshaft pulley, D,F,D,F. However, in order to
properly follow the LDW 1204 and 1204/T firing order, an initial
establishment of TDC compression stroke for No. 1 cylinder must be
made.
72
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
FUEL SYSTEM
VI
UNIT INJECTOR DELIVERY EQUALIZATION- PREPARATION
Due to the fact that unit injectors are both injection pump and injector, all unit
injectors within a FOCS diesel engine must be equalized to facilitate the
identical delivery of fuel within individual cylinders. The equalization procedure
is a operational test with the valve cover removed. Therefore, proper eye
protection must be worn and great care must be taken to insure no body or
clothing contact with rotating engine components.
After carefully removing the engine valve cover, install a M8x1.25x10mm
capscrew and 8mm copper gasket at position(1) as shown. Failure to install
the bolt as shown will result in a large scale oil spill and loss of oil pressure to
the engine during the operational procedure presented below.
NOTE: SEE PAGE 74 FOR INITIAL INJECTOR CONTROL RACK AND
GOVERNOR ADJUSTMENT PROCEDURES.
UNIT INJECTOR DELIVERY EQUALIZATION- PREPARATION (cont.)
Remove the fuel manifold assembly(A). In place of the fuel manifold, install
on each unit injector a test head(B). The test heads are supplied as part of
the equalization tool package. Please note that early versions of the unit
injector and late versions of the unit injector require different test heads.
Please refer to page 56 for further details.
EQUALIZATION TOOL INSTALLATION, PLUMBING
Place the equalization tool on a stable surface , with the base of the
equalization tool at least 20cm higher than the level of the unit injectors.
Close all valves(2,3). Remove fuel cap(6) and fill the reservoir with clean
diesel fuel. With reference to the diagram, connect the lower hoses
(A)coming from the equalization fixture to the test head position(A). The
hoses should be connected to the test heads in a logical manner. That is, the
left most hose should be connected to No. 1 unit injector (flywheel side), then
subsequent hoses from left to right, connected to cylinders 2, 3, 4 as
required. Connect the upper hoses(B) to the test head position (B). Make
sure that the control lever(4) is in the upper position.
After completion of the hose routing/ plumbing, open the valves (2,3). Start
the engine and allow to idle. Increase and lock the engine speed to 1500 rpm.
Once the engine operates smoothly and the 1500rpm is reconfirmed, pull the
control lever(4) downward for approximately one(1) minute. While closely
watching the fuel level in the cylinder tubes(5), note the rate at which fuel is
consumed. NOTE:, the control lever(4) must be returned to the upper
position prior to fuel depletion in the tubes(5).
During operation with the control lever down, determine the cylinder(s) which
are consuming more fuel as indicated by the speed at which the fuel is
depleted from each individual tube(5). Delivery rates in each cylinder should
be within 2 cm3 during one(1) minute of operation. Reduce the fuel delivery
rate to the cylinder(s) consuming the most fuel. Delivery may be adjusted as
follows:
FUEL RATE ADJUSTMENT DETAILS
To increase the fuel delivery of an individual unit injector, the injector rack
must be moved slightly toward the flywheel end of the engine. With reference
to the figure on the left, loosen screws (1) and (2) 1/2 turn. Increase the
cylinder fuel delivery by moving plate (4) slightly towards the flywheel, thus
changing the relative position of control rod (3). Reductions in fuel delivery
can be facilitated by moving the plate away from the flywheel. After
adjustment, torque screws (1) and (2) to 1.1 Nm.
Repeat the equalization test until the individual cylinder fuel consumptions are
within 2 cm3 during a one(1) minute period.
NOTE: The equalization procedure should be performed following an injector
re
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
73
VII
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM SERVICE PRECAUTIONS / WARNING:
The improper service of electrical components can result in shock injuries, burn injuries (from both
heat and chemical acids) and produce sparks which could ignite fires. Therefore proper precautions
must always be taken.
1. Always wear safety glasses and hand protection when performing diagnostic work of electrical
systems.
2. Keep hands, arms, clothing, hair, etc. well away from rotating components.
3. Always remove the negative (-) battery cable before removing and/or handling any electrical system
wires or components.
4. Use extreme care when handling batteries. Hand protection and eye protection should be worn at all
times. Batteries contain acids which can cause severe chemical burns.
5. The fumes emitted from batteries are flammable, therefore do not weld, smoke or use an open flame
around batteries.
6. Read, understand and follow the operational and safety precautions supplied with your electrical
service equipment (battery chargers, load testers, meters, etc.).
BATTERY SIZING: The chart presented below provides strict guidelines for the sizing of system batteries for Lombardini
FOCS diesel engines. Batteries must be sized so as to provide sufficient reserve capacity (Amp-Hours), but yet not so
large as to damage the starter motor due to excessive amperage. Depending on the cold starting ambient conditions
(Normal or Extreme), size the system battery according to the data presented below with respect to the engine model and
engine starter rating.
ENGINE MODEL
LDW
LDW
LDW
LDW
LDW
LDW
LDW
LDW
LDW
LDW
74
502 FOCS
502 FOCS
602 FOCS
602 FOCS
903 FOCS
903 FOCS
1204 FOCS
1204 FOCS
1204/ T FOCS
1204/ T FOCS
STARTER
RATING
(KW)
1.2
1.1
1.1
1.6
1.1
1.6
1.1
1.6
1.1
1.6
COMPILER TECO/ATI
NORMAL AMBIENT CONDITIONS
Amp-Hours
@ 20 hour Rating
EXTREME AMBIENT CONDITIONS
Maximum Battery Amp-Hours @ 20
Amps @ -18°C
hour Rating
44
44
44
66
44
66
44
66
55
66
210
210
210
300
210
310
210
310
255
300
Maximum Battery
Amps @ -18°C
66
66
66
88
66
88
66
88
66
88
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
300
300
300
330
300
330
300
330
300
330
04
DATE
15.11.99
ENDORSED
ELECTRICAL SYSTEM
VII
ISKRA ALTERNATOR- 14V / 33A
NOMINAL VOLTAGE:
14V
NOMINAL CURRENT OUTPUT:
33A
MAXIMUM r/min:
12000 r/min
VOLTAGE REGULATOR:
AER 1503
ROTATION (VIEWED AT PULLEY END): CLOCKWISE
NOTE: Pulley nut torque (1):
35-45 Nm
ISKRA 14V / 33A PERFORMANCE CURVE
The attached performance curve was plotted at a constant system
voltage
voltage of 13V and at an ambient temperature of 25°C.
NOTE: The rpm shown is reflective of an ISKRA alternator fitted to
an engine with a 88mm crankshaft pulley. The rpm shown is that of
the alternator rotor. Thus, at at an engine speed of 3600 rpm, the
alternator is turning approximately 4680 rpm, or a ratio of 1.3 :1.
12V ELECTRICAL SCHEMATIC- ISKRA 14V-33A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Alternator
Starter Motor
Battery- (See below for sizing details)
Glow Plugs
Thermistor (Glow Plug Controller Circuit)
Glow Plug Controller / Timer
Key Switch
System Fuse, 30A (502, 602), 50A (903), 80A (1204,
1204/T)
Fuse (Accessory)- 5A
Fuel Valve
Glow Plug Indicator Lamp
Coolant High Temperature Lamp
Coolant High Temperature Switch (N.O.)
Oil Pressure (Low) Lamp
Oil Pressure Switch (N.C.)
Alternator Charging Lamp (Off if Charging)
Air Filter High Restriction Indicator Lamp
Air Filter Restriction Switch (N.O.)
Low Fuel Level Lamp
Low Fuel Level Switch (N.O.)
A Accessory Position
B Off Position
C On Position
Starting Position
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
75
VII
ELECTRICAL SYSTEM
MARELLI ALTERNATOR (AA 125 R) - 14V / 45A
NOMINAL VOLTAGE:
14V
NOMINAL CURRENT OUTPUT:
45A
MAXIMUM r/min:
14000 r/min
VOLTAGE REGULATOR:
RTT 119 A
BEARING (Pulley End):
6203-2Z
BEARING (Voltage Regulator End)
6201-2Z/C3
ROTATION (VIEWED AT PULLEY END): CLOCKWISE
NOTE:1. Pulley nut torque (1):
60 Nm
2. Use only high temperature grease when servicing bearings.
MARELLI AA 125 R, 14V / 45A PERFORMANCE CURVE
The attached performance curve was plotted at a constant system
voltage
voltage of 13.5V and at an ambient temperature of 25°C.
P1 =
I=
n=
Power Output (KW)
Current Output (Amps)
Efficiency
NOTES:
1. The RPM shown is that of the alternator. The value of the rpm axis
must be multiplied by 1000.
2. Alternator speed is a function of engine speed and the crankshaft
pulley diameter. If the engine pulley is 88 mm, then the alternator
speed ration is 1.3:1. If the engine pulley is 108 mm, then the
alternator speed ratio is 1.6 : 1.
76
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
ELECTRICAL SYSTEM
VII
12V ELECTRICAL SCHEMATIC- MARELLI 14V-33A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Alternator
Starter Motor
Battery- (See below for sizing details)
Glow Plugs
Thermistor (Glow Plug Controller Circuit)
Glow Plug Controller / Timer
Key Switch
System Fuse, 30A (502, 602), 50A (903), 80A (1204, 1204/T)
Fuse (Accessory)- 5A
Fuel Valve
Glow Plug Indicator Lamp
Coolant High Temperature Lamp
Coolant High Temperature Switch (N.O.)
Oil Pressure (Low) Lamp
Oil Pressure Switch (N.C.)
Alternator Charging Lamp (Off if Charging)
Diode
Air Filter High Restriction Indicator Lamp
Air Filter Restriction Switch (N.O.)
Low Fuel Level Lamp
Low Fuel Level Switch (N.O.)
A
B
C
D
Accessory Position
Off Position
On Position
Starting Position
BATTERY SIZING- PLEASE REVIEW PAGE 62
FLYWHEEL ALTERNATOR- 12V
Flywheel driven alternators are available in two(2) amperage ratings
at 3600 r/min - 20A and 30A.
COMPONENTS:
1
2
3
4
COMPILER TECO/ATL
REG. CODE
MODEL N°
Flywheel
Ring Gear
Magnet Ring (Rotor)
Stator
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
77
VII
ELECTRICAL SYSTEM
PERFORMANCE CURVE- 20A FLYWHEEL ALTERNATOR
The performance curve at the left was plotted at a constant system
voltage of 12V and an ambient temperature of 20°C.
RPM values shown on the performance curve are engine speeds.
The statistical charging output of the flywheel alternator is +10% to 5% of the values shown.
PERFORMANCE CURVE- 30A FLYWHEEL ALTERNATOR
The performance curve at the left was plotted at a constant system
voltage of 12V and an ambient temperature of 20°C.
RPM values shown on the performance curve are engine speeds.
The statistical charging output of the flywheel alternator is +10% to 5% of the values shown.
78
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
ELECTRICAL SYSTEM
VII
12V ELECTRICAL SCHEMATIC- 20/30A FLYWHEEL
ALTERNATOR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Alternator
Starter Motor
Battery- (See below for sizing details)
Glow Plugs
Thermistor (Glow Plug Controller Circuit)
Glow Plug Controller / Timer
Key Switch
System Fuse, 30A (502, 602), 50A (903,702,1003), 80A (1204,
1204/T, 1404)
Fuse (Accessory)- 5A
Fuel Valve
Glow Plug Indicator Lamp
Coolant High Temperature Lamp
Coolant High Temperature Switch (N.O.)
Oil Pressure (Low) Lamp
Oil Pressure Switch (N.C.)
Alternator Charging Lamp (Off if Charging)
Voltage Regulator
Air Filter High Restriction Indicator Lamp
Air Filter Restriction Switch (N.O.)
Low Fuel Level Lamp
Low Fuel Level Switch (N.O.)
A
B
C
D
Accessory Position
Off Position
On Position
Starting Position
BATTERY SIZING- PLEASE SEE PAGE 62
VOLTAGE REGULATOR CONNECTION DETAILS (FLYWHEEL
ALTERNATOR ONLY)
SAPRISA,
AETSA,
NICSA
~
R
+
LE
COMPILER TECO/ATL
REG. CODE
MODEL N°
STD. WIRE
COLOR
50563
DATE OF ISSUE
04.90
WIDTH
YELLOW
RED
RED
GREEN
BROWN
REVISION
1-5302-351
CONNECTOR DIMENSIONS
DUCATI
04
G
R
B
L
C
DATE
15.11.99
6.35
9.5
9.5
4.75
6.35
ENDORSED
THICKNESS
0.8
1.2
1.2
0.5
0.8
79
VII
ELECTRICAL SYSTEM
LOMBARDINI SUPPLIED CONTROL PANEL
As an accessory, LDW-FOCS series engines may be fitted with a Lombardini supplied engine control panel. The
control panel includes indicator lamps for low oil pressure, high coolant temperature, charging failure, high air filter
restriction, low fuel level, glow plug heating and “OK”. Intergral to the panel, a glow plug relay and solid state glow
plug controller is included. The diagram below provides details of the control panel. Please also refer to the
diagram on page 70, which details the interface engine side wiring harness for the Lombardini control panel. The
panel connector index numbers correspond to the index numbers for the engine side harness.
80
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
ELECTRICAL SYSTEM
VII
ENGINE SIDE WIRING HARNESS FOR THE LOMBARDINI SUPPLIED CONTROL PANEL
In conjuction with the engine control panel detailed on page 69, LDW-FOCS engines may be fitted with an engine side wiring harness and optional
sensors. The following diagram details the engine side wiring harness. Please also reference the diagram on page 69. The connector index numbers
as shown on the engine side wiring harness interfaces with the connector index numbers for the control panel.
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
81
VII
ELECTRICAL SYSTEM
BOSCH 12V / 1.1 KW STARTER MOTOR (DW 12V)
NOTE: Before removing the starter motor or attempting to service
any electrical component, remove the negative(-) cable from the
system battery.
Distance (A), from starter mounting flange to ring gear face must be
checked and confirmed to be 17.5 / 19.5mm.
Please refer to your local BOSCH distributor for service parts, repair
criterion and warranty service.
PERFORMANCE CURVE- BOSCH 12V / 1.1KW (DW 12V)
STARTER
The performance data presented is reflective of an ambient
temperature of
-20°C and operation with a fully charged 66Ah battery.
U=
n=
I=
P=
M=
Starter Motor Voltage
Armature r/min
Absorbed Amperage
Starter Output Power (KW)
Starter Output Torque (Nm)
BOSCH 12V / 1.6 KW STARTER MOTOR (DW 12V)
NOTE: Before removing the starter motor or attempting to service
any electrical component, remove the negative(-) cable from the
system battery.
Please refer to your local BOSCH distributor for service parts, repair
criterion and warranty service.
Distance (A), from starter mounting flange to ring gear face must be
checked and confirmed to be 29.5 / 31.5mm.
PERFORMANCE CURVE- BOSCH 12V / 1.6KW (DW 12V)
STARTER
The performance data presented is reflective of an ambient
temperature of
-20°C and operation with a fully charged 88Ah battery.
U=
n=
I=
P=
M=
82
COMPILER TECO/ATI
Starter Motor Voltage
Armature r/min
Absorbed Amperage
Starter Output Power (KW)
Starter Output Torque (Nm)
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
ELECTRICAL SYSTEM
VII
GLOW PLUG
One(1) glow plug is required per engine cylinder. Proper glow plug
operation is required for good start ability at any ambient
temperature. All FOCS diesel engines should be preheated before
attempting to start the engine. Further, Lombardini recommends that
all applications be fitted with an automatic glow plug controller
system such as is detailed below. The use of a glow plug control
circuit will insure the proper amount of preheat at all temperatures.
Glow Plug Specifications:
Nominal Voltage12.5V
Current Absorption-12/14A at 5 seconds
Sheath Temperature-850°C at 5 seconds
COMPONENTS:
1 Sheath
2 Primary Heating Coil
3 Secondary Heating Coil
NOTE: GLOW PLUG TORQUE- 20Nm
GLOW PLUG CONTROLLER / RELAY WITH COOLANT TEMP.
SENSOR
As discussed above, a glow plug control circuit is available. The glow
plug controller acts as both a load relay and timer. The timer function
is a function of coolant temperature as measured by a temperature
sensor (thermistor) as shown below. An electrical schematic of the
glow plug control circuit is shown on page 65.
THERMISTOR
INPUT
GLOW PLUG HEAT TIME (sec)
Resistance (ohms) Coolant Temp. (°C)
Pre-heat
Post-heat
7000
-20
26.5±3
5 (+2, -1)
2400
0
15.0±1.5
5 (+2, -1)
1000
+20
9.5±1
5 (+2, -1)
460
+40
7.0±1
5 (+2, -1)
#320
+50
0
0
TEMPERATURE SENSOR (THERMISTOR)
The thermistor is located on the thermostat housing, adjacent to the
high coolant temperature switch. The thermistor must be installed in
the thermostat housing in the port located nearest to the cylinder
head. (see the figure to the left)
THERMISTOR SPECIFICATIONS:
Temperature Range: 30-50°C
Voltage Range:
6-24V
Maximum Temperature:
150°C
Installation Torque:
30 Nm
OIL PRESSURE (LOW) SWITCH, COOLANT TEMPERATURE
(HIGH) SWITCH
Oil Pressure (low) Switch Specifications:
General:
Opening Pressure:
Installation Torque:
Single Pole, N.C.
0.15 / 0.45 bar
25 Nm
Coolant Temperature (High) Switch Specifications:
General:
Closing Temp.:
Max. Power Absorption:
Voltage Range:
Installation Torque:
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
Single Pole, N.O.
107 / 113°C
3W
6 / 24V
25 Nm
DATE
15.11.99
ENDORSED
83
VIII
TESTING-OPERATIONAL-ADJUSTMENTS
IDLE SPEED ADJUSTMENT
1. Check and/or fill the engine with coolant and engine oil. Fill the
engine or machine fuel tank with fuel.
2. Attach or set-up a calibrated tachometer.
3. Start the engine and allow a 10 Minute warm-up period.
4. Remove all loads from the engine.
5. Loosen the locknut at position(1). Adjust screw(1) until an idle
speed of 850 - 900 r/min is achieved.
6. Tighten the locknut at position(1).
NOTE: Rotating the screw(1) clockwise increases the idle speed,
while rotating the screw(1) counter-clockwise reduces the idle speed.
HIGH (MAXIMUM) SPEED ADJUSTMENT
1. Check and/or fill the engine with coolant and engine oil. Fill the
engine or machine fuel tank with fuel.
2. Attach or set-up a calibrated tachometer.
3. Start the engine and allow a 10 Minute warm-up period.
4. Remove all loads from the engine.
5. Loosen the lock nut at position(2). Simultaneously adjust screw(2)
and hold the throttle lever at full travel as shown until the maximum
speed is 3800 r/min.
6. Tighten the locknut at position(2)
NOTES: Rotating screw(2) clockwise will reduce the maximum
speed, while rotating the screw(2) counter-clockwise will allow a
higher maximum speed. Setting the maximum no-load speed at 3800
r/min will allow for 3600 r/min operation when the engine is fully
loaded. Some fine adjustment may be required after the engine is
applied within the given machine.
TORQUE DEVICE ADJUSTMENT (WITHOUT DYNAMOMETER)
Lombardini recommends that the engine torque device be adjusted
on a dynamometer. Therefore, the adjustment procedure presented in
the following is only approximate. WARNING: ADJUSTMENT OF
THE TORQUE DEVICE WILL REQUIRE THE USE OF TOOLS IN
CLOSE PROXIMITY TO THE COOLING FAN. DO NOT PERFORM
THIS OPERATION WITHOUT A PROPER FAN GUARD IN PLACE.
USE EXTREME CARE NOT TO ALLOW TOOLS OR BODY PARTS
TO COME IN CONTACT WITH THE COOLING FAN, FAN
SUPPORT OR FAN BELT.
1. Loosen the torque device locknut at point(C).
2. Rotate the torque device(C) clockwise several revolutions.
3. Tighten the torque device locknut.
4. Start the engine, allow to warm and lock the speed at 3800 r/min.
5. Loosen the locknut at position(C)
6. Rotate the torque device(C) counter-clockwise until the speed
begins to reduce.
7. Rotate the torque device(C) clockwise 2.5 revolutions.
8. Tighten the locknut at position(C).
TORQUE DEVICE DETAILS
The torque device(C) serves two(2) primary functions. First, the
torque device limits the maximum power output by limiting maximum
fuel delivery. Fuel delivery is limited by controlling the travel of
lever(L), thus the injection control rack. Secondly, the torque
device(C) provides a torque rise in the engine as the fuel delivery is
limited. As the governor spring(N) pulls the lever(L) toward the torque
device(C) during high load situations, an additional travel equivalent
to (H) is allowed providing for the maximum fuel delivery and
maximum enginer torque. The distance (H) is a direct function of the
internal torque device spring(M). (H) is typically equal to 0.4mm.
84
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
TESTING-OPERATIONAL-ADJUSTEMENTS
VIII
INJECTION PUMP CONTROL ROD STROKE LIMIT ADJUSTMENT
1. Remove the valve/ rocker cover.
2. Loosen bolt(B) completely.
3. Push the injection pump control rod toward the fan end of the
engine and hold in position as shown.
4. Rotate screw(B) clockwise until contact is made with the control
rod.
5. Rotate screw(B) clockwise an additional 1/2 to 1 turn.
6. While holding screw(B) in position and preventing rotation, tighten
the locknut.
7. Replace the valve cover following the instructions from page 29.
GOVERNOR / UNIT INJECTOR RACK ADJUSTMENT
1. Remove the valve/ rocker cover.
2. Loosen screws(C).
3. Make sure that starting aid spring(D) is connected to the control
arm(A) as shown.
4. Push the control arm(A) fully toward the flywheel (“right” as
shown).
5. Slide each plate(B)- (One(1) per unit injector) toward the
flywheel(“right as shown).
6. While holding the plates in the direction shown tighten screws(C)
at each unit injector.
7. Torque screws(C) to 1.1Nm
POWER, TORQUE DEVICE and SPEED ADJUSTMENTSDYNAMOMETER METHOD. (SEE WARNINGS REGARDING
TORQUE DEVICE ADJUSTMENT ON PAGE 73.)
1. Assemble the engine to the dyno. Fill the engine with fluids. Start
the engine and allow an idling warm-up of 5 minutes.
2. Loosen the torque device locknut and rotate the torque device
several revolutions clockwise. Tighten the locknut.
3. Adjust the engine speed and dynamometer load as required.
4. Allow the engine to stabilize thermally.
5. Check the specific fuel consumption. If the fuel consumption is not
within specification, remove the load, allow the engine to cool and readjust the governor and fuel delivery rates. Repeat steps 1-4.
6. Rotate the torque device counterclockwise until the engine speed
begins to fall. Lock the torque device locknut.
7. Remove the dyno load while maintaining the existing throttle
position. Note the speed increase for purposes of droop calculation.
8. Allow the engine to cool at idle speed for 10 minutes.
DYNO TEST PARAMETERS- kW and
SPECIFIC FUEL CONSUMPTION
ENGINE
r/min NB Output (kW)
LDW 502
LDW
LDW
LDW
LDW
COMPILER TECO/ATL
REG. CODE
MODEL N°
2200
3600
602
2200
3600
903
2200
3600
1204 2200
3600
1204/T3600
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
5.5
9.1
7.4
10.3
11.1
15.6
22.0
20.2
28.5
DATE
15.11.99
Specific Fuel Consumption
Sec./100cc g/kW*hr
285-299
115-120
326-340
147-155
265-279
89-93
326-340
99-105
261-274
58-60
328-342
75-79
258-272
44-45.8
326-340
35-36
284-290
ENDORSED
85
IX
STORAGE
STORAGE
Measures shouLd be taken to protect your FOCS series engine if the
engine is not operated for a period of 30 days or more. Proper
storage will protect the engine from corrosion and prevent costly
repairs due to storage induced problems.
STORAGE - 1 to 6 MONTHS
1. Start and idle the engine at a no-load condition for 15 minutes.
2. Stop the engine, allow the engine to cool enough to safely drain
the oil as shown. Reinstall the oil drain plug, then fill the crankcase
with MIL-L-644-P9
protectant oil. Fill the fuel tank with a high grade fuel preservative
(add-mix) such as STA-BIL per the manufacturer recommendations.
3. Start and operate the engine at 3/4 speed for 5-10 minutes.
4. Stop the engine, allow to cool enough to safely drain the engine oil
as shown. Reinstall the oil drain plug.
5. Refill the engine with standard recommended lubricating oil. See
page 17.
6. Drain the fuel tank. Remove the fuel filter. Install a new fuel filter.
7. Carefully clean all debris from the radiators fins.
8. Remove the intake manifold. Rotate the engine until the íntake
valve opens at each cylinder. Using suitable means, pour
approximately one(1) teaspoon of engine oil into each cylinder.
Rotate the engine several revolutions. Spray the inside of the intake
manifold with SAE 10 W oil. Replace the intake manifold
using a new gasket.
9. Spray the inside of the exhaust manifold with SAE 10 W oil.
10. Cover all openings with tape.
11. Apply grease to any and all unpainted surfaces.
12. Loosen the fan belt.
13. Wrap the engine in plastic film and store in a dry place off of the
ground and away from any high voltage source.
STORAGE- IN EXCESS OF 6 MONTHS
Perform the storage preparation procedures approximately as detailed above, except with the following changes.
I. Replace the oil in step 2 above with MIL-L-21260 P 10, grade 2, SAE 30W rustproof oil.
2. Delete step 5 from above.
3. Delete step 11 from above.
4. Cod any and all unpainted surfaces with MIL-C 16173D, grade 3 anti-rust grease.
5. Replace the anti-freeze solution every two(2) years by draining the crankcase water jacket as shown and refilling with a premixed coolant solution according to the prevailling lowest ambient temperatures and the recommendations from pag 17.
PREPARING THE ENGINE FOR USE AFTER STORAGE
I. Romun all plastic wraps and protective tape.
2. Clean all grease, dirt and oil from the exterior of the engine.
3. Drain the oil.
4. Drain the coolant as shown.
5. Refill the engine with the recommended lubricating oil (page 17). Install a new oil filter.
6. Refill the engine with the recommended anti-freeze / coolant (page 19)
7. Remove the injectors. Test and repair the injectors as required.
8. Pour a teaspoon of oil into each cylinder. Rotate the engine several revolutions.
9. Reassemble the injectors, adjust the govemor, adjust the valves.
10. Inspect the fuel tank for rust and corrosion. Clean as required.
11. Fill the fuel tank with fresh fuel. Install a new fuel filter.
12. Install a new air filter.
13. Carefully start the engine and allow to idle for 20 minutes. Repeat step 5.
NOTE: lf the engine has been stored for more than six(6) months, remove the oil pan and inspect several engine bearings to
make sure no corrosion damage has taken place.
86
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
1-5302-351
50563
04.90
REVISION
04
DATE
15.11.99
ENDORSED
NOTE
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04.90
04
DATE
15.11.99
ENDORSED
87
42100 Reggio Emilia – Italia - ITALY
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Tel. (+39) 0522 3891 - Telex 530003 Motlom I – Telegr.: Lombarmotor
R.E.A. 227083 - Reg. Impr. RE 10875
Cod. fiscale e Partita IVA 01829970357 - CEE Code IT 01829970357
E-MAIL: [email protected]
Internet: http://www.lombardinifim.it
La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione.
Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette
publication.
Lombardini reserves the right to modify the information in this publication at any moment.
Lombardini vorbehält alle Rechte, diese Angabe jederzeit verändern.
La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación.
88
COMPILER TECO/ATL
REG. CODE
MODEL N°
DATE OF ISSUE
REVISION
1-5302-351
50563
04-90
04
DATE
10.06.99
ENDORSED
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