WORKSHOP MANUAL LDA 422 engines, code 1-5302-596 LDA 422 1st Edition COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 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). COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED INDEX This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled, indirect injection Diesel engines type LDA 422: updated May 15, 2003. TABLE OF CONTENTS SAFETY DECALS - SAFETY INSTRUCTIONS I Pag. 6-7 TROUBLESHOOTING " 8-9 II MAINTENANCE- RECOMMENDED OIL TYPE - REFILLING " 10 III MODEL NUMBER AND IDENTIFICATION " 11 IV TECHNICAL DATA " 12 V FEED INDUCTION DIAGRAM " 13 VI LUBRICATION SYSTEM " 14-15 VII TIMING DIAGRAM " 16 VIII ENGINE- DIFFERENTIAL UNIT IX DISASSEMBLY / REASSEMBLY 17 19-80 Adjusting lever in max. delivery position: Adjustment of pump control rod Advance variator Armature Assembly and disassembly of timing belt and oil dipstick Assembly play Belt assembly Belt cover and fan scroll Belt tensioning check Camshaft Camshaft Camshaft and tappet support Camshaft extraction Camshaft oil seal and timing pulley Camshaft support Check of tappets clearance Clearance “A” on assy (mm) Clutch Clutch assembly Clutch-side housing half Clutch-side housing half – Disassembling of gearbox shaft roller case and multiple gear ball bearing. Connecting rod Connecting rod small end bush Cooling fan flywheel Coupling pinion Crankcase, half, flywheel side Crankshaft - big end Crankshaft – Reverse shaft – Gearbox shaft – Multiple gear – Differential gear assembly Cylinder head Cylinder head Cylinder head unit Cylinder-cylinder head securing studs COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 48 73 70 58 21 41 22 20 23 68 68 67 25 68 26 72 41 28 64 60 33 54 42 20 58 60 43 32 27 50 67 67 ENDORSED INDEX Cylinder-Piston Delivery regulator – reassembly Delivery regulator: Description of the injection advance regulator Differential case Differential gear box Dismantling values Drive shaft and connecting rod Drive shaft clamping Drive shaft gear Drive shaft, reverse gear shaft, multiple gear, gearbox shaft and differential gear Dynamic control static ENGINE AT FULL LOAD ENGINE AT IDLE SPEED ENGINE AT MAX SPEED ENGINE AT PARTIAL LOAD Engine gear ENGINE STANDING OR AT STARTING Engine stop lever adjustment Features of the pump on the bench Feeding pump Fireproof bulkhead and injector FLAME BREAKER BUSH Flywheel-side housing half – Roller case, multiple gear and roller case, gear FUEL FLOW GOVERNOR DESCRIPTION FUEL INJECTION Gear assembly measure check Gear cluster ball bearing and drive shaft d.c. roller bearing Gearbox Gearbox shaft Governor assembly Injection advance variator Injection advance variator INJECTION EQUIPMENT DESCRIPTION AND FUNTIONING Injection pump Injection pump Injection pump : “MICO” type F 002 F 10 006 Injection pump and check static injection advance Injection pump control cam INJECTOR Injector : MICO F 002 C 6 Z 396 Injector setting Injector, fireproof bulkhead LUBRICATION SYSTEM DESCRIPTION Magneto positioning on the governor Main features of electrical starter Mass play axial play and adjusting spacers Measure execution for determination of cylinder head gasket thickness Min. and max r.p.m. regulation Oil filter and cooling covers and starting motor Oil pressure regulating valve Oil pump Oil pump gear and oil pump Oil pump gear and oil pump - reassembling Piston - Piston pin Piston – wrist pin Piston and cylinder Piston rings Piston slots - piston rings Precombustion chamber – disassembly and reassembly Primary gearbox ring gear and clutch housing pan Reassembling – Oil filter – Injection pump inspection cover – Fuel supply pump – High pressure pipe – Tappets cover Reassembling – Oil level rod - Starting motor - Flywheel – Fan scroll together with the stator – Belt cover - Exhaust manifold – Cooling covers – Fan scroll cover - Muffler - etc COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 41 37 36 71 57 57 50 54 21 29 61 75 39 38 40 39 63 38 34 48 78 77 77 33 34 73 55 60 56 55 24 24 70 73 24 48 48 74 25 77 49 49 23 30 34 59 34 66 80 19 31 53 29 62 42 31 65 41 42 52 63 78 79 INDEX Reassembling the gearbox shaft Reassembly of valves Remote control switch Replacement of the brushes Ring gear disassembling Separation of the housing halves Shim thickness for tappet gap adjustment Small end bush - wrist pin Speed gear control box Tappet Tappet disassembling Then check injection advance tinning as follows. Timing gear and speed gear control box. Timing pulley Timing pulley and camshaft sealing ring Valve guide - valve stim Valve seat Valves - inside spring Valves - outside spring Valves caps Valves grinding 55 51 58 58 28 32 72 42 65 44 26 74 31 69 25 43 43 44 44 44 51 X TOOLS 81-84 XI MAIN TORQUE SPECIFICATIONS 85-86 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 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. COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 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/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED TROUBLE SHOOTING I POSSIBLE CAUSES AND TROUBLE SHOOTING The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before removing or replacing any part. REMEDIES FAULT FINDING STARTING PROBLEMS Faulty fuel pump Check and, if necessary, replace Presence of air inside the injection system Purge by operating the fuel pump lever Faulty glow plug Replace Faulty starting motor or remote control switch Detect the problem and, if necessary, overhaul or replace Faulty or dirty injector Check and, if necessary, replace Faulty injection pump Check and, if necessary, replace Faulty engine stop solenoid valve Check and, if necessary, replace LOW POWER Air filter clogged Clean and, if necessary, replace Diesel fuel filter clogged Replace Delayed injection Check and time correctly Inadequate diesel fuel delivery Verify fuel filter, check injection and fuel pumps efficiency Faulty delivery or advance regulators Check the assembly and, if necessary, overhaul it THE ENGINE STOPS Low idling speed Work on the appropriate register Presence of impurities inside the diesel fuel tank Empty the tank and clean it, replace the diesel fuel and the filter Absence of air Clean the air filter and, if necessary, replace it Faulty engine stop solenoid valve Check and, if necessary, replace THE ENGINE OVERHEATS Dirt inside head and cylinder cooling system fins Remove the covers and clean adequately Inadequate engine oil level Restore COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED I TROUBLE SHOOTING REMEDIES FAULT FINDING WHITE EXHAUST SMOKE Cold engine Heat the engine for few minutes at low speed Faulty injector Check and, if necessary, replace High oil level Restore the level BLACK EXHAUST SMOKE Air filter clogged Replace Incorrect injection pump delivery Check and restore Faulty injector Clean and, if necessary, replace NOISY ENGINE Wrong injection advance Check the static and dynamic advance and restore Faulty injector Clean and, if necessary, replace Tappets with excessive clearance Adjust Excessive wear of the engine internal parts Overhaul LOW OIL PRESSURE Insufficient oil level Restore the level Worn oil pump Overhaul Worn or damaged crankshaft or small end bearings Overhaul CLUTCH : SLIPPING Insufficient idle stroke Adjust the stroke Weak return spring Replace Worn or burnt driven disk gasket Replace the disk SPEED GEAR : SPONTANEOUS GEAR DISENGAGEMENT Worn or damaged gearbox Check and, if necessary, replace Incorrectly adjusted control rod Adjust Wrongly assembled or worn gearbox or coupling spider gears Overhaul VIBRATIONS TRANSMITTED FROM ENGINE TO FRAME The silent-blocks anchoring the engine to the frame are not locked correctly or are damaged 10 COMPILER TECO/ATI Lock or replace REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING II Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system LDA 422 ENGINE - SPECIAL MAINTENANCE CLEANING INTERVAL KM COMPONENT OPERATION after the first after the first 1000 Km 5000 Km Dry-type air filter Valve clearance Water in the fuel filter CHECK Clutch pedal stroke Bolts and nuts correct fastening Injection Advance Engine oil REPLACEMENT Oil filter LDA 422 ENGINE - ORDINARY MAINTENANCE INTERVAL KM COMPONENT OPERATION 1000 2500 5000 10000 20000 40000 Dry-type air filter Injector Cooling system (fan, guards, fins) Valve clearance Water in the fuel filter Integrity of propeller shaft boot Low-pressure fuel lines CHECK Clutch pedal stroke Bolts and nuts correct fastening Glow plug performance Injection Advance Injector calibration Engine oil Oil filter REPLACEMENT Fuel filter cartridge Dry-type air filter cartridge Timing belt CLEANING COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 11 III MODEL NUMBER AND IDENTIFICATION Lombardini r.p.m. Diesel Customer's code Air cooled Displacement (cc) Engine serial number 12 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED TECHNICAL DATA IV LDA 422 ENGINE MAIN SPECIFICATIONS - 4-stroke single cylinder engine - Indirect-injection Diesel-cycle type - Forced air-cooling system - Differential gear and gearbox assembly on rear axle - OHC axle driven by toothed belt - Lubrication is made through a lobe pump controlled by driving-shaft chain - Injection system by immersed-type pump, fed by diaphragm fuel pump - Dry-type cartridge air filter - Oil filter with cartridge - Oil type SAE 15 W 40 API CF LDA 422 TECHNICAL DATA N° mm mm Cm³ Number of cylinders Bore Stroke Displacement Compression ratio R.P.M./1' min R.P.M./1' max Power kW Max torque at 2800 R.P.M./1' Fuel consumption Oil quantity without oil filter Oil quantity with oil filter Dry weight COMPILER TECO/ATI kW Nm gr kW/h l. l. Kg REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED LDA 422 1 83 78 422 23 : 1 1100 ± 50 3800 6,3 18 300 3,0 3,5 94,5 13 V FEED INDUCTION DIAGRAM Components : 1) Air cleaner (paper filtering cartridge) 2) Induction duct 3) Induction valve 4) Fuel tank 5) Fuel feed pump 6) Fuel filter 7) Injection pump 8) Injector 14 COMPILER TECO/ATI 9) Fuel return pipe from injector 10) Return pipe to tank of exceeding fuel 11) Preheating plug 12) Piston 13) Cylinder 14) Camshaft 15) Delivery adjusting rod 16) Fuel delivery regulator unit REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED LUBRICATION SYSTEM COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED VI 15 VI LUBRICATION SYSTEM LDA 422 OIL CIRCUIT DIAGRAM OIL PICK UP OIL PUMP OIL FILTER OIL PRESSURE VALVE CYLINDER VALVE FOR PISTON COOLING CRANKSHAFT CONROD CYLINDER HEAD OIL VALVE CAMSHAFT SUPPORT CYLINDER HEAD OIL SUMP CAMSHAFT GOVERNOR 16 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED TIMING DIAGRAM VII Timing diagram Data concern 1 mm. cold play between tappets and valves COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 17 VIII ENGINE-DIFFERENTIAL UNIT Components: 1) Starting motor 14) Dipstick 2) Cylinder 15) Tappet 3) Preheating plug 16) Timing belt 4) Injector 17) Induction valve 5) Injection pump 18) Piston 7) Accelerator lever 19) Belt tensioner 9) Delivery control 20) Starting crown gear 12) Feed pump 21) Starting pinion 13) Camshaft 22) Rotor with fan COOLING SYSTEM COOLING SYSTEM DESCRIPTION The engine cooling is carryed out by means of air blown by the centrifugal fan, attached on the flywheel, on the cylinder head unit . The heat is removed from the cylinder and cylinder head through the appropriate finning of themself. Moreover, particularly in the cylinder head area, close to the exaust valve seat and to the pre-combustion chamber, the heat is removed by the lubrication oil, as previously described in the chapter relative to the lubrication system. When the engine is cold, because of high oil pressure due to the high viscosity, a by-pass valve limits the oil quantity sent to the area to be cooled. 18 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Apart from disassembly and reassembly operations, this handbook also includes checks, setting up, dimensions, repairs and running instructions. It is necessary to use LOMBARDINI original spare parts for a correct repair. During repair operations, when using compressed air, wear eye protection. First drain the engine oil through the drain hole, then remove the negative cable (-) from the battery, the electric cables from the alternator flywheel and from the starting motor, the fuel pipes, the controls of accelerator, braking lights, speed gear, clutch, etc, remove the inlet boot and the aprons. Oil filter and cooling covers and starting motor Install the engine gear box assembly on support 986171.193, remove the oil filter and remove the scroll cover and the cooling covers by removing the relevant retaining screws. After removing the guard, disassemble the starting motor. support 986171.193 A 1 2 3 4 5 6 7 8 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 19 IX DISASSEMBLY/REASSEMBLY Cooling fan flywheel Place tool 981075.414 onto the starting motor (Fig. 9) housing to fix the flywheel, remove the flywheel retaining screw using a 22 mm socket wrench and extract the cone and remove the flywheel (Fig. 11) using extractor 981075.420 (equipped with component 984651.457). NOTE: After extracting the cone, if flywheel removal should prove difficult use extractor 981075.418 (Fig. 14). tool 981075.414 Part. 984651.457 puller 981075.420 9 10 11 puller 981075.418 12 13 14 Belt cover and fan scroll After removing the belt cover (Fig. 15), unscrew the 6 screws and remove the fan scroll together with the stator and detach the alternator cable clamp (Figg. 16÷17) . 15 20 COMPILER TECO/ATI 16 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 17 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Assembly and disassembly of timing belt and oil dipstick Before disassembling the timing belt . Turn the camshaft gear and fit timing pin 8430.123 into its housing on the support ( see figure 20 ) so that it coincides with the hole that can be found on the shaft ( the pin must rest against the boss surface). pin 8430.123 18 19 20 Loosen the belt tensioner and clamp it up high as shown, remove the timing belt (Fig. 21÷22) and the oil dipstick (Fig. 23) by removing the 3 coupling screws. Loosen the timing pulley fastening bolt so that it can turn freely on the shaft. 21 22 23 + 8430.124 Drive shaft clamping Disassemble the clutch, then fit clamping hub 5900.217 (together with component 8430.124) on the drive shaft and refer to the key for the clutch assembly (Fig. 25). Tighten the hub using the washer and the nut with a 120 ÷ 140 Nm torque (Fig. 26). Then fit timing pin 8430.124 and screw it onto the hub so that it coincides with the hole on the clutch housing pan (Fig. 27). tool 5900.217 24 25 COMPILER TECO/ATI 26 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 27 00 DATE 15-05-2003 ENDORSED 21 IX DISASSEMBLY/REASSEMBLY Belt assembly Clamp the belt tensioner in the minimum load position, then fit the belt on the drive shaft pulley and next on the camshaft pulley (Fig. 28). Unscrew the idler nut to tension the belt. Then tighten the belt tensioner nut with a 40÷40,4 Nm torque (Fig. 29). Tighten the camshaft pulley to 70 Nm, then fit again the safety washer on the bolt (Fig. 30-31). Now remove both pins to allow the shafts to turn, plug the hole on the camshaft support with the washer and the plug (Fig 3233). Use the flywheel to rotate the engine for 2/3 revs thus bedding the belt. Remove the clamping hub of the drive shaft using a multi-purpose extractor as shown in the figure (34), then reassemble the clutch (Fig. 35). 28 29 30 31 32 33 34 35 22 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Belt tensioning check Use the DENSO tool to measure the belt tension, carefully place the denso on the belt tooth as shown in figure 36. The belt tension should be between 25 and 28 Nm, see Fig. 37. If this is not the case loosen the idler, let it slide downwards and tighten it again to the rated torque, then re-check the tension. When removing the timing belt you must replace it even though its scheduled life spar is not over. 36 37 Injector, fireproof bulkhead - Remove the tappets cover (Fig. 38) - Wher disassembling the injection tube keep the injection pump fitting clamped using a 19 mm wrench (Fig. 39). - Assemble 981075.413 extractor in place of the injector, as shown in the picture (42), and extract the fireproof bulkhead. 38 39 40 When reassembling the injector always use a new fireproof bulkhead. puller 981075.413 41 COMPILER TECO/ATI 42 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 23 IX DISASSEMBLY/REASSEMBLY Injection pump - Remove the inspection plug. - Disengage the injection pump control rod and extract the pump. - Remove the injection tappets with the related collar housed inside it (Fig. 45÷46). 43 44 45 46 47 48 Governor assembly Unscrew the 5 bolts (Fig. 47) and remove the governor assembly (Fig. 48). Injection advance variator - Unscrew the fixing bolt using a 14 mm wrench, use extractor 981075.421 and turn the screw to remove the weights while keeping the central hexagon clamped (Fig. 51). puller 981075.421 49 24 COMPILER TECO/ATI 50 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 51 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Injection pump control cam Extract the key from its slot (Fig. 52), remove the snap ring (use pliers for internal snap rings), extract the shoulder washer and extract the cam (Fig. 53). 52 53 Timing pulley and camshaft sealing ring Straighten the retaining washer, unscrew the bolt and remove the timing pulley (Fig. 54). Remove the sealing oil ring (use a screw driver) (Fig. 55), the snap ring (use pliers for internal snap rings) and the clearance shim (Fig. 56). When reassembling replace the sealing oil ring with a new one 54 55 56 57 58 Camshaft extraction Turn the shaft and position the cam lobe to coincide with the opening provided for it (Fig. 57). Repeat the procedure on the second cam lobe to extract the shaft completely (Fig. 58). COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 25 IX DISASSEMBLY/REASSEMBLY Tappet disassembling Mark the tappets and the adjustment shims, making sure that they are reassembled in the same position. The collar surface on which the shim identification code is indicated shall be assembled facing the tappets socket. 59 60 61 62 Camshaft support Disassemble the fuel supply pump, the plastic support, and the fuel supply pump control rod. By using the appropriate wrench unscrew the coupling screws to the head and remove the camshaft support. 63 64 26 COMPILER TECO/ATI 65 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 66 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Cylinder head Unscrew the 4 retaining nuts (Fig. 67), extract the cylinder head assembly (Fig. 68) and remove the gasket (Fig. 69). When reassembling always replace the cylinder head gasket with a new one 67 COMPILER TECO/ATI 68 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 69 00 DATE 15-05-2003 ENDORSED 27 IX DISASSEMBLY/REASSEMBLY Clutch - Disassemble the cover (Figg. 70÷71)and place the stop key 985110.039 - Using pliers extract the snap ring then remove the clutch pressure plate. - Unscrew the nut (Figg. 73-74), use extractor 981075.419 and extract the clutch by turning the central screw (Fig. 76). 70 stop key 985110.039 71 72 73 puller 981075.419 74 75 76 Ring gear disassembling Disassemble the cover by removing the single nut and the 10 screws (Fig. 77), then use the provided tool 981075.412 to clamp the ring gear and unscrew the bolt (Fig. 79). N.B. When reassembling, the bolt shall be locked by using the same tool. nut tool 981075.412 77 28 COMPILER TECO/ATI 78 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 79 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Using tool 981075.425 together with component 984651.457 extract the cone (Fig. 81) and remove the ring gear (Fig. 82). 984651.457 puller 981075.425 80 81 82 Drive shaft gear First remove the snap ring using the specific pliers, then remove the clearance shim (Fig. 83) and the camshaft gear (Fig. 84÷85). 83 84 85 86 87 Oil pump gear and oil pump Hold the oil pump control gear using a screwdriver and unscrew the lock bolt (Fig. 86), then remove the chain (Fig. 87). Unscrew the two bolts which secure the oil pump (Fig. 88) and extract the oil pump noticing the correct sequence for reassembly.(see Fig. 89). Replace the gasket whenever you remove the oil pump (Fig. 90). delivery 88 COMPILER TECO/ATI intake 89 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 90 00 DATE 15-05-2003 ENDORSED 29 IX DISASSEMBLY/REASSEMBLY LUBRICATION SYSTEM DESCRIPTION The oil contained in the engine sump is deaerated through the labyrinth (1) and filtered by the filter (2) before it is sucked by the pump (3) through the suction duct (4). From the pump the oil is pushed towards a circuit machined in the cylinder head in proximity to particular points to be cooled (5). The cooling circuit internal pressure is limited by the by-pass valve (7). The by-pass valve is necessary because, with the engine cold and therefore with high oil viscosity the oil pressure wouldbecome too high. The diaphragm (6) regulates the oil quantity for the camshaft lubrication. A by-pass valve (8) regulate the lubrication pressure at a predetermined value. Before being sent to the cylinder head (5), to camshaft support (9) and to the journal bearings (10) the oil is filtered through a total flow filter cartridge (11). In case of obstruction of the filter an internal by-pass valve (12) opens up. Nearby on the clutch side crankshaft support, a nozzle with a closing valve is fixed. These nozzle valve is preset and has the function of cooling the piston through its oil jet and to lubricate the connecting rod small end bearing and the piston pin. The oil that comes out from the cylinder head and camshaft carrier compartment is returned into the crankcase through an appropriate pipe that is not represented in the figure. 7- Characteristics of the spring located in the oil pressure regulating valve for lubrication and cooling circuits - By-pass spring free length —> 33 mm - Load exerted by the above mentioned spring at a length of: 27.5 mm —> 3.1 ± 0.15 Kg 8- Lubrication by-pass - Spring free length —> mm 48 - Load exerted by the above mentioned spring at a length of: 36 mm —> 3.4 ± 0.10 Kg 29 mm —> 5.3 ± 0.13 Kg 91 30 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Oil pressure regulating valve Remove the snap ring, extract the spring and the by-pass valve.Check for possible dirt build up in the ducts and for good spring condition. 91 93 Piston – wrist pin After extracting the cylinder (Fig. 94) remove the snap rings from their seat by means of a screwdriver (Fig. 95÷96), then extract the wrist pin (Fig. 97). 94 95 96 97 Timing gear and speed gear control box. Remove the timing gear (Fig. 98). Unscrew the 5 fastening bolts and remove the speed gear control box (Fig. 99). 98 COMPILER TECO/ATI 99 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 31 IX DISASSEMBLY/REASSEMBLY Separation of the housing halves Unscrew the 15 union screws (Fig. 100), position the engine horizontally as shown in the figure and separate the two housing halves by hitting with a mallet. When reassembling, the shoulder washers which are located between drive shaft and flywheel-side housing should be placed with the 4 lubrication marks turned towards the drive shaft. 100 Crankshaft – Reverse shaft – Gearbox shaft – Multiple gear – Differential gear assembly 101 1 Remove reverse gear “1” (Fig. 102), gearbox shaft “2”, multiple gear “3”, crankshaft “4” and remove differential gear assembly “5” using extractor 981075.411 which is provided (Fig. 107÷108). 102 3 2 103 4 104 105 5 puller 981075.411 106 32 COMPILER TECO/ATI 107 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 108 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Flywheel-side housing half – Roller case, multiple gear and roller case, gear Remove the two gearbox shaft roller cases by using a crop end as a punch, with an external Ø of 24 mm for the roller case of the multiple gear “A” and with an external Ø of 36 mm for roller case of the gear shaft “B”. A B external diameter mm 24 external diameter mm 36 109 110 Clutch-side housing half – Disassembling of gearbox shaft roller case and multiple gear ball bearing. Assemble puller 981075.415 onto the gearbox shaft roller case and work on the central nut until the extraction is completed (Fig.112). Remove the snap ring “D”, work on the opposite side to the one shown in the figure and expel “E” (Fig. 114) ball bearing using a 30 mm external Ø punch. puller 981075.415 111 D E 112 COMPILER TECO/ATI 113 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 114 00 DATE 15-05-2003 ENDORSED 33 IX DISASSEMBLY/REASSEMBLY FUEL FLOW GOVERNOR DESCRIPTION From figures 1 and 2 one can see the essential components and the functioning of the governor. The mass holder (1) is driven in rotation by its own shaft driven in turn by the camshaft. In to the mass holder (1) there are 4 centrifugal counterweights (2) that act on the push rod (3) . The push rod activate's the lever (4) hinged on the pivot (5) which is fixed to the governor housing, the other end of the lever links to the injection pump regulation rod (7) . Between the lever (6) and the lever (4) acts a spring (8) for the starting maximum fuel flow. On the control lever (6) acts : the spring (9) for the idle-speed control ; the spring (20) for the adjust of the fuel flow to the engine rpm ; and through the cup (10) and the shaft (11) , the maximum engine rpm control spring (12). The last spring , assembled with pre-load in the frame (17) , is futter compressed by the lever (13) which is connected with the speed control lever (14). The lever (15) , which is connected to the engine stop control (16) , acts on the lever (4) and then on the injection pump control rod (7). On the governor box a magnet (18) is fixed , its function is to keep the lever (4) in the position of supplementary flow at the engine start position. The lever (6) pushcs on the regulation screw (19) that puts in a correct position the rod (7). Magneto positioning on the governor Insert the injection pump on the cylinder head and lock it after positioning in may del position. Loosen the magneto fixing screws and move the magneto itself in order to meet the push rod lever; fix the magneto in this position and check that the release load of the push rod lever is 700 ÷ 800 gr. Engine stop lever adjustment Running position: adjust the catch screw (20) of the engine stop lever (16), in such a way that it’s internal part does not interfere with the rod control lever (4). Stop position: adjust the stop screw (21) of the engine stop lever (16), in such a way that the stop does not take place through the rod control lever (4) and the connection rod (7), on the injection pump Mass play axial play and adjusting spacers Play : 0,1÷0,16 mm Spacers : mm 1,2 - 1,3 - 1,4 Tolerance : ± 0,05 34 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX The governor main functions are the following: - Engine low idling speed adjustment - Engine maximum RPM limitation - Delivery increase during start up FIG. 1 FIG. 2 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 35 IX DISASSEMBLY/REASSEMBLY Delivery regulator: Remove the cover by way of the 6 retaining screws.Remove retainer A, cap B and idling spring C.Set adjustment lever 13 towards the outside, extract supplementary spring D, extract retainer E and remove pump control rod 6. 115 6 D C A B 116 13 E 117 118 Remove the snap ring, extract pin 7, disassemble the adjustment lever, rod control lever 4, spacers F and shim washers G which are located between the two levers; when assembling follow the correct sequence. 7 G 4 F 10 119 120 121 1) Shaft 2) Cup 3) Idling speed governor spring 4) Rod control lever 5) Throttle control 6) Pump connection rod 7) Pin 8) Centrifugal weights 9) Weight container 10) Maximum RPM governor spring 11) Delivery control screw 12) Adjustment spring container 13) Adjustment lever 14) Magnet 122 36 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Remove the snap ring from its slot using the pliers which are provided (see Fig. 124) then extract the shaft and the weights holder shaft (Fig. 125). Now unscrew the two retaining nuts A (see Fig. 126 ÷ 127), then remove the metal plate and disassemble the magnet holding the lever in extra fuel position (Fig. 122). If the spring holder shaft for maximum RPM governing has to be replaced, use a pin-driver punch as shown in Fig. 126. When reassembling follow a reverse sequence than the above-described one. 123 124 125 127 128 A 126 Delivery regulator – reassembly When reassembling is completed, check the axial endfloat of “Z” shaft using the special no-studbolts tool 981075.417 which comprises a bore gauge; axial endfloat should be between 0.10 and 0.16 mm. If you find that the axial endfloat is different from schedule, replace clearance shim “V”. To this end 8 washers having different thickness values are provided. tool 981075.417 V 129 COMPILER TECO/ATI Z 130 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 37 IX DISASSEMBLY/REASSEMBLY GOVERNOR'S WORKING DESCRIPTION ENGINE STANDING OR AT STARTING In these conditions the governor flyweight are completely closed, due to the slider thrust on which acts the minimum and the extra-fuel springs (see fig. 3) . The control lever, pushed at one end by the minimum spring, reacts on the regulation screw. The control rod lever, pushed by the relative extra-fuel spring, puts the pump control rod in the maximum fuel flow position and therefore in the engine start position. Notice that acting on the accelerator lever there will not be any effect on the pump control rod because the control lever is already in contact with the regulation screw ; so this mean that you can start the engine with the accelerator at the minimum position. The magnet, with the help of the supplementary spring, keep in the maximum fuel flow position the control rod until the engine has not reached about 2000 rpm. When the engine exceed 2000 rpm the flyweight centrifugal force exceed the spring and magnet force, so open the flyweight that shift by means of the slider i the control rod lever and then the pump connecting rod i to lower fuel flow positions. ENGINE AT IDLE SPEED After the starting of the engine, if someone does not act on the accelerator lever, the governor flyweight are in equilibrium with the minimum spring at about 1200 rpm. The engine speed increasingly open the flyweight moving the slider , the regulation lever until the system do not reach a new equilibrium position; at the same time the pump connecting rod is moved to lower fuel flow positions, for this reason the engine comes back to the initial speed. The opposite happens if the engine reduce the speed. With the engine at idle speed the governor will fluctuate continuously around the equilibrium position in order to maintain the speed as constant as possible. ACCELERATORE 38 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX ENGINE AT PARTIAL LOAD From the minimum position, by acting on the accelerator lever, the minimum spring is completely pre-loaded; after that, the cup. Is push directly on the regulation lever carrying the pump connection rod toward greater fuel flow positions partially closing the governor flyweight. In this situation the injection pump flow regulation rod acts as if it is directly connected to the accelerator lever, that means that the movements of the accelerator lever produce proportional mouvements of the pump connection rod. At intermediate engine speed, the governor generate a load that compress partially the flow adjusting spring moving the rod control lever, producing consequently change of the pump flow against change of rpm. ENGINE AT FULL LOAD Moving completely the accelerator lever until the position of full load, the lever will touch the regulation screw, after that the maximum rpm regulation spring will be compressed. Starting from low speed, when the speed increases, the governor flyweights centrifugal load compress the flow adjust spring, proportionally reducing the pump fuel flow. This is the wasking position of the pump connecting rod for maximum fuel flow . COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 39 IX DISASSEMBLY/REASSEMBLY ENGINE AT MAX SPEED When the engine reaches the maximum working speed the governor flyweights centrifugal force exceede the reaction of the maximum speed regulating spring; the expanding flyweights move the regulating lever and the pump connecting rod towards a position of lower fuel flow. If the engine continues to accelerate the flyweights continue to move until the pump connecting rod reaches the position of zero flow. The governor begins to operate at about 3800 rpm and the zero fuel flow occures at about 4200 rpm. 40 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Assembly play Pistons and cylinders supplied by the Factory as spares are marked with letters of the alphabet. In cases where a cylinder or a piston is to be substituted, it should be replaced with the same letter as the mating component. In case of a rebored cylinder, the dimension “E” should exceed the dimension “C” on the piston to be fitted (marked on the piston itself), by the value indicated for each part, “clearance on assy”. Cylinder-Piston Piece name nominal dimension Cylinder normal E = 83 -0 +0,05 Piston normal C = 82,96 ± 0,025 Class symbol A B C D E Matching class Cylinder Piston 83,000÷83,010 83,010÷83,020 83,020÷83,030 83,030÷83,040 83,040÷83,050 82,935÷82,945 82,945÷82,955 82,955÷82,965 82,965÷82,975 82,976÷82,985 Assembling gap "A" 0,055÷0,075 131 Piston rings Part name Diameter (mm) Piston ring, upper Piston ring, lower Scraper ring assy 83 Superiore =Upper Inferiore =Lower Raschiaolio = Scraper 132 N.B. - Piston rings must be fitted with inscription “Top” facing piston crown and the inside spring of scraper ring must be positioned with the joint at 180° from scraper ring joint. Clearance “A” on assy (mm) Piston ring, upper 0,25÷0,50 Piston ring, lower 0,25÷0.50 Scraper ring assy 0,10÷0,30 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 41 IX DISASSEMBLY/REASSEMBLY Piston slots - piston rings Part name Part name Clearance -A- (mm) Piston ring, upper 2,095÷2,075 (Ø80) 0,065÷0,115 1st piston slot 2,160÷2,190 (Ø80) 2nd piston slot 2,040÷2,060 Piston ring, lower 1,990÷1,970 0,050÷0,090 3rd piston slot 3,020÷3,040 Scraper ring 2,990÷2,975 0,030÷0,065 133 Piston - Piston pin Piston “A” Ø 25 - 0,001 - 0,006 Piston pin “B” Ø 24,991 ± 0,002 Assembling gap “C” Ø 0,001÷0,010 134 Small end bush - wrist pin Small end “A”: Ø 25,006÷25,009 Wrist pin “B”: Clearance “C” on assy: Ø 24,991±0,002 0,013÷0,020 Connecting rod small end bush Con rod S.E. Bush “A”: Ø 28 +0,80 + 0,118 Con rod SM. end “B”: Ø 28 -0 -0,021 Interference 135 0,059÷0,118 - Parallelism tolerance allowed between big end and small end axis (measured at 125 mm from the stem of the connecting rod) must be = 0,08 mm 42 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Crankshaft - big end Part name Dimension (mm) Big end “A” 51,333 - 0 + 0,013 Con-rod bearing, half “C” 1,535÷1,526 Crankshaft “B” 48,288 - 0,02 +0 136 Valve guide - valve stim Part name Dimension (mm) Valve guide “A” 8,015÷8,033 Valve stim exh. and ind. “B” 7,974÷7,992 Clearance “C” on assy 0,023÷0,059 N.B. Dimension of valve guide inside dia. is understood to be after assembly and after machining. 137 Valve seat Denomination Inlet Outlet Valve seat chanfer angle 45 ° ± 5' 45 ° ± 5' Valve head chanfer angle 45° 30' ± 7' 45° 30' ± 7' Valve head diameter 38,300÷38,600 33,300÷33,600 Valve seat housing diameter 39,988÷40,012 34,988÷35,012 Valve seat outside diameter 40,094÷40,119 35,094÷35,119 0,082÷0,131 0,082÷0,131 Valve seat-cylinder head mounting interference COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 43 IX DISASSEMBLY/REASSEMBLY Tappet 35,000÷35,025 Tappet dia. “A” 34,975÷34,995 Tappet seat dia. “B” Clearance on assy “C” 0,005÷0,050 139 Valves caps Thickness “A”: 3,25 - 3,30 - 3,35 - 3,40 - 3,45 - 3,50 - 3,55 - 3,60 - 3,65 - 3,70 - 3,75 - 3,80 - 3,85 - 3,90 - 3,-95 - 4,00 - 4,05 - 4,10 - 4,15 - 4,20 - 4,25 - 4,30 - 4,35 - 4,40 - 4,45 - 4,50 - 4,55 - 4,60 Tolerance ± 0,015 140 Valves - outside spring Free length “L” mm 53,9 Load at 36 mm heightkg 38,9±1,5 Load at 26.5 mm height kg 59,5±2,5 141 Valves - inside spring Free length “L” mm 41,8 Load at 31 mm. heightkg 14,9±0,5 Load at 31 mm. heightkg 27,4±1,2 142 44 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX CRANCKCASE - BEARINGS CLUTCH SIDE MULTIPLE GEAR BALL BEARING Bearing external diameter Seat diameter Assemble interference Ø 62,000÷61,987 Ø 61,979÷61,949 gap 0,008 mm interf. 0,051 mm NEEDLE BEARING HOUSING Seat diameter for multiple gear needle bearing flyweel side Seat diameter for gear needle bearing clutch side Ø 25,979÷26,000 Ø 46,983÷46,958 REVERSE GEAR Shaft seatØ 18,016÷18,034 Reverse gear shaftØ 18,000÷17,982 Reverse gearØ 17,944÷17,962 Gap 0,016÷0,052 Interference 0,056÷0,020 DIFFERENTIAL HOUSING Denomination Dimensions Differential box Differential seat Ø 75,970÷75,924 Ø 76,000÷76,046 Matching gap 0,122÷0,030 CRANKSHAFT - CRANKCASE - BEARING HOUSING Denomination Timing side half crankcase Clutch side half crankcase Free bearing Machined bearing assembled on the crankcase Crankshaft COMPILER TECO/ATI Dimensions Matching Ø 60 0 - 0,030 Interference 0,133÷0,195 Ø 60 +0,133 +0,165 Ø 55 +0,010 +0,029 Ø 55 -0,030 -0,043 gap Ø 0,040 ÷0,072 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 45 DISASSEMBLY/REASSEMBLY IX Injection pump : "MICO" type F 002 F 10 006 Test conditions Pumping element dia.: L.H. helix pitch: Test Oil: Test Oil temperature: Pump inlet pressure: Pumping element prelift: 6 mm 12 mm SHELL S 93 65 40°C±2° 0,2 Kg/cm2 2÷3 mm Features of the pump on the bench Adjusting lever in reference to central position: Rack rod stroke form r.p.m. Delivery mm3/cycle max delivery position 1500 23,3 ± 0,5 9 1900 20,8 ± 1 8,3 2250 29 ± 1 9,5 Adjusting lever in max. delivery position: r.p.m. 150 Delivery mm3/cycle 45 ± 3,5 146 Injection pump Caption: 1- High pressure injector pump delivery pipe 2- Nut for connection to the delivery pipe 3- Spring 4- Filler 5- Valve 5- Plunger barrel 6- Plunger blade 7- Plunger barrel 8- Plunger piston 9- Spring collar 10- Spring 11- Spring retainer collar 12- Delivery control lever 13- Pump housing 14- Fuel inlet coupling 147 46 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Injector : MICO F 002 C 6 Z 396 Caption: 1- High pressure delivery pipe ( Ø 6 - Ø 1,75x168 ) 2- Nut for connection to the delivery pipe 3- Pressure duct 4- Pressure setting shim 5- Pressure spring 6- Pressure pin 7- Nozzle MICO DNO SD 287 8- Nozzle clamping ring nut 9- Intermediate washer 10- Nozzle case 11- Connection for leakage recovery 12- Fire ring 148 Injector setting Connect injector to a hand pump and check that setting pressure is 150 +10 - 0 bar; Make the required adjustments, if any, by changing the shim over the spring. Eleven different shims are available as spares with size from 1 to 2 mm. When replacing the spring, setting should be performed at a 10 bar greater pressure(160 bar) to allow for bedding during operation. Check needle valve sealing by slowly moving the hand pump until approximately 120 bar for 10 seconds. Injector sealing Seal: Keep inside injector a oil pressure 10÷20 kg/cm2 lower than the opening pressure.No drop should form on the end of the injector in less than 10 seconds.However a light sweating is allowed. Caution - The injector jet, because of high output pressure car cause wounds whose consequences can be very serious. Take care that during the tests the jet itself doesn’t hit any part of the body. 149 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 47 IX DISASSEMBLY/REASSEMBLY Cylinder head Caption: 1- Cotters 2- Valve spring upper collars 3- Internal valve spring 4- External valve spring 5- Valve guide sealing rings 6- Valve spring lower collars 7- Precombustion chamber 8- Exhaust valve 9- Intake valve 150 Dismantling values Compress valves springs by using a valve lifting clamp as shown in fig. 157 ( the tool was not included in the special tool set as it is commercially available), take away cotters, halves and release the fixture until spring and valves are removed all purpose valve lifter clamp 151 48 COMPILER TECO/ATI 152 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 153 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Valves grinding Carefully remove carbon deposit without notching the metal and wash with cleaning liquid. Inspect valves seats: they shouldn’t present indentations or scorings, but they must have a uniform surface so as to assure a perfect valve seal. Otherwise carry out valves seat grinding. This operation must be performed as follows with the best attention: smear valves with fine emery, introduce the valve in its guide and fix wrench “O” to the stem end. Alternately maneuver the wrench by changing, from time to time, position. Absolutely avoid that emery is introduced into valves guides. When the operation has been carried out carefully wash and blow cylinder head and valves. For the checking of the perfect seal of valves pour some gasoline (petrol) into admission and exhaust ducts, then check that gasoline (petrol) doesn't flow through valves themselves. O 154 N.B. - If valves seats are worn or with deep indentations it is necessary, before carrying out the grinding, to perform on the valves seats with proper milling cutters. Reassembly of valves R Prior to valve reassembling, which is done in reverse sequence as to disassembling, always replace the two sealing rings on the valve guides using punch 986290.109. Important - Before reassembling valves lubricate guides and stems. 155 punch 986290.109 156 COMPILER TECO/ATI 157 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 158 00 DATE 15-05-2003 ENDORSED 49 IX DISASSEMBLY/REASSEMBLY Precombustion chamber – disassembly and reassembly To extract the precombustion chamber, top the injector seat with a purch (Fig. 159) from the injector seat.This expulsion method causes damages to the precombustion chamber, therefore it must be replaced every time it is extracted.Before assembling the new precombustion chamber, the depth of the seat inside the head shall be measured (Fig. 160÷161); the resulting measurement will determine the most appropriate precombustion chamber of the four of different height that are available.In order to identify them, each precombustion chamber is marked with a paint brush-stroke in different colors according to its height (as indicated in the table).The precombustion chamber shall be inserted into the seat so that the dowel 1 coincides with the appropriate seat 2. The interference between the precombustion chamber external diameter and the seat internal diameter shall be 0.01÷0.05. The precombustion chamber housing shall conform to the specifications shown in the related table with respect to the head surface. See table 159 160 161 163 164 1 2 162 Class symbol Color Prechamber cap thikness Prechamber seat depth Recess in cylinder head A Yellow 4,080÷4,090 4,100÷4,109 0,010÷0,029 B Red 4,091÷4,100 4,110÷4,119 0,010÷0,028 C Blue 4,101÷4,110 4,120÷4,129 0,010÷0,028 D White 4,111÷4,120 4,130÷4,140 0,010÷0,02 Nominal dimension Piece name 50 Combustion prechamber housing inter. diam Ø 27,50÷27,52 Combustion prechamber exter. diameter Ø 27,53÷27,55 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 Interference 0,01÷0,05 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Oil pump Clean all parts and check : - that the union surfaces are flat. - Replace the faulty parts in case of deformation - The side play of the rotors and the radial play between the two rotors If the desired values are not found, replace the faulty parts 165 delivery 166 167 intake 168 169 Oil pump Pump: lobe type. Pump control: through a chain gear dragged by the drive shaft Pressure adjusting valves: on pump body. Rotor seat dia. “A”: 40,601÷40,626 Rotor outside dia. “B”: 40,551÷40,576 Clear, bet. seat and rotor “C”: 0,025÷0,075 Rotor height “D”: 21,96÷21,98 Rotor seat depth “E”: 22,00÷22,02 Side clear, between rotors and pump body “F”: 0,02÷0,06 Radial clearance between rotors “G”: 0,02÷0,10 Lubrication pressure with oil at 100°C: at slow running 1÷2 kg/cm2 at max. r.p.m 3,5÷4,5 kg/cm2. COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 51 IX DISASSEMBLY/REASSEMBLY Drive shaft and connecting rod 1- Connecting rod shaft 2- Connecting rod cap fastening screw 3- Connecting rod half bearings 4- Breech plug 5- Crankshaft 6- Connecting rod cap fastening nuts 7- Connecting rod cap 8- Oil pump gear 170 Connecting rod Remove the two retaining nuts and the connecting rod. When reassembling place the connecting rod onto the crankshaft keeping the cap and connecting rod marks oriented in the same way as before the disassembling, see Fig 173. Then tighten the two bolts gradually to a 70 Nm torque. 171 172 173 N.B. - Replacement of con-rod bearings, halves is possible if crankshaft is without scratches, scorings or ovalization. 52 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Caption: 1- Gearbox shaft with differential gear control coil 2- Speed coupling spider 3- Spacer 4- 4th speed gear 5- 3rd speed gear 6- 2nd speed gear 7- 1st speed gear 8- Reverse gear 9- Clearance ring 10- Stop ring 11- Speed control stem 174 Gear assembly measure check After reassembling the gears, the spacer “R” (with the groove facing the shoulder washer), the shoulder washer “S”, with the snap gauge (go and not go) 984980.324, check the gear assembly measure (mm 132 –0.12 -0.17). If the gauge does not fit or the play is excessive, replace the shoulder washer with one of higher or lower size as needed. Once the check is completed reassemble the snap ring. S R IMPORTANT: the shoulder washer “S” is provided, as spare part, in eight different sizes of thickness. ( 1,750 - 1,830 - 1,910 - 1,990 - 2,070 - 2,150 - 2,230 - 2,310 ) 175 Gearbox shaft Remove the snap ring “Q”, the shoulder washer “P” and the gears. Unscrew the stem “R”, set the coupling spiders, one at a time, to coincide with the slot for the sliding groove and extract them from the shaft. Q R P 176 Reassembling the gearbox shaft Insert the 1st – 2nd speed coupling spider and reverse “A”, caulk by using the punch 986800.255 at a pressure of Nm 15,500 through a hydraulic press. Place the 3rd and 4th speed coupling spider “B” , and caulk by using the punch 986800.254. 177 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 53 IX DISASSEMBLY/REASSEMBLY Gearbox After unscrewing the gearbox coupling screws, disengage the gear speed control stem from the selector switch sliding block and disassemble the gearbox. 178 Caption: 1- Lever pin with P.I. 2- O-ring 3- Sliding block 4- Selector switch 5- Elastic pin 6- Lock ring 7- Ball 8- Spring 9- Spring housing 10- Reverse sensor 11- Return spring 12- O-ring 13- Safety pin 14- Lock ring 15- Pin 16- Pin 17- Lever 179 54 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Differential gear box Caption: 1- Differential gear ring 2- Screws 3- Differential gear pin 4- Differential gear box 5- Differential gear side pinions 6- Clearance ring 7- Snap ring 8- Differential gear crown wheel 9- Differential gear pin check squares 10- Washers 180 Differential case Take away the 6 bolts “E”, side pinions pin retaining brackets “F” and drive gear. With the specific pliers remove circlips “G”, shoulder washer “H” and crown wheel. Extract pin and remove side pinions and the other crown wheel.Replace the damaged parts and reassemble by following the reverse procedure of removal. Torque the 6 bolts “E” according to values of locking torque 55÷60 Nm. 181 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 55 IX DISASSEMBLY/REASSEMBLY Remote control switch By means of a Screwdriver unscrew the 3 screws “D”, disconnect cable “E” and remove remote control switch “R” complete with movable element. 182 Replacement of the brushes After removing cap unscrew both nuts “F” take away cir-clip “G” and remove cover. 183 Release the springs “H”, take off both brushes “l” connected to the magnetic fields and remove brush holder plate “L”. Release copper plated cables by breaking loose both brushes “l”, previously withdrawn, then introduce plated cables into the new brushes foreseen with hole and solder (by the countersunk part of the hole) plated cables; be careful to tin penetrate into holes. Fit a new plate with both brushes on which the two new brushes “l” should be fitted. Charge the spring “H” and reassemble the previously removed parts. 184 Armature After removing cap, cover and brushes holder plate “L” remove stator “N”, bolt “O” retaining coupling fork and extract armature “P”. 185 Coupling pinion By means of an inside dia. 15 mm. (0,59") tube remove ring “Q”, slip off circlip “R” and take away coupling pinion, assy. N.B. - For the reassembly of the unit follow the inverse procedure of removal. 186 56 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Main features of electrical starter Type MAICO Rated voltage 12V Rated output 1,1 kW Direction of rotation Left hand Connection with engine with pinion and crown gear on the flywheel-fan Warning: Values within brackets are specific for the test with 66 Ah battery. 1) No-load test: maximum input of no-loaded starter: 7.5 A by feeding voltage of 11.5 (12) V r.p.m. ³ 8.000. 2) Under load test: brake the starter so that the input reaches 390 A by feeding voltage of 7.5 (9) V the torque should be ³ 1 Kgm. and the revolving speed ³ 1200 (1500) r.p.m. 3) Start test: by jammed starter and feeding voltage ³ 5 (6) V the input should result £ 600 (780) A and torque ³ 2 (2.2) Kgm. Notice : - Above features must be noted with charged battery and after the starter has turned during 30" in the conditions of point 1. COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 57 IX DISASSEMBLY/REASSEMBLY Crankcase, half, flywheel side C Drive shaft and gear cluster d.c. roller bearings: B A place crankcase half on a base plate and fit, by using the specific punches 986290.106 d.c. roller bearing “A” of drive shaft and 986290.104 d.c. roller bearing “B” of gear cluster. Position on crankcase, half, duly greased on housing face, to avoid fall during assembling operations, shoulder bearing “C” with 4 tracks for the lubrication facing crankshaft and the appendix placed in its housing as pointed out by arrow in fig. 182. 187 A B 188 C 189 190 Clutch-side housing half Place the housing half on a base plate and warm it to 80° C in the ball bearing seat by using a thermal gun. By using the appropriate punch 986290.108 fit the bearing into its seat. punzone 986290.108 191 192 Gear cluster ball bearing and drive shaft d.c. roller bearing Fit by using, if necessary an outside dia. 50 mm (1.96") punch, ball bearing “D” and with pliers introduce circlip “E”. Let crankcase cool and by using the specific punch 986290.105 position d.c. roller bearing “F” of drive shaft. Then in the same way as carried out on crankcase, half, flywheel side, position shoulder bearing “G”. D E F G 193 58 COMPILER TECO/ATI 194 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 195 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Drive shaft, reverse gear shaft, multiple gear, gearbox shaft and differential gear Insert the differential gear (Fig. 196) assembly, the multiple gear (Fig. 197), the gearbox shaft (Fig. 198), the reverse gear (Fig. 199), the drive shaft (Fig. 200), the oil filter “G” , the pipe “N” and the sealing ring “I” (Fig. 201÷202), as indicated in the figure. Clean the union surfaces of housing halves (Fig. 203÷204), smear with sealant (Loctite 518) (Fig. 205) and couple the housing halves by setting the screws to the specified torque (Fig. 206÷207). 196 197 198 N I 199 200 201 203 204 206 207 G 202 205 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 59 IX DISASSEMBLY/REASSEMBLY Oil pump gear and oil pump - reassembling When reassembling the oil pump, always replace the seal with a new one. Reassemble the oil pump paying attention to the correct assembly direction (suction and delivery). We advise you to fill the pump case with oil before the assembly. Before and after final tightening the two fastening bolts “A” of the pump case to the housing half, check that the pump turns freely by rotating the shaft manually 4 or 5 times. The two bolts “A” are tightened to an 8 Nm torque. Reassemble the chain after attaching it by using the oil pump control gear. The bolt fastening the gear to the oil pump shaft shall be tightened to a 10÷12 Nm torque. Oil pump pressure check The oil pressure check shall be performed with the oil at a temperature of 100° C. Connect the pressure gauge in the place of the pressure or switch placed on the main duct. Run the engine and measure the following pressure values: - at minimum rpm - at 3000 RPM ≥ 1 Kg/cm2 3.5 to 4.5 Kg/cm2 delivery 208 209 210 212 213 intake A 211 60 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Engine gear Assemble the gear “L”, the clearance shim “M” and the snap ring “N” by using the pliers for internal snap rings. Use the tool 986782.034 provided with a dial indicator on the housing pan and verify that the gear axial endfloat is mm 0.04÷0.1. If this endfloat is not obtained, replace the clearance shim “M” with a washer of appropriate size; 13 washers having different thickness are provided. L M N Tool 986782.034 214 215 Primary gearbox ring gear and clutch housing pan 216 O Place the ring gear “O” the cone “P” and lock with the bolt “Q” to a 120÷140 Nm torque by using a wrench. Assemble the oil seal on the clutch housing pan by using the appropriate tool 986290.110. Smear the coupling surface with sealant (Loctite 510), assemble the clutch housing pan by the 10 bolts and the single nut by tightening them to a 8 Nm torque P Q 217 218 nut A Tool 986290.110 219 COMPILER TECO/ATI 220 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 221 00 DATE 15-05-2003 ENDORSED 61 IX DISASSEMBLY/REASSEMBLY Clutch assembly To replace the duct disk no particular tools are required, simply remove the 6 bolts “B” and remove the duct disk. When reassembling, before locking bolts “B” , assemble the clutch assembly on the drive shaft to help centering the duct disk, then place washer “C”, secure nut “D” 120÷140 Nm and the 6 bolts “B” 10 Nm by fastening the clutch assembly using the appropriate stop key 985110.039. Complete the operations by assembling the clutch pressure cap of the cover retaining ring. 222 C B D stop key 985110.039 223 224 225 226 227 228 Caption: 1- Collar retaining ring 2- Thrust cap 3- Nut 4- Cup spring 5- Clutch pressure pad 6- Clutch disk 7- Flange 8- Centering pin 9- Fastening bolt 229 62 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Speed gear control box Rotate the drive shaft and bring the gears in a position such to allow stem “A” the maximum protusion, position upper lever in 2nd gear; spread with seal paste (Loctite 510) speed-gear control box union surface, engage sliding bloc of 3rd and 4th gears lever, then the one of reverse, bottom and 2nd gears. Lock the box by means of the 5 securing bolts and check the regular speed gear operation. A 230 231 233 234 232 Piston and cylinder B TOP Fit piston with combustion chamber A facing upwards; lubricate and turn piston rings so that ring gops result between themselves displaced by about 120°. Position gasket B on crankcase base and after lubricating cylinder barrel introduce the cylinder by using tool 985820.212. Push cylinder down on crankcase by it self. A 235 236 tool 985820.212 237 COMPILER TECO/ATI 238 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 239 00 DATE 15-05-2003 ENDORSED 63 IX DISASSEMBLY/REASSEMBLY Measure execution for determination of cylinder head gasket thickness Use the dial indicator on the tool 981075.417 and set it to zero on the surface plate. Assemble the tool on the cylinder by using the 2 head clamping stud bolts , set the piston to the top dead centre and measure on the dial indicator the piston protrusion beyond the zero. In order to keep the compression rate within the tolerance value, select the head gasket thickness according to the indications of the following specification table. Tool 981075.417 240 241 242 Piston projection (over zero) mm Gasket thickness 0,45÷0,60 0,60÷0,75 0,75÷0,90 1,50 1,65 1,80 243 External identification 1 notch 2 notches 3 notches Compression ratio 22,5÷23,5 Warning : The above measurements given for the determination of the suitable gasket are necessary only in case of replacement of one of the following parts: cylinder, piston, con-rod, crankshaft or crank-case, half: if one of the mentioned conditions is absent, the new gasket must be equal (external identification) to the previously fitted one. 64 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Cylinder head installation Fit the cylinder head and after lubricating washers, studs and the 4 nuts, in order to carry out a perfect locking act as follows, by bearing in mind that for each tightening stage the sequence pointed out below must be performed according to the diagram in fig. 246. 1) Torque the four nuts with a locking torque of 5 N.m. 2) Torque to 40 N.m.. 3) Carry out a 90° rotation (1/4 turn). 4) Complete the torquing with a second rotation of 90° (1/4 turn). 244 245 246 247 Cylinder-cylinder head securing studs to avoid progressive permanent elongation from repeated torquing operations it is necessary to replace the studs every three dismantling and reassembly operations of the cylinder head. If in doubt, replace them every time. Camshaft and tappet support - Tappet seat diameter - Normal tappet external diameter - Seat-tappet : assembly gap D C Assemble the camshaft support on the head by tightening the bolts to a 20÷22 Nm torque, lubricate the camshaft supports as well as the intake and exhaust tappet seats “C” and “D” supports. Fit the tappets fitted with adjustment shims in their seats “C” and “D””. Place the gasket “E”. 35,000÷35,025 34,975÷34,995 0,005÷0,050 248 E 249 COMPILER TECO/ATI 250 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 251 00 DATE 15-05-2003 ENDORSED 65 DISASSEMBLY/REASSEMBLY IX Camshaft 253 Shoulder washers 1 2 3 4 5 6 Tool 981075.417 254 A B Insert the camshaft into the support, assemble ther shoulder washer “A” and the retaining snap ring “B”. Use the dial indicator on the tool 981075.417, assemble it on the support and check that the camshaft axial endfloat is mm 0.15÷0.20. If the right axial endfloat is not obtained, replace the shoulder washer with one of a higher or lower size as required until the specified endfloat is obtained (to this end 6 washers having different thickness are 252 provided). 255 Thickness (mm) 1,80 +0/-0,05 1,85 +0/-0,05 1,90 +0/-0,05 1,95 +0/-0,05 2,00 +0/-0,05 2,05 +0/-0,05 256 Camshaft Camshaft pivots diameter belt side: regulator side: 31,959÷31,980 55,961÷55,980 Seat diameters of camshaft pivots into the camcarrier belt side: regulator side: 32,000÷32,025 56,000÷56,030 Mounting gap between seat and Camshaft pivots belt side: regulator side: 0,020÷0,066 0,020÷0,069 Cam lift 8,29 Camshaft oil seal and timing pulley Insert by using the 986290.110 oil seal. proper punch Tool 986290.110 257 66 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Timing pulley Fit the camshaft clamping pin, assemble the timing pulley, then tighten the bolt as torque specified, refit again the retorning washer 258 259 260 261 WARNING Assembly of toothed belt and timing The assembly, timing and tension adjustment of the timing drive toothed belt have already been described from page 21 to page 23. COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 67 IX DISASSEMBLY/REASSEMBLY Advance variator Position injection pump control cam with lobe opposed to regulator hub key and insert centrifugal weights unit making sure that pins of centrifugal weights “L” engage the slots “M”. Working on the side opposed to the one shown in the figure, keep the timing gear locked and clamp the weight-holder hub along with the related bolt by tightening it to a 25÷28 Nm torque. Important : - When the unit is installed check that weights carry out their complete stroke without sticking. 262 L M 263 266 264 267 265 268 Injection advance variator Caption: 1- Injection advance variator fastening screw 2- Washer 3- Calibrated spring cases 4- Lock rings 5- Centrifugal weights 6- Lock rings 7- Lock rings 8- Counterflange 9- Snap ring for shafts 10- Washer 11- Cam for injection pump with P.I. 269 68 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Description of the injection advance regulator When starting, and at a low idling speed the correct value of injection advance is 11° before P.M.S.. This value increases in accordance with the engine RPM, attains 24° at 3500 R.P.M., then renains constant. The advance variation is obtained through the injection advance regulator, see fig. 270. It consists of the flange A splined to the camshaft and the carrier, both with the fulcrum on two pins, of the centrifugal weights C; of a counterflange F, integral with the injection cam and free to rotate on the camshaft, on which two slots are made where the pins D connected to the centrifugal weights slide. Appropriate springs B are applied between the centrifugal weights C and the flange A. 270 With the engine stopped and at low idling speed the spring load is higher than the weights centrifugal force, therefore they remain closed, see fig. 271. 271 When the RPM increases, the centrifugal weights force becomes higher than the spring load, the weights move and through the pins D engaged into the slots rotating the injection cam. At 3500 R.P.M. the weights are completely open, see fig. 272 and the injection advance is 24° before P.M.S. 272 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 69 IX DISASSEMBLY/REASSEMBLY Check of tappets clearance Rotate the engine and put the piston at T.D.C. in compression stroke. With a thickness gauge check that tappets clearance is 0.30 mm for inlet valve and 0.40 mm for the exhaust valve, with the engine cold. If such a clearance doesn’t occur act as follows: 1) Rotate backwards the engine about 40° (to avoid the stroke of valves manual lowering and the hittling of valves against the piston). Rotate the tappets so as to position cuts “A” on the upper part to make easier caps removal. 2) Insert tool 981075.424 between suction valve cap and camshaft and push so as to compress the tappet. Insert part 2 to hold the tappet and extract part 1. 3) Undermine the cap by using a shin point, remove it and replace with another one with a suitable dimension. As spares 28 caps from 3.25 mm. up to 4,60 mm. are pointed out on this page. Important - The value of the cap appears on one of the surfaces of the cap itself, which on assembly must face the tappet. Make sure that the real thickness of the cap correspond to the recommended value. Shim thickness for tappet gap adjustment Thickness 3,25 - 3,30 - 3,35 - 3,40 - 3,45 - 3,50 - 3,55 - 3,60 - 3,65 - 3,70 - 3,75 - 3,80 - 3,85 - 3,90 - 3,-95 - 4,00 4,05 - 4,10 - 4,15 - 4,20 - 4,25 - 4,30 - 4,35 - 4,40 - 4,45 - 4,50 - 4,55 - 4,60 Tolerance ± 0,015 981075.424 984620.319 985620.320 tool 981075.424 273 274 275 A 276 70 COMPILER TECO/ATI 277 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 278 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX INJECTION EQUIPMENT DESCRIPTION AND FUNTIONING FUEL INJECTION In the Diesel engine the fuel is injected towards the end of the compression process into the precombustion chamber via the injection pump and relative injector. The quantity of fuel injected for each cycle is regulated by a function of the power/capacity required through the rotation of the pumping element of the injection pump that is carried out by the regulation rod. FUEL FLOW CONTROL The regulation rod is set into action by the governor. The governor is connected to the upper part of the engine and is driven by a shaft connected with the camshaft. - engine idle speed control - to limit engine maximum rpm - to increase fuel flow at the engine starting. The principal functions of the governor are : Adjustment of pump control rod In case of engine overhauling or interventions on delivery control it is necessary to check the position of injection pump control rod and if necessary carry out the adjustment as follows: fit dial gauge on tool 981075.423, insert ring 984070.499 on tool making sure that pin "R"seats in its concerning slot; let tool reference 984070.499 hole match with the one of the ring; insert punch “A” and set to zero dial gauge. Take away the ring "A" and fit the tool on the place of the injection pump making sure that pin “R” of tool is inserted into the hole of pump control rod, then fit reference punch “A” and lock the tool with both nuts. Place lever “B” of accelerator to max. position and check that dial gauge is on the previously carried out zero setting position. If these conditions do not occur act on adjusting screw “Z” until such zero setting is realized.Lock, by holding the screw “Z” steady, lock-nut “V” and check by placing more times lever “B” to max position, that the dial gauge result is set to zero. Warning - The mentioned checking operations must be carried out without injection pump control tappet. tool 981075.423 A R ring 984070.499 279 280 281 A V B Z R 282 COMPILER TECO/ATI 283 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 284 00 DATE 15-05-2003 ENDORSED 71 IX DISASSEMBLY/REASSEMBLY Injection pump and check static injection advance Insert the tappet in its housing equipped with cap, position the shims and the injection pump making sure, before the locking, that pin is correctly inserted into the control rod and reference dowel into its housing. 286 287 288 Then check injection advance tining as follows. 1) Connect delivery pipe “C” of the proper hand pump (for inst. BOSCH Type) to the feed union of injection pump and insert suction pipe into a container filtered and full of gas oil and plug the hole of gas oil recovery “D” by means of a threaded plug. 2) Rotate the engine so as A.I.D. (dynamic injection advance) reference mark coincide on clutch cover (compression stroke). 3) Operate hand pump and bleed the circuit by means of plug on hole “D”, previously fitted. Then exert pressure on the gas oil so as it comes out from injection union “F”. 4) Fit a transparent pipe “H” on union “F”. Operate again the pump and at the some time rotate the engine towards T.D.C. up the point where the climbing of gas oil in the transparent hose doesn’t cease. Timing is correct if in such a point reference mark the clutch is aligned to A.I.S mark (static injection advance 11° before T.D.C.). If the engine results are advanced or retarded replace the shins below the injection pump (as spares to this aim two packings of 0.2 mm and 0.3 mm are supplied) or fit more packings according to need. Bear in mind that by increasing 0.1 mm. the packing we obtain a retard of 1° and by reducing 0.1 mm the packing we have 1° in advance. 289 N.B. - In order to be certain of the correct timing of injection advance repeat more times the test carried out on the point 4. A B 290 72 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Injection advance dynamic control The dynamic control of the injection advance is made through a suitable equipment - stroboscopic gun - according to the following: 1) Clean carefully the injection pipe and check that the sensor coupling zone “V” is free from scoring signs 2) Install the sensor “V” of tester, paying attention not to turn it after fastening. Connect the tester supply cable as shown in fig. 311 3) Start and heat the engine. With the engine idling at 1200 rpm, use the button on the stroboscopic gun to make path “S” on the clutch flywheel coincide with path “T” of TDC on the clutch cover. Check that the advance read on the tester display is 13°. Increase rpm rating gradually and check that at 3200 - 3500 rpm the advance gradually increased reaches 26° If the range is lower than the one provided, it is necessary to overhaul the advance variator. 310 311 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 73 DISASSEMBLY/REASSEMBLY IX S T T S P.M.S 313 312 314 315 4) If the conditions described at point 3 are not satisfied, and the injection timing is advanced or delayed, replace or increase the gaskets under the injection pump, following the instructions given in Injection pump and checking the static injection advance relevant to the engine static timing. 74 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Fireproof bulkhead and injector A Insert the fireproof bulkhead A into the seat on the head, place the copper seal B on the injector, screw the injector into its seat and tighten it to a 70 Nm torque, as specified. Then fit the rubber cap with the elastic self-tightening clamp on the injector waste union. B Note: The copper seal and the fireproof bulkhead must be replaced every time the injector is disassembled. 291 292 293 294 FLAME BREAKER BUSH PIECE NAME NOMINALDIMENSION SPARK ARRESTOR OUTSIDE DIAMETER 15,973 ÷16,00 SPARK ARRESTOR HOUSING 16,00 ÷ 16,018 ASSEMBLING GAP 0,00 ÷ 0,036 INJECTOR PIECE NAME NOMINALDIMENSION Nozzle holder Ø 19,85 ÷19,97 Nozzle holder seat Ø 21,00 ÷ 21,10 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION ASSEMBLING GAP 1,03 ÷ 1,25 00 DATE 15-05-2003 ENDORSED 75 IX DISASSEMBLY/REASSEMBLY Reassembling – Oil filter – Injection pump inspection cover – Fuel supply pump – High pressure pipe – Tappets cover Screw the oil filter on the appropriate union, screw or the injection pump inspection plug, fit the fuel supply pump control rod, then reassemble the pump, fixing it with the appropriate nuts to a 20 Nm torque, as specified. Reassemble the injection pump-injector high pressure union pipe by tightening it to an 18÷20 Nm torque. Assemble the tappets cover by anchoring them with the 4 screws tightened to 8 Nm. 295 296 297 298 299 300 Feeding pump Minimum flow at 2000 r.p.m. of camshaft : ≥ 100 l/h Control lever stroke : 2,0 mm Feeding pressure at 2000 rpm of the camshaft : 0,2 bar 76 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED DISASSEMBLY/REASSEMBLY IX Reassembling – Oil level rod - Starting motor - Flywheel – Fan scroll together with the stator – Belt cover - Exhaust manifold – Cooling covers – Fan scroll cover - Muffler - etc.. Complete the engine with the above mentioned details 301 302 303 304 305 306 307 308 309 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 77 IX DISASSEMBLY/REASSEMBLY Min. and max r.p.m. regulation The operations of min. and max r-p.m. must be carried out with a warm engine, as follows: act after unlocking the lock nut, on screw “F” of accelerator lever position so as min. r.p.m. result 1200 and lock again lock nut. loosen the lock nut of screw “G”, gradually accelerate the engine until 4150 r.p.m. are reached and by means of a screw limit accelerator lever stroke in this position and lock the lock nut. F F G 316 78 COMPILER TECO/ATI G 317 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 318 REVISION 00 DATE 15-05-2003 ENDORSED TOOLS DRAWING X DESCRIPTION LOMBARDINI DRAWING CODE LOMBARDINI PART CODE Timing reference tool A.G and Pin for camshaft timing 5900.217 5900.217 + part. 8430.124 + part. 8430.124 8430.124 Pin for camshaft timing Differential box extraction tool COMPILER TECO/ATI 8430.123 8430 123 981075.411 1460.170 Primary gear blocking tool 981075.412 1460.169 Flame protection cover extraction tool 981075.413 1460.168 Flywheel blocking tool 981075.414 1460.172 Bearing extractot diam. 35 mm 981075.415 1460.166 Head blocking tool 981075.416 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 1460.165 ENDORSED 79 X TOOLS DRAWING DESCRIPTION LOMBARDINI DRAWING CODE LOMBARDINI PART CODE Head seal identification tool 981075.417 1460.163 981075.418 1460.162 Flywheel extraction tool Clutch extraction tool 981075.419 1460.181 Flywheel cone extraction tool 981075.420 + 984651.457 1460.180 + 1460.179 Anticipation extraction tool 981075.421 1460.156 984651.457 Engine support tool 422 Maximum load control tool 80 COMPILER TECO/ATI 1460.177 981075.422 981075.423 + 984070.499 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 1460.184 00 DATE 15-05-2003 ENDORSED TOOLS DESCRIPTION DRAWING 981075.424 984620.319 985620.320 Valve plates replacement tools LOMBARDINI DRAWING CODE 981075.424 + 984620.319 + 985620.320 X LOMBARDINI PART CODE 1460.161 + 1460.182 + 1460.183 984651.457 Bearing extractor 981075.425 + 984651.457 1460.178 + 1460.179 Bearing extractor 981075.426 1460.167 Double fork to check the P-NP differential shaft Clutch stop hook 985110.039 1460.173 Buffer handle 985430.007 1460.176 985820.212 1460.159 Punch to install roller box on the primary shaft of the cover (flywheel side) 986290.104 1460.187 Punch for roller box for elbow shaft on clutch side 986290.105 1460.174 Piston insertion spring COMPILER TECO/ATI 1460.158 984980.324 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 81 X TOOLS DRAWING DESCRIPTION LOMBARDINI DRAWING CODE LOMBARDINI PART CODE Punch for roller box for elbow shaft on flywheel side 986290.106 1460.189 Punch for roller box diam35 986290.107 1460.188 Differential bearing punch Punch to install sealing ring on the valve trach 986800.255 986290.109 1460.160 Punch to install sealing rings 986290.110 1460.157 Comparator support to check the play of the engine gear 986782.034 1460.164 986800.254 + 986800.255 1460.186 e 1460.171 Punch to calk the crosspiece 986800.254 82 COMPILER TECO/ATI 1460.175 986290.108 REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED MAIN TORQUE SPECIFICATIONS XI MAIN TORQUE SPECIFICATIONS POSITION Connecting rod cap fixing nut Flywheel fixing screws Clutch – flywheel fixing screws Fan – alternator rotor fixing screws Clutch disk pusher fixing screw Primary ring gear of gear box fixing screw Differential ring gear fixing screws Half crankcases assembly screws Clutch housing fixing screws Clutch cover fixing screws Axle shaft hood flange fixing screws Shift-select lever case fixing screws Shift-select lever case fixing screws Fan volute fixing screws Air shroud cover fixing screws Belt tensioner fixing nut Oil pressure switch Starter motor fixing screws Cylinder head – exaust system fixing screws Guard tile fixing screws Oil termal switch Air shroud fixing screws Cylinder head fixing nuts Timing belt cover fixing screws Cylinder head fixing stud bolt Cam shaft carrier fixing screws Oil pump fixing screws Timing belt gear fixing screw Injection timing fixing screws Injector Injection pump fixing screws Spark plug Feed pump fixing nuts Tappet cover fixing screws Cylinder head exhaust manifold fixing nuts Dipstick tube fixing screw Clamp for starter motor fixing screws Starter motor to clamp fixing nuts Oil duct plugs Injector – injection pump connecting pipe Stator to volute fixing screws Piston cooling valve Plug wire fixing nut Diam. and pitch ( mm ) Torque ( Nm ) M 10x1 M 14x1,5 M 22x1,5 M6 M6 M 14x1,5 M 10x1,25 M8 M6 M6 M6 M6 M8 M8 M6 M 10 M 12x1,5 M6 M8 M6 M 22x1,5 M6 M 10x1.25 M6 M 14x1,5 M8 M 10x1,25 M8 M 24 M8 M 12x1,25 M8 M6 M8 M6 M6 M6 M6 M 26x1,5 M 12x1,5 M5 M7 M5 70 180÷200 120÷140 8 10 120÷140 65÷70 20÷22 8 8 8 8 20÷22 20÷22 8 40÷44 22 20÷22 25÷30 8 45÷50 8 40 Nm + 180° 8 15 20÷22 70÷75 25÷28 60÷80 30 15 20÷22 8 19÷21 8 8 8 8 6 18÷22 4 12 4 M 10 40 Setting up with belt driven alternator Bracket to crankcase fixing screws COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 83 XI TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS DESCRIPTION Diameter x pitch (mm) R ≥ 800 N/mm2 R ≥ 1000 N/mm2 Nm Kgm Nm Kgm 4x0,70 3,6 0,37 5,1 0,52 5x0,80 7 0,72 9,9 6x1,00 12 1,23 7x1,00 19,8 8x1,25 R ≥ 1200 N/mm2 Nm Kgm 6 0,62 1,01 11,9 1,22 17 1,73 20,4 2,08 2,02 27,8 2,84 33 3,40 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 12x1,75 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 84 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED 85 42100 Reggio Emilia – Italia - ITALY Via Cav. del Lavoro Adelmo Lombardini, 2 - Cas. Post. 1074 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.lombardini.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. Data reported in this issue can be modified at any time by Lombardini. Lombardini vorbehält alle Rechte, diese Angabe jederzeit verändern. La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación. 86 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-596 50881 15-05-2003 REVISION 00 DATE 15-05-2003 ENDORSED
* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project
advertisement
© 2021