LOMBARDINI LDW 502 602,LDW 903,LDW 1204,LDW 1204T Workshop M

WORKSHOP MANUAL Focs series engines, code 1-5302-351 SERVICE 1 LDW 502 LDW 602 LDW 903 LDW 1204 LDW 1204/T LDW 702 LDW 1003 LDW 1404 5st Edition COMPILER TECO/ATL REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 ENDORSED DATE 10.06.99

SERVICE 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/ATL REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 ENDORSED DATE 15.11.99 3 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.

REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 DATE 15.11.99 ENDORSED COMPILER TECO/ATI 4 INDEX TROUBLESHOOTING CHART - LDW FOCS SERIES SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS I GENERAL POWER RATINGS FOR LDW-FOCS GENSET SPEC DIESEL ENGINES LDW FOCS SERIES - TECHNICAL SPECIFICATIONS AND CAPACITIES LDW 502-602- 903-1204-1204/T FLUID CAPACITIES (STANDARD) LDW 502-602-903-1204-1204/T LDW FOCS SERIES - TECHNICAL SPECIFICATIONS AND CAPACITIES LDW 702-1003- 1404 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 II DISASSEMBLY / REASSEMBLY 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 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 702-1003- 1404: updated November 15, 1999. Pag. 9 " 10 " 12 " 13 " 14 " 14 " 16 " 16 " 18 " 19 " 20 " 21 " 22 " 23 " 24 " 25 " 26 " 27 " 28 " 28 " 29 " 30 " 25 32 31 32 43 43 43 44 43 35 52 50 51 51 32 33 40 40 55 56 57 56 33 56 INDEX

COMPILER TECO/ATL REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 ENDORSED DATE 15.11.99 5 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 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

REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 DATE 15.11.99 ENDORSED COMPILER TECO/ATI 6 Valve / rocker cover gasket Valve adjustment Valve guide installation guidelines and post installation valve/valve guide specifications Valve guides / valve guide bore Valve recess and seat sealing width Valve removal Valve seats Valve specifications Valve springs Valve stem seal installation Valve timing angles Valve timing confirmation III TURBOCHARGER Turbocharger identification Turbocharger components Turbocharger pressure testing Turbocharger waste gate adjustement-bench method IV LUBRICATION SYSTEM Lubrication system Oil pick-up screen and oil drain back tube Oil pump specification Oil filter Oil pressure testing V COOLING SYSTEM LDW-FOCS cooling system schematic Cooling system pressure check/radiator cap inspection Coolant pump details Thermostat VI 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) 40 41 45 45 46 44 46 45 45 44 37 37 " 58 58 58 58 59 " 60 60 61 61 62 62 " 63 63 64 64 64 " 65 69 69 71 72 73 65 73 65 67 65 65 65 70 71 71 72 71 68 68 73 73 70 68 70

COMPILER TECO/ATL REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 ENDORSED DATE 15.11.99 7 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 VII ELECTRICAL SYSTEM 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 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 IX STORAGE Storage Storage - 1 to 6 months Storage - in excess of 6 months Preparing the engine for use after storage 70 69 68 69 " 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 " 84 85 84 84 85 85 84 84 " 86 86 86 86 86

REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 DATE 15.11.99 ENDORSED COMPILER TECO/ATI 8 NOTE

COMPILER TECO/ATL REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 ENDORSED DATE 15.11.99 9 TROUBLESHOOTING CHART- LDW FOCS SERIES POSSIBLE CAUSE 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 knocks Engine will not crank Engine does not start Engine starts, but stops Poor acceleration White smoke Unsteady RPM Black smoke Blue smoke Low oil pressure Oil level rising Excessive oil consumption Wet exhaust Overheating TROUBLESHOOTING CHART- LDW FOCS SERIES SYMPTOM · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · ·· · ·· · ·· · ·· · · · · · · · · · · · · · ·· · ·· · · · · · · · · · · ·· ·· · · ·· · ·· · · · ·· · · · · · · · · · · · · ···· ··· ··· ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · ·· ··· · ·

REG. CODE 1-5302-351 MODEL N° 50563 DATE OF ISSUE 04.90 REVISION 04 DATE 15.11.99 ENDORSED COMPILER TECO/ATI 10 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 DANGER SAFETY AND W ARNING DECALS CAUTION 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. SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS

LOMBARDINI LDW 502 602,LDW 903,LDW 1204,LDW 1204T Workshop M

You're Reading a Preview

Recently Viewed