Manuale Officina LGW 523-627 - lombardini service

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-REGISTRATION OF MODIFICATIONS TO THE DOCUMENTAny modifications to this document must be registered by the drafting body, by completing the following table.DraftingbodyDocumentcodeModelN°EditionRevisionIssue dateReviewdateEndorsedCUSE/ATLO1-5302-351 505637° 6 04-90 15.03.2008- 4 - FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06
CHAPTER INDEX-This manual contains pertinent information regarding the repair of LOMBARDINI water-cooled, indirect injection Dieselengines type LDW 502-602-903-1204-1204/T e LDW 702-1003-1404: updated March 15 th , 2006.CHAPTER INDEX1 GENERAL REMARKS AND SAFETY INFORMATION ................................................................ Pag. 9 - 11GENERAL SAFETY DURING OPERATING PHASES .................................................................................................... 11GENERAL SERVICE MANUAL NOTES ............................................................................................................................ 9GLOSSARY AND TERMINOLOGY ................................................................................................................................... 9SAFETY AND ENVIRONMENTAL IMPACT ....................................................................................................................11SAFETY AND WARNING DECALS ................................................................................................................................. 10SAFETY REGULATIONS ........................................................................................................................................... 10-11WARRANTY CERTIFICATE ............................................................................................................................................... 92 TECHNICAL INFORMATION .................................................................................................................. 12-23MANUFACTURER AND ENGINE IDENTIFICATION ................................................................................................ 14-15OVERALL DIMENSION .............................................................................................................................................. 21-23PERFORMANCE DIAGRAMS .................................................................................................................................... 18-20TECHINICAL SPECIFICATIONS ............................................................................................................................... 16-17TROUBLE SHOOTING ............................................................................................................................................... 12-133 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING .............................................................. 24-27ACEA Regualtions - ACEA Sequences ............................................................................................................................ 25API / MIL Sequence .......................................................................................................................................................... 25COOLANT ......................................................................................................................................................................... 27FUEL SPECIFICATIONS ..................................................................................................................................................27International specifications ............................................................................................................................................... 25LUBRICANT ...................................................................................................................................................................... 25PRESCRIBED LUBRICANT ............................................................................................................................................. 26ROUTINE ENGINE MAINTENANCE ............................................................................................................................... 24SAE Classification ........................................................................................................................................................... 254 DISASSEMBLY / REASSEMBLY ........................................................................................................... 28-65Air filter support ................................................................................................................................................................ 30Air restriction switch ......................................................................................................................................................... 29Alternator/Cooling fan belt drive....................................................................................................................................... 33Big end bearing ................................................................................................................................................................. 58Camshaft journals and housings - Dimensions ............................................................................................................... 47Camshaft lobe measurement ........................................................................................................................................... 47Camshaft timing - Belt Reassembly ................................................................................................................................37Camshaft timing - Belt Tightening and Fastening ........................................................................................................... 38Camshaft timing - Belt tightening tool ............................................................................................................................. 38Camshaft timing pulley - Disassembly/Assembly ........................................................................................................... 37Camshaft timing pulley - Reference marks ..................................................................................................................... 37Camshaft, disassembly .................................................................................................................................................... 46Camshaft, journal and housing measurement ................................................................................................................ 46Central main bearing caps ............................................................................................................................................... 60Check the clearances between the bearings and the journal.......................................................................................... 60Clearances between the bearings and corresponding pins ............................................................................................64CONNECTING ROD ......................................................................................................................................................... 58Connecting rod alignment ................................................................................................................................................ 59Connecting rod with bearings and pin ............................................................................................................................. 58Connecting tod, weight ..................................................................................................................................................... 58Cooling fan ........................................................................................................................................................................ 33Crankcase breather LDW 502 .......................................................................................................................................... 44Crankcase vacuum regulator valve .................................................................................................................................. 43Crankshaft axial clearance ............................................................................................................................................... 61Crankshaft front and back oil seal rings ..........................................................................................................................62FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06- 5 -
Page 1: WORKSHOP MANUALFOCS Engine Seriesco
Page 6 and 7: -Chapter indexCrankshaft timing pul
Page 8 and 9: -Chapter indexSetting of injector a
Page 10 and 11: 1General remarks and safety informa
Page 12 and 13: 2TECHNICAL INFORMATIONTROUBLE SHOOT
Page 14 and 15: 2 Technical informationMANUFACTURER
Page 16 and 17: 2 Technical informationTECHINICAL S
Page 18 and 19: 2 Technical informationPERFORMANCE
Page 20 and 21: 2 Technical informationLDW 702 LDW
Page 22 and 23: 2 Technical informationLDW 1204LDW
Page 24 and 25: 3MAINTENANCE - RECOMMENDED OIL TYPE
Page 26 and 27: 3Maintenance - Recommended oil type
Page 28 and 29: 4DISASSEMBLY / REASSEMBLYRECOMMENDA
Page 30 and 31: 4Disassembly / ReassemblyAir filter
Page 32 and 33: 4Disassembly / ReassemblyVacuum pum
Page 34 and 35: 4Disassembly / ReassemblyFlywheelDa
Page 36 and 37: 4Disassembly / ReassemblyTiming bel
Page 38 and 39: 4Disassembly / ReassemblyCamshaft t
Page 40 and 41: 4Disassembly / ReassemblySPEED GOVE
Page 42 and 43: 4Disassembly / ReassemblyOil pump -
Page 44 and 45: 4Disassembly / ReassemblyCrankcase
Page 46 and 47: 4Disassembly / ReassemblyRocker arm
Page 48 and 49: 4Disassembly / ReassemblyCYLINDER H
Page 50 and 51: 4Disassembly / ReassemblyValve seat
Page 52 and 53: 4Disassembly / ReassemblyOil pan, r
Page 54 and 55:
4Disassembly / ReassemblyPiston, we
Page 56 and 57:
4Disassembly / ReassemblyHead gaske
Page 58 and 59:
4Disassembly / ReassemblyCONNECTING
Page 60 and 61:
4Disassembly / ReassemblyCentral ma
Page 62 and 63:
4Disassembly / ReassemblyShoulder h
Page 64 and 65:
4Disassembly / ReassemblyMain beari
Page 66 and 67:
5TURBOCHARGERTURBO CHARGEROnly the
Page 68 and 69:
6LUBRIFICATION CIRCUITDanger - Atte
Page 70 and 71:
6Lubrification circuitOil pressure
Page 72 and 73:
7COOLANT CIRCUITDanger - Attention-
Page 74 and 75:
8FUEL SYSTEMFuel feeding / injectio
Page 76 and 77:
8Fuel systemPlunger barrel ring nut
Page 78 and 79:
8Fuel systemHIGH PREASSURE HOLEREFE
Page 80 and 81:
8Fuel systemInjection advance contr
Page 82 and 83:
8Fuel systemStatic injection advanc
Page 84 and 85:
9ELECTRIC SYSTEMELECTRIC CONTROL PA
Page 86 and 87:
9Electric SystemElectric starting l
Page 88 and 89:
Page 90 and 91:
Page 92 and 93:
9Electric SystemStarter motor, Bosc
Page 94 and 95:
10SETTINGSSPEED SETTINGSSetting the
Page 96 and 97:
10SettingsPump/injector unit delive
Page 98 and 99:
11STORAGEENGINE STORAGE (NOT INSTAL
Page 100 and 101:
12 TORQUE SPECIFICATIONS AND USE OF
Page 102 and 103:
13SPECIAL TOOLSSPECIAL TOOLS DESCIP
Page 104:
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Manuale Officina LGW 523-627 - lombardini service

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