Manuale Officina LGW 523-627 - lombardini service

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-Chapter indexSetting of injector according to current pump/injector unit ............................................................................................. 79Static injection advance regulation .................................................................................................................................. 82Static injection advance tuning ........................................................................................................................................ 81TDC (Top Dead Center) references ................................................................................................................................. 81Test head B assembly ...................................................................................................................................................... 82Tester and special coupling for injection advance control (Old-type injection pump) ................................................... 819 ELECTRIC SYSTEM .............................................................................................................................. 84-93Alternator battery charger curve 12V 20A ....................................................................................................................... 89Alternator battery charger curve 12V 30A ....................................................................................................................... 89Alternator, Iskra 14V 33A ................................................................................................................................................ 85Alternator, Iskra 14V 33A - Performance Curve ............................................................................................................. 85Alternator, Marelli type AA 125 R 14V 45A ..................................................................................................................... 87Alternator, Marelli type AA 125 R 14V 45A - Performance Curve .................................................................................. 87Coolant high temperature lamp sensor............................................................................................................................ 93ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP ............................................................................. 84Electric starting layout (12V) with flywheel alternator ..................................................................................................... 90Electric starting layout (12V) with Iskra alternator 14V 33A .......................................................................................... 86Electric starting layout (12V) with Marelli type AA 125 R 14V 45A alternator ............................................................... 88Flywheel Alternator ........................................................................................................................................................... 88Oil pressure switch ........................................................................................................................................................... 93Pre-heating glow plug .......................................................................................................................................................92Pre-heating glow plug control unit with coolant temperature sensor ............................................................................. 92STARTER MOTOR - Bosch DW 12V 1,1 KW ................................................................................................................ 91Starter motor, Bosch 12V 1,6 Kw .................................................................................................................................... 91Starter motor, Bosch DW 12V 1,1 KW - Performance Curve........................................................................................ 91Starter motor, Bosch DW 12V 1,6 KW - Performance Curve........................................................................................ 92Temperature sensor for control unit ................................................................................................................................. 93Voltage regulator connections .......................................................................................................................................... 9010 SETTINGS ............................................................................................................................................... 94-97E.G.R. calibration .............................................................................................................................................................97Injection pump flow limiter and standard engine torque gearing device ........................................................................ 95Pump injection delivery standard setting without dynamometric brake ......................................................................... 94Pump/injector unit delivery setting with braked engine ................................................................................................... 96Pump/injector unit timing with speed governor ............................................................................................................... 95Required settings (as most commonly applies) ..............................................................................................................96Setting the idle maximum (standard) ............................................................................................................................... 94Setting the idle minimum (standard) ................................................................................................................................94Setting the stop ................................................................................................................................................................. 95SPEED SETTINGS ........................................................................................................................................................... 9411 STORAGE ............................................................................................................................................... 98-99ENGINE STORAGE (NOT INSTALLED) ......................................................................................................................... 98PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT ................................................. 99PROTECTIVE TREATMENT ............................................................................................................................................9812 TORQUE SPECIFICATIONS AND USE OF SEALANT ........................................................... 100-101Table of tightening torques for standard screws (coarse thread) .................................................................................101Table of tightening torques for standard screws (fine thread) ......................................................................................101Table of tightening torques for the main components ...................................................................................................10013 SPECIAL TOOLS ....................................................................................................................................... 102- 8 - FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06
GENERAL REMARKS AND SAFETY INFORMATION1WARRANTY CERTIFICATE- The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24 months fromthe date of delivery to the first end user.- For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed within thesetting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned period (24 months) isnot expired.- If no hour-meter is fitted , 12 working hours per calendar day will be considered.- For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling system,sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above mentioned period(24 months) is not expired.- For correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the documentationsupplied with each engine.- To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be carried outby qualified personnel only.- The list of the Lombardini authorized dealers is reported in the “Service” booklet, supplied with each engine.- Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump), filteringsystem, turbo-charged models, will require special written warranty agreements.- Within the above stated periods Lombardini Srl directly or through its authorized network will repair and/or replace free ofcharge any own part or component that, upon examination by Lombardini or by an authorized Lombardini agent, is found tobe defective in conformity, workmanship or materials.- Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine use orfrom both the total or partial impossibility of use, is excluded.- The repair or replacement of any component will not extend or renew the warranty period.Lombardini warranty obligations here above described will be cancelled if:- Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respectedand altered.- Lombardini engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied witheach engine.- Any seal affixed to the engine by Lombardini has been tampered with or removed.- Spare parts used are not original Lombardini.- Feeding and injection systems are damaged by unauthorized or poor quality fuel types.- Electrical system failure is due to components, connected to this system, which are not supplied or installed by Lombardini.- Engines have been disassembled, repaired or altered by any part other than an authorized Lombardini agent.- Following expiration of the above stated warranty periods and working hours, Lombardini will have no further responsibilityfor warranty and will consider its here above mentioned obligations for warranty complete.- Any warranty request related to a non-conformity of the product must be addressed to the Lombardini Srl <strong>service</strong> agents.GENERAL SERVICE MANUAL NOTES1 - Use only genuine Lombardini repair parts.Failure to use genuine Lombardini parts could result in sub-standard performance and low longevity.2 - All data presented are in metric format. That is, dimensions are presented in millimeters (mm), torque is presented inNewton-meters (Nm), weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) andpressure is presented in barometric units (bar).GLOSSARY AND TERMINOLOGYFor clarity, here are the definitions of a number of terms used recurrently in the manual.- Cylinder number one: is the timing belt side piston .- Rotation direction: anticlockwise «viewed from the flywheel side of the engine».FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06- 9 -
Page 1: WORKSHOP MANUALFOCS Engine Seriesco
Page 4 and 5: -REGISTRATION OF MODIFICATIONS TO T
Page 6 and 7: -Chapter indexCrankshaft timing pul
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
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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
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10SETTINGSSPEED SETTINGSSetting the
Page 96 and 97:
10SettingsPump/injector unit delive
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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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