Lombardini FOCS Engine Series Service Repair Manual
Description:
Lombardini FOCS Engine Series Service Repair Manual
Every attempt has been made to present within this service manual, accurate and up to date technical information.
However, development on the LOMBARDINI series is continuous.
Therefore, the information within this manual is subject to change without notice and without obligation.
The information contained within this service manual is the sole property of LOMBARDINI.
As such, no reproduction or replication in whole or part is allowed without the express written permission of LOMBARDINI.
Information presented within this manual assumes the following:
1 – The person or people performing service work on LOMBARDINI series engines is properly trained and equipped to safely and professionally perform the subject operation;
2 – The person or people performing service work on LOMBARDINI series engines possesses adequate hand and LOMBARDINI special tools to safely and professionally perform the subject service operation;
3 – The person or people performing service work on LOMBARDINI series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand.
This manual was written by the manufacturer to provide technical and operating information to authorised LOMBARDINI after-sales service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations.
As well as employing good operating techniques and observing the right timing for operations, operators must read the information very carefully and comply with it scrupulously.
Time spent reading this information will help to prevent health and safety risks and financial damage. Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases.
Table of Contents:
Lombardini FOCS Engine Series Service Repair Manual
1 GENERAL REMARKS AND SAFETY INFORMATION Pag 9 – 11
GENERAL SAFETY DURING OPERATING PHASES 11
GENERAL SERVICE MANUAL NOTES 9
GLOSSARY AND TERMINOLOGY 9
SAFETY AND ENVIRONMENTAL IMPACT 11
SAFETY AND WARNING DECALS 10
SAFETY REGULATIONS 10-11
WARRANTY CERTIFICATE9
2 TECHNICAL INFORMATION 12-23
MANUFACTURER AND ENGINE IDENTIFICATION 14-15
OVERALL DIMENSION 21-23
PERFORMANCE DIAGRAMS 18-20
TECHINICAL SPECIFICATIONS 16-17
TROUBLE SHOOTING 12-13
3 MAINTENANCE – RECOMMENDED OIL TYPE – REFILLING 24-27
ACEA Regualtions – ACEA Sequences 25
API / MIL Sequence 25
COOLANT 27
FUEL SPECIFICATIONS 27
International specifications 25
LUBRICANT 25
PRESCRIBED LUBRICANT 26
ROUTINE ENGINE MAINTENANCE 24
SAE Classification 25
4 DISASSEMBLY / REASSEMBLY 28-65
Air filter support 30
Air restriction switch 29
Alternator/Cooling fan belt drive 33
Big end bearing 58
Camshaft journals and housings – Dimensions 47
Camshaft lobe measurement 47
Camshaft timing – Belt Reassembly 37
Camshaft timing – Belt Tightening and Fastening 38
Camshaft timing – Belt tightening tool 38
Camshaft timing pulley – Disassembly/Assembly 37
Camshaft timing pulley – Reference marks 37
Camshaft, disassembly 46
Camshaft, journal and housing measurement 46
Central main bearing caps 60
Check the clearances between the bearings and the journal 60
Clearances between the bearings and corresponding pins 64
CONNECTING ROD 58
Connecting rod alignment 59
Connecting rod with bearings and pin 58
Connecting tod, weight 58
Cooling fan 33
Crankcase breather LDW 502 44
Crankcase vacuum regulator valve 43
Crankshaft axial clearance 61
Crankshaft front and back oil seal rings 62
Crankshaft timing pulley 36
Crankshaft, check journals and crank63
Crankshaft, lubrication lines 63
Cylinder head assembly 57
Cylinder head tightening procedure LDW 1204-1204/T-1404 57
Cylinder head tightening procedure LDW 502-602-702-903-1003 57
CYLINDER HEAD, removal 48
Cylinder roughness 59
Cylinder, class 59
CYLINDERS 59
Driving pulley 34
Dry type air filter 29
EGR Circuit 30-31
Exhaust maniflod 32
Flywheel 34
Fuel rail 44
Fuel tank (optional) 33
Governor springs 40
Governor springs for Gensets 40
Head gasket 56
Hydraulic pump drive 65
Injection pump control rod 44
Intake / Exhaust / Injection camshaft lobe height – LDW 903 47
Intake manifold – Remote air filter 30
Journal and connecting rod pins diameters 63
Main bearings and connecting rod big ends diameters 64
Oil bath air cleaner ( on request ) 29
Oil pan, removal 52
Oil pump – disassembly 42
Oil pump – Reassembly 42
PISTON 52
Piston clearance 55
Piston coolant nozzles 61
Piston ring, Clearance between grooves 54
Piston ring, mounting order 55
Piston rings – End gaps 54
Piston, assembly 55
Piston, class 53
Piston, disassembly and inspection 53
Piston, weight 54
Pre-combustion chamber 51
Pre-combustion chamber ring nut removal 51
Pre-combustion chamber, installation 51
Pre-combustion chamber, removal 51
Pump/injector unit – Disassembly 45
Pump/injector unit – non-return valve 45
Rear and forward main bearing caps 60
RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING 28
RECOMMENDATIONS FOR OVERHAULS AND TUNING 28
Return pulley 34
Ringfeder-type rings on LDW 1204-1204/T-1404 35
Ringfeder-type rings on LDW 1204-1204/T-1404 – Assembly 35
Rocker arm assembly 45
Rocker arm cover42
Rocker arm cover gasket 43
Rocker arm pivot, dismounting and remounting 46
Shoulder half rings 61
Shoulder half rings, oversized elements 62
Speed governor 40
Speed governor – Limiting speed governor 41
Speed governor – Reassembly 41
Speed governor components 40
Stop pin rings, dismounting and remounting52
Third drive, components 65
Tightening pulley 36
Timing belt / Timing pulley arrangement 36
Timing belt cover 35
Timing belt removal 36
Vacuum pump and vacuum pump flange 33
Valve / Rocker arm clearance 44
Valve guide insertion 49
Valve guides and valve guide housings 49
Valve recess and seat sealing width 50
Valve seats and housings – Dimensions 50
Valve springs 48
Valve stem sealing rings – Reassembly 48
Valve timing – Angles 39
Valve timing check 38
Valve, specifications 49
Valves 48
5 TURBOCHARGER 66-67
TURBO CHARGER66
Turbocharger components 66
Turbocharger pressure testing 66
Turbocharger west gate adjustment – Regolazione corsa asta comando valvola ” Waste gate ” 67
6 LUBRIFICATION CIRCUIT 68-71
Internal oil filter and oil sump return pipe 69
LUBRIFICATION CIRCUIT 68
Oil filter cartridge 70
Oil pressure check 70
Oil pressure regulating valve 70
Oil pump 69
Oil pump, clearance between rotors 69
7 COOLANT CIRCUIT 72-73
COOLANT CIRCUIT 72
Coolant circulation pump, components 73
Radiator and compensation, check and seal tank cap 73
Thermostatic valve73
8 FUEL SYSTEM 74-83
Closing the oilhole 82
Fuel feeding / injection circuit 74
Fuel filter detached from the tank (on request) 74
Fuel lift pump 74
Fuel pump drive rod projection 74
Injection advance control and regulation 80
Injection advance for currently used pump/injector unit 80
Injection advance references on timing belt protector 81
Injection pump assembly/disassembly 76
Injection pumps delivery balancing 83
Injector, nozzle projection 79
Injector, setting (old type) 79
Injector, spark arrester 79
Instrument connection 83
Plunger barrel ring nut assembly/disassembly 76
Plunger injection pump reassembly 76
Preliminary steps to pump/injector unit delivery balancing test 82
Pump/injector unit 75
Pump/injector unit seno 6590285 control data 77-78
Pump/injector unit, components 75
Pumping element 77
Pumping element (old-type injection pump) 77
Setting of injector according to current pump/injector unit 79
Static injection advance regulation 82
Static injection advance tuning 81
TDC (Top Dead Center) references 81
Test head B assembly 82
Tester and special coupling for injection advance control (Old-type injection pump) 81
9 ELECTRIC SYSTEM 84-93
Alternator battery charger curve 12V 20A 89
Alternator battery charger curve 12V 30A 89
Alternator, Iskra 14V 33A 85
Alternator, Iskra 14V 33A – Performance Curve 85
Alternator, Marelli type AA 125 R 14V 45A 87
Alternator, Marelli type AA 125 R 14V 45A – Performance Curve 87
Coolant high temperature lamp sensor93
ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP 84
Electric starting layout (12V) with flywheel alternator 90
Electric starting layout (12V) with Iskra alternator 14V 33A 86
Electric starting layout (12V) with Marelli type AA 125 R 14V 45A alternator 88
Flywheel Alternator 88
Oil pressure switch 93
Pre-heating glow plug 92
Pre-heating glow plug control unit with coolant temperature sensor 92
STARTER MOTOR – Bosch DW 12V 1,1 KW91
Starter motor, Bosch 12V 1,6 Kw 91
Starter motor, Bosch DW 12V 1,1 KW – Performance Curve91
Starter motor, Bosch DW 12V 1,6 KW – Performance Curve92
Temperature sensor for control unit 93
Voltage regulator connections 90
10 SETTINGS 94-97
EGR calibration 97
Injection pump flow limiter and standard engine torque gearing device 95
Pump injection delivery standard setting without dynamometric brake 94
Pump/injector unit delivery setting with braked engine 96
Pump/injector unit timing with speed governor 95
Required settings (as most commonly applies) 96
Setting the idle maximum (standard) 94
Setting the idle minimum (standard) 94
Setting the stop 95
SPEED SETTINGS 94
11 STORAGE 98-99
ENGINE STORAGE (NOT INSTALLED) 98
PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT 99
PROTECTIVE TREATMENT 98
12 TORQUE SPECIFICATIONS AND USE OF SEALANT 100-101
Table of tightening torques for standard screws (coarse thread) 101
Table of tightening torques for standard screws (fine thread) 101
Table of tightening torques for the main components100
13 SPECIAL TOOLS 102
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Please Note:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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