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LDW502
Lombardini LDW502 User Manual
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SERVICE MANUAL
code 1.5302.727
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 General Remarks and Safety
5
Purpose of the Manual
5
Using this Manual
5
Manufacturer and Engine Identification
5
Glossary and Terminology
6
Warranty Clauses
6
General Safety Regulations
6
General Safety During Operating Phases
6
Safety and Environmental Impact
7
Precautions When the Engine Is Installed on the Machine
7
Precautions When the Engine Is on the Rotating Stand
7
2 Technical Information
9
General Description of the Engine
9
Technical Specifications
10
Characteristic Curve Diagrams
12
Alternator Load Curve Diagrams
13
Lubricants
14
SAE Classification
14
API/MIL Sequences
14
ACEA Standards
14
Recommended Oil
14
Operating Principle for Lubrication
15
Operating Principle for Cooling
15
Operating Principle for Fuel Injection
16
Wiring Diagram
17
Special Tools and Equipment for Maintenance
19
Table of Tightening Torques
19
Table of Sealants
21
Routine Engine Maintenance
21
3 Malfunctions
23
Looking for Malfunctions
23
4 Storing the Engine
25
Handling and Lifting
25
Storing the Engine (Uninstalled)
25
Storing the Engine (Installed)
25
Protective Treatment
26
Preparing the Engine for Operation (Uninstalled)
26
Preparing the Engine for Operation (Installed)
27
5 Removing the Assemblies
29
Recommendations for Removing the Assemblies
29
Removing the Exhaust and Intake Manifolds
29
Disassembling the Intake Manifold
29
Disassembling the Exhaust Manifold
30
Removing the Cooling Fan Belt Drive
30
Disassembling the Cooling Fan Belt (with External Alternator)
31
Disassembling the Cooling Fan Belt (with Internal Alternator)
31
Removing the Timing Belt Drive
31
Disassembling the Timing Belt Casing
31
Disassembling the Timing Belt
32
Disassembling the Pulleys (Camshaft and Crankshaft)
32
Removing the Cylinder Head
33
Disassembling the Rocker Arm Cover
33
Disassembling the Rocker Arms
33
Disassembling the Fuel Pump
33
Disassembling the Injection-Pumps
34
Disassembling the Precombustion Chamber
34
Disassembling the Speed Governor and Flow Limiter
35
Disassembling the Camshaft
36
Disassembling the Cylinder Head
36
Removing the Crank Gear and Crankcase
36
Disassembling the Flywheel
36
Disassembling the Oil Pump
37
Disassembling the Crankcase and Crankshaft
38
Disassembling the Connecting Rod and Piston
39
Disassembling the Valves
39
Disassembling the Piston
40
6 Overhauls and Tuning
41
Recommendations for Overhauls and Tuning
41
Shaft Seals
41
O-Rings
41
Bearings
41
Overhauling the Crank Gears and Crankcase
41
Overhauling Cylinders and Pistons
41
Dimensional Check and Overhaul of Cylinders
42
Dimensional Check and Overhaul of Pistons
42
Dimensional Check of Sealing Rings
43
Dimensional Check and Overhaul of Crankshaft
44
Dimensional Check and Overhaul of Connecting Rods
45
Checking Parallelism of the Connecting Rod Axes
45
Checking and Overhauling the Fuel Pump
46
Important
46
Overhauling the Decanting Device
47
Overhaul of Cylinder Head and Related Components
47
Checking and Overhauling the Cylinder Head
47
Checking and Overhauling the Rocker Arm Pin
48
Checking and Replacing the Camshaft
49
Checking and Replacing the Fuel Pump Drive Rod
50
Checking and Overhauling the Valves
51
Important
51
Adjusting Valve-Rocker Arm Clearance
52
Checking Clearance Volume
52
Calibrating the Injector
53
Checking and Overhauling the Speed Governor
53
Checking Timing Belt Rating
54
Valve Adjustments
54
Diagram of Timing Belt Rates
55
Adjusting Static Injection Timing
55
Important
57
Balancing Injection-Pump Delivery
58
Important
58
Important
59
Adjusting Minimum and Maximum Idle Speed Rpms
60
Adjusting Injection Delivery
60
Adjusting Injection Delivery (Without Dyno Brake)
60
Adjusting Injection Delivery (with Dyno Brake)
61
Checking Oil Pressure
61
7 Installation of Assemblies
63
Recommendations for Installing the Assemblies
63
Pre-Assembly of Sealing Rings-Pistons
63
Pre-Assembly of Connecting Rods - Pistons
64
Installing Valves
64
Assembling the Valves
64
Installation of Crank Gear and Crankcase
65
Installing Piston/Connecting Rod - Engine Block
65
Assembling the Crankshaft
66
Assembling the Crankcase
66
Measuring Crankshaft Axial Clearance
67
Assembling the Crankshaft Flange (Flywheel Side)
67
Installing the Oil Pump
68
Assembling the Flywheel
69
Installation of Cylinder Head and Components
70
Assembling the Precombustion Chamber
70
Assembling the Cylinder Head
71
Assembling the Camshaft
71
Assembling the Speed Governor and Flow Limiter
72
Assembling Injection-Pumps
73
Assembling the Mechanical Fuel Pump
74
Assembling the Rocker Arms
75
Assembling the Rocker Arm Cover
75
Installing the Timing Belt Drive
76
Assembling the Timing Belt Pulley
76
Assembling the Timing Belt
76
Assembling the Belt Drive Cover
77
Installation of the Cooling Fan Belt Drive
78
Assembling the Fan Belt Drive Pulleys
78
Assembling the Fan Belt Drive
79
Assembling the Cooling Fan
80
Installing Intake and Exhaust Manifolds
80
Assembling the Exhaust Manifold
80
Assembling the Intake Manifold
80
8 Replacing Parts
83
Recommendations for Replacing Parts
83
Replacing the Alternator - Fan Belt
83
Important
84
Replacing the Timing Belt
85
Replacing the Oil Filter
85
Replacing the Air Filter
86
Replacing the Alternator
87
Replacing the Starter Motor
87
Replacing the Flywheel Ring Gear
88
Replacing the Coolant Thermostat
88
Replacing the Coolant Pump
89
Replacing the Thermostatic Valve
89
Replacing the Negative-Pressure Vent Valve
90
Replacing the Preheating Glow Plugs
90
Replacing Injector Pump Parts
91
Pumping Element Replacement
91
Important
92
Replacing the Nozzle-Injector
93
Replacing the Cooling Fan Support
93
Index
95
4
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Lombardini LDW502 Specifications
General
Engine Type
Diesel
Number of Cylinders
2
Fuel System
Direct injection
Displacement
505 cm³
Starting System
Electric
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