OM Pimespo LDW 2204T CHD ENGINE FOR FORK LIFT TRUCKS REPAIR Manual

LDW 2204/T CHD ENGINE FOR FORK LIFT TRUCKS

REPAIR RULES

Edited by SAT Documentation Service Lainate (MI) Edition July 2002 Code: 60424141 – English

The manufacturer reserves the right to make changes to the types herein described for technical or commercial reasons, without any obligation whatsoever of immediate updating of this manual.

OM CARRELLI ELEVATORI S.p.A. Customer Service – Viale A. De Gasperi, 7 – 20020 LAINATE - MILANO

Series LDW 2204/T Motor Table of Contents

General Table of Contents of the Workshop Manual General Rules

Page 1

Avoiding Accidents Safety Precautions Electric System Hydraulic System Disconnections and Connections

Page 1 Page 1 Page 4 Page 5 Page 5

Overall Dimensions

Page 1.1

Specifications

Page 2.1

Troubleshooting

Page 3.1

Performance Equipment Power Characteristic Curves

Page 2.1 Page 2.1 Page 2.2

Probable Causes and Troubleshooting

Page 3.1

Engine Identification Plate

Page 4.1

Basic Condition for Intervention Optimization

Page 5.1

Driving Shaft

Page 6.1

Driving Shaft Lubrication Lines Main Journal and Crank Pin Diameter Check Inside Diameters of the Crankshaft and Connecting Rod Big End Bearings Timing System Control Gear

Page 6.1 Page 6.1

Cylinder Block Cleaning

Page 7.1

Cylinder-Piston Fit Inspection

Page 8.1

Cylinders Cylinder Roughness Piston Class Piston Weight Piston Rings – Centre-to-Centre Distance Piston Rings – Clearance between Slots Piston Rings – Order of Assembly Edition July 2002 Revision July 2002

General Table of Contents

Page 6.3 Page 6.4

Page 8.1 Page 8.3 Page 8.3 Page 8.5 Page 8.5 Page 8.6 Page 8.6

Page 1

Series LDW 2204/T Motor Table of Contents

Connecting Rod

Page 9.1

Dimensional Sizes of the Connecting Rod complete with Bearings and Piston Pin Connecting Rod Alignment Connecting Rod Weight

Page 9.1 Page 9.2 Page 9.2

Piston Assembly

Page 10.1

Connecting Rod and Piston Weight

Page 11.1

Piston Cooling Spray Nozzle

Page 12.1

Shoulder Half Rings

Page 13.1

Shoulder Half Rings and Oversizes

Page 13.3

Driving Shaft Assembly

Page 14.1

Crankshaft Bearing Positioning Fitting in of the Driving Shaft Rear and Front Main Bearings Central Main Bearings Inspection of the Driving Shaft End Float

Page 14.1 Page 14.2 Page 14.3 Page 14.6 Page 14.10

Piston Positioning

Page 15.1

Fitting in of the Oil Suction Pipe

Page 16.1

Camshaft

Page 17.1

Fitting of Pistons in Liners Connecting Rod Big End Closing

Page 15.1 Page 15.3

Camshaft Bush Inside Diameter Check Camshaft Support Diameter Check Camshaft Bush Replacement Dimensional Check of Cams Camshaft Positioning Inspection of the Camshaft Radial and End Float

Page 17.1 Page 17.2 Page 17.3 Page 17.4 Page 17.6 Page 17.9

Idling Gear Pin Positioning

Page 18.1

Pump Control Rod Assembly

Page 19.1

Injection Pump Control Tappets

Page 20.1

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General Table of Contents

Page 2

Series LDW 2204/T Motor Table of Contents

Oil Pressure-Regulating valve

Page 21.1

Timing Cover Assembly

Page 22.1

Timing System

Page 23.1

Injection Pump Delivery Control Fork Adjustment Pumping Element Control Fork Assembly Centrifugal Flyball Governor Assembly Timing Phase Middle Gear and Hub Timing Phasing without Considering the References Timing Phase Control

Page 23.1 Page 23.2 Page 23.7 Page 23.10 Page 23.12 Page 23.14 Page 23.15

Timing Cover

Page 24.1

Lubrication Circuit

Page 25.1

Oil Pump

Page 25.2

Cooling System

Page 26.1

Coolant Circulation Pump

Page 26.2

Motor Oil Pressure Switch

Page 27.1

Thermostat

Page 28.1

Oil Filter Support with Heat Exchanger

Page 29.1

Alternator Support

Page 30.1

Accelerator Control Assembly

Page 31.1

Hydraulic Tappets

Page 32.1

Driving Pulley

Page 33.1

Fuel Pump

Page 34.1

Assembly of the Hydraulic Tappets Positioning of the Hydraulic Tappets

Edition July 2002 Revision July 2002

Page 32.1 Page 32.3

General Table of Contents

Page 3

Series LDW 2204/T Motor Table of Contents

Flywheel Bell Housing

Page 35.1

Driving Shaft Gasket on Flywheel Side

Page 36.1

Flywheel

Page 37.1

Flywheel Positioning

Page 37.1

Starter

Page 38.1

Head

Page 39.1

Precombustion Chamber Valve Seats and Housings Valve Guides and Housings Valve Guide Assembly Valves Valve Embedding and Bearing Surfaces of Seats Oil Seal Ring in the Valve Guide Valve Assembly Spring Check Half Cones

Page 39.1 Page 39.5 Page 39.6 Page 39.7 Page 39.8 Page39.9 Page 39.9 Page 39.10 Page 39.13 Page 39.14

Head Gasket

Page 40.1

Piston Clearance Volume Inspection Determining the Thickness of the Head Gasket Positioning of the Gasket Positioning of the Head

Page 40.1 Page 40.2 Page 40.3 Page 40.4

Tightening of the Head

Page 41.1

Valve Control Tappets

Page 42.1

Transmission Rods Rocker Arm Pin Assembly

Page 42.2 Page 42.4

Exhaust Manifold

Page 43.1

Feeding / Injection Circuit

Page 44.1

Injector Assembly Calibration of the Injectors Fireproof Partition Assembly of the Injectors

Edition July 2002 Revision July 2002

Page 44.2 Page 44.6 Page 44.7 Page 44.7

General Table of Contents

Page 4

Series LDW 2204/T Motor Table of Contents

Injection Pump

Page 45.1

Installing the Thermostat Unit

Page 46.1

Placing the Oil Dipstick Guide Pipe and the Fuel Stop Solenoid Valve

Page 47.1

Injection Pump Assembly Pumping Element Installing the Pumps on the Engine

Page 45.2 Page 45.6 Page 45.8

Check of Advanced Injection Timing as regards the TDC

Page 48.1

Adjustment of Advanced Injection Timing

Page 48.9

Rocker Arm Cap

Page 49.1

Intake Manifold

Page 50.1

Oil Vapour Recovery Line

Page 51.1

Multistage Centrifugal Blower

Page 52.1

Pre-Heating Glow Plugs

Page 53.1

Assembly of the Diesel Oil Thrust Pipes

Page 54.1

Anti-Supplement Device

Page 55.1

Oil Sump

Page 56.1

Alternator Assembly

Page 57.1

Pipe Assembly

Page 58.1

Pressure Relief Valve

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Page 49.2

General Table of Contents

Page 5

Series LDW 2204/T Motor Table of Contents

Calibrations

Page 59.1

Tool for the Injection Pump Delivery Trimming Injection Pump Delivery Trimming Calibration of the Stroke Adjustment Actuator of the “Wastegate” Valve Control Rod Test of the Multistage Centrifugal Blower Adjustment of Idling Speed (Standard) Adjustment of Maximum Speed (Standard) Standard Adjustment of the Brakeless Injection Pump Delivery Limiting Device of the Injection Pump Delivery and Torque Trimmer Anti-Supplement Device Adjustment of the Anti-Supplement Device

Page 59.1 Page 59.2

Expansion Tank and Plug

Page 60.1

Radiator Tightness Check

Page 61.1

Oil Pressure Check

Page 62.1

Operating Features

Page 63.1

Page 59.7 Page 59.8 Page 59.9 Pag.59.10 Page 59.11 Page 59.13 Page 59.14 Page 59.15

Fuel Filter Oil Filter Cartridge Alternator Starter Control Unit Features of Pre-Heating Time

Page 63.1 Page 63.2 Page 63.3 Page 63.5 Page 63.6 Page 63.7

Special Equipment

Page 64.1

Tool designed to compress the Valve Springs

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General Table of Contents

Page 64.2

Page 6

Series LDW 2204/T Engine General Rules

General Rules Avoiding Accidents Most accidents that take place in workshops are caused by the noncompliance with some simple and basic care and safety rules. That is why in most cases, they could be avoided: their probable causes should be envisaged and, therefore, caution and care are required during operation.

It is impossible to fully exclude all possible accidents for any kind of equipment, however well-designed and well-manufactured it may be.

A careful and wise mechanic is the best guarantee against accidents.

The scrupulous compliance with a single and simple safety rule should be more than enough to avoid many serious accidents.

Safety Precautions General Carefully follow all maintenance and repair procedures.

Warning!

Never perform any cleaning, lubrication or maintenance operation when the battery is connected, unless otherwise prescribed.

Do not wear rings, wrist-watches, loosen or unlaced garments, such as, for instance, ties, torn clothes, scarves, unbuttoned jackets or unzipped sweaters that may get entangled in moving parts. We recommend, instead, to wear clothing items that are approved for accidentprevention purposes, for instance: hard hats, non-slip shoes, gloves, safety goggles.

Never perform any maintenance operation on the equipment when the operator is sitting on its seat, unless in the event of skilful operators aiding with the operation to be performed.

Never operate the machine nor use its equipment from a position other than the proper driving position.

Edition July 2002 Revision July 2002

General Rules

Page 1

Series LDW 2204/T Engine General Rules

Make sure that there is no more pressure in hydraulic circuits before removing either plugs or covers. Please refer to the instructions supplied on the subject in this manual.

All maintenance operations should be carried out with the utmost care and attention.

All service stairs and platforms, which are used in the workshop or on site, should be built according with accident-prevention standards in force.

Label all controls to indicate that an operation is in progress.

Lock the machine and any other equipment that is to be lifted.

Do not check nor top up the battery while smoking, as involved fluids are inflammable.

Brakes are non-working, when they are manually released in the event of maintenance operations: in these cases, it is necessary to keep on controlling the equipment through proper locking or similar devices.

In order to transport damaged equipment, use a tow or a trailer with lowered full load, if available.

In order to load or unload the equipment on/from a means of transport, prefer a flat area offering a firm support to the wheels of the trailer or truck. Firmly fasten the equipment to the loading platform of the truck or of the trailer and lock its wheels.

As for electric heaters, battery chargers and similar devices, use only current auxiliary power supply sources having a sound earth connection so as to avoid any electric shock.

If you should lift or transport heavy parts, use hoists and similar devices having a suitable capacity and keep at a distance all close-by persons.

Watch out at all close-by persons.

Never use petrol, gas oil or other inflammable fluids, such as detergents; use instead non-inflammable and non-toxic commercial solvents.

When using compressed air to clean small parts, protect your eyes with side-protected goggles.

Limit the pressure to the maximum value set out according to local and national rules in force.

Do not smoke, do not use naked flames and do not cause sparks in the surrounding area, when you are handling easily flammable materials.

Do not use flames as lighting means, when you are performing an operation or you are looking for “leakages” from the equipment.

Leave all guards at their proper place when the equipment is working.

Do not leave the equipment unattended when its members are moving.

Do not leave the driving position, if you have not previously applied the hand brake.

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General Rules

Page 2

Series LDW 2204/T Engine General Rules

Remove the start-up key. Should a member be jammed, release it only when the motor is stopped.

Move with the utmost care, when you are carrying out works under, on or close by the equipment. Put on the prescribed safety garments: hard hats, goggles and safety boots.

In the event of an operation outside the workshop, preferably transport the equipment on a flat ground and lock it.

In the event that the truck cannot be transferred to the designated working area and, therefore, an on-site operation is required, before beginning to work, take care of marking the boundary of the truck surrounding area by means of posts and of chains/strips in order to indicate that works are in progress.

When an operation on a slope cannot be avoided, previously lock the equipment and shift it to a level area as soon as it is possible with a reliable safety margin.

Beware of crushed and bended chains or ropes: do not use them to lift or to pull. Always put safety gloves on in order to handle them.

Chains should always be firmly fastened: make sure that they are fastened strongly enough as to support the expected load. No one should stand close to the junction, to the chains or to the ropes to be pulled.

The area where maintenance operations are carried out should always be kept clean and dry.

Immediately clean and dry any water pool or grease spot.

Do not heap up rags that are soaked with grease or oil: they could cause fires. Always put them in a closed metallic box.

Before starting up the equipment, check, adjust and lock the operator’s seat.

Make sure that nobody is close to the area of operation of the machine or of the equipment.

Do not bring in your pockets objects that can fall, when unseen, in the open compartments of the equipment.

When you are likely to be hit by the projections of metallic or similar parts, use side-protected goggles, hard hats, special boots and safety gloves.

When welding operations must be performed, accident-prevention protections are to be used: dark-screened goggles, hard hats, overalls, gloves and boots. Also the persons, who are not welding but are close Edition July 2002 Revision July 2002

General Rules

Page 3

Series LDW 2204/T Engine General Rules

to where a welding is being performed, should put dark-screened goggles on.

Warning!

When metallic ropes are used, they tend to fray: always protect your hands in a suitable way. (Leather protection gloves).

Never watch the welding arc without protecting your eyes in a proper way. (Welding goggles).

Handle any small part with the utmost care. Keep your hands and fingers away from gaps, gears and similar things. Always wear approved protection devices, such as safety goggles and safety boots.

Should you perform operations under the truck, use only the hole or a lifting bridge having a suitable capacity.

After any operation, remove all the tools from the equipment and check that there are no unfastened parts or screws.

Electric System {tc "Impianto elettrico"} When using batteries, always remember that cables should be connected to the terminals at both ends in the prescribed way: (+) to (+) and (-) to (-).

Avoid short-circuiting terminals; the gas released by batteries is highly inflammable. When recharging batteries, leave the battery compartment uncovered so as to benefit from more effective ventilation. Never check the charge level of batteries by means of “bridges” that are made by placing metallic objects on the terminals. Avoid sparks or flames in the battery area.

Do not smoke so as not to provoke explosions.

Before any operation, check that there are no fuel or electrolyte leakages: repair such leakages before going on working.

Before any operation, check that there are no short-circuited elements: repair any such a short-circuit before going on working.

Never recharge batteries in closed rooms: make sure that there is a suitable ventilation so as to avoid any accidental explosion due to the accumulation of gases released during recharges.

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General Rules

Page 4

Series LDW 2204/T Engine General Rules

Always disconnect batteries before any operation on the electric system.

Hydraulic System A fluid leaking from a very small hole can be almost invisible but be strong enough to filter under the skin. In these cases, when an inspection is required, use a cardboard or a wood stick. Never do it with bare hands: if the fluid comes into contact with your skin, turn immediately to a doctor; actually, serious infections or dermatitis may occur if you do not ask a doctor for advice.

If you need to check the system pressures, use suitable tools.

Disconnections and Connections Lift and handle all heavy parts with a lifting means having a suitable capacity. Make sure that suitable slings or hooks support the parts. Use the lifting suspension rings that are prescribed for that purpose. Watch out at the persons, who are close to the load to be lifted.

Carefully handle all parts. Do not put your hands and fingers between one part and another. Put on accident-prevention approved garments, such as goggles, gloves and safety boots.

Avoid winding metallic chains or ropes. Always put on accidentprevention gloves when handling cables or chains.

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General Rules

Page 5

Series LDW 2204/T Engine Section 1

Overall Dimensions

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Overall Dimensions

Page 1.1

Series LDW 2204/T Engine Section 1

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Overall Dimensions

Page 1.2

Series LDW 2204/T Engine Section 1

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Overall Dimensions

Page 1.3

Series LDW 2204/T Engine Section 1 Fig. page 1.1: To the radiator P.T.O. centre 3 and 4 Filter disassembly From the radiator M16 x 1.5 (No. 4 holes) Air inlet No. 12 equidistant M10 holes M18 x 1.5 Oil drain plug No. 12 equidistant M10 holes Filter disassembly Fig. page 1.2: No. M8 x 1.25 holes Usable depth 12.5 Oil inlet plug To the radiator To the tank Fuel supply Oil filter cartridge No. 8 M12 x 1.75 holes Usable depth 24 Water pump inlet Exhaust gas outlet Air inlet M14 x 1.5 water drain plug Fig. page 1.3: To the radiator

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Overall Dimensions

Page 1.4

Series LDW 2204/T Engine Section 2

Specifications LDW 2204/T CHD Motor Cycle………………………………………..4-stroke diesel Injection……………………………….…….…..…..Indirect Intake…………………………..…….……………..Boosted No. of Cylinders……………………….….…….….4 in-line Total Displacement....………………….………..2199 Cm2 Cooling……………………….…...…………………..Liquid Bore……………………………….……………….....88 mm Stroke…………………………...……….…………90.4 mm Compression Ratio…………………..………….….22.5 : 1

Performance Max Revolutions..…………………..…..2650/2700 rpm Power Rating: Gross……..……….…...……….…42 kW Max Horsepower Rated Revolutions:…....….2500 rpm Max Torque / Revolutions:……..….178 Nm / 2000 rpm Minimum Revolutions:…...…………………850+50 rpm Max Regulator Deviation Revolutions:…..2700+50 rpm Equipment Alternator……………………………….……....14V 65A Starter……….…………...……………...…..12V 2.0 kW Motor – Fan Revolution Ratio….………………..1 / 1.5 Cabin Heating Set-up Blown-by Oil Vapour Breather Pipe Motor Stop with Solenoid Valve Cooling Fluid Pilot Light Thermometric Switch Oil Pressure Switch Thermostat Opening Temperature.……….…77-81 °C Exhaust Emissions complying with 97/68/EC Directive Edition July 2002 Revision July 2002

Specifications

Page 2.1

Series LDW 2204/T Engine Section 2

Power Characteristic Curves

N Power in accordance with ISO 3046/1 – IFN M Torque K Opacity according with 72/603/EEC C Specific Consumption

• The curves show the rated values of the setting under examination on fully run-in motors.

• The maximum power is guaranteed with a tolerance of 5%.

•

Powers decrease by 1% every 100 m of height and by 2% for every 5°C over 20°C.

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Specifications

Page 2.2

Series LDW 2204/T CHD Engine Section 3

Troubleshooting Probable Causes and Troubleshooting The table shows the probable causes of some defects that may occur during operation. In any case, proceed in a systematic manner, always carrying out the simpler checks before performing any disassembling or replacement.

Edition July 2002 Revision July 2002

Troubleshooting

Page 3.1

Series LDW 2204/T CHD Engine Section 3

Clogged pipes Obstructed fuel filter

FUEL CIRCUIT

Air in the fuel circuit Plugged tank vent hole Defective fuel pump Blocked injector Blocked injection pump valve Non-adjusted injector Pumping element excessive blow-by Bound injection pump delivery control Wrong injection pump delivery calibration

LUBRICATION

High oil level Blocked pressure adjustment valve Worn oil pump Air to the oil suction pipe Defective pressure gauge or switch Clogged oil suction pipe

ELECTRIC SYSTEM

Burnt-out pre-heating glow plug fuse Failure of the glow plug control unit Exhausted battery Insecure or wrong cable connection Defective start-up switch

Obstructed air filter Extended operation with idling engine Incomplete running-in Overloaded engine

A D

MAINTENANCE

Defective starter

Advanced injection timing

Edition July 2002 Revision July 2002

Troubleshooting

Page 3.2

Coolant overheating

Oil and fuel dripping from the exhaust pipe

Excessive oil consumption

Oil level increase

Low oil pressure

White smoke

Black smoke

Erratic running

It does not accelerate

It starts but stops at once

PROBABLE CAUSE

It does not start

DEFECTS

Series LDW 2204/T CHD Engine Section 3 Retarded injection timing Faulty-timed speed regulator leverages Broken or released speed regulator spring Low idling speed Worn or stuck piston rings Worn or scored cylinders Worn valve guides Blocked valves Worn crankshaft/connecting rod bearings Non-sliding regulator leverages Non-sliding driving shaft Damaged head gasket Slow pump/injector control rod Wrong pump/injector delivery trimming

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Troubleshooting

Page 3.3

Series LDW 2204/T CHD Engine Section 4

Engine Identification Plate COMMERCIAL ABBREVIATION

NUMBER OF CYLINDERS DISPLACEMENT WATER COOLING

ENGINE IDENTIFICATION

SERIAL NUMBER COSTUMER CODE HOMOLOGATION

DIESEL LOMBARDINI

Edition July 2002 Revision July 2002

Engine Identification Plate

Page 4.1

Series LDW 2204/T Engine Section 4

COMMERCIAL ABBREVIATION Number of cylinders Displacement (approximate, multiplied by 10) Water cooling Diesel LOMBARDINI ENGINE IDENTIFICATION Engine identification serial number Customer code Type-approval mark

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Engine Identification Plate

Page 4.2

Series LDW 2204/T Engine Section 5

Basic Conditions for Intervention Optimization Clean and tidy environment that is suitable for the work to be performed.

Standard and special equipment (see relevant Table at the end of this Manual).

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Basic Conditions for Optimization

Page 5.1

Series LDW 2204/T Engine Section 5

Clamping of the cylinder block by means of the suitable support frame that enables its rotation.

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Basic Conditions for Optimization

Page 5.2

Series LDW 2204/T Engine Section 6

Driving Shaft Driving Shaft Lubrication Lines Place the driving shaft in an oil bath.

Remove the plugs and clean the ducts A, B, C by means of a point, then blow them with compressed air.

Put the plugs back in, caulking them in place and check their tightness.

Main Journal and Crank Pin Diameter Check Use an outside micrometer caliper.

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Driving Shaft

Page 6. 1

Series LDW 2204/T Engine Section 6

Pay attention not to scratch the sliding surfaces of the bearings.

Dimensions (in mm): A = 57.980 / 58.000 B = 49.989 / 50.000 The driving shaft is made of spheroidal graphitic cast iron and it is hardened in the working zones of the oil seal rings 1 and 2: Hardness 55 hrc, Treatment Depth 0.5 – 1.5 mm.

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Driving Shaft

Page 6.2

Series LDW 2204/T Engine Section 6

Inside Diameters of the Crankshaft and Connecting Rod Big End Bearings

Dimensions (in mm): E = 50.035 – 50.066 F = 58.041 – 58.091 The reported dimensions refer to tight bearings.

Clearances between the bearings and their relevant pins (in mm): (E-B) = 0.035 – 0.077 (E-B) wear limit = 0.150 (F-A) = 0.041 – 0.111 (F-A) wear limit = 0.200

Note: Inside diameter undersizes of 0.25 and 0.50 mm are available for both crankshaft and connecting rod big end bearings.

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Driving Shaft

Page 6.3

Series LDW 2204/T Engine Section 6

Timing System Control Gear

After a thorough cleaning of the driving shaft, place it on a table having a surface, such as to avoid dents during work operations.

In case the gear needs to be replaced, carry out the following procedure: - To remove it, use a bearing puller.

- To reassemble it, first it needs to be heated at a temperature of 180 – 200 °C, then it is to be driven fully tight.

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Driving Shaft

Page 6. 4

Series LDW 2204/T Engine Section 6

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Driving Shaft

Page 6. 5

Series LDW 2204/T Engine Section 7

Cylinder Block Cleaning

Carry out a thorough cleaning of the cylinder block (Scaling and degreasing).

Check that there are no remains of sealant material on the surfaces to be connected.

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Cylinder Block Cleaning

Page 7.1

Series LDW 2204/T Engine Section 8

Cylinder-Piston Fit Inspection Cylinders Zero-adjust the dial gauge by means of a gauged sample ring.

Check the diameter D in points 1, 2 and 3 (see drawing below); then, repeat the same operation by rotating the dial gauge of 90° at the same heights.

Check that the surface x, where piston rings operate, is not worn.

Dimensions (in mm): D = 88.00 – 88.01 Wear limit= 88.100 The diametrical values reported pertain to class A cylinders, to which pistons belonging to the same class are to be coupled.

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Cylinder-Piston Fit Inspection

Page 8.1

Series LDW 2204/T Engine Section 8

Subdivision of the barrel into points, where wear resistance is different.

The references to piston classes (A, B, C, R) are marked inside the piston itself, whereas they are marked in the position shown by E on the cylinders.

E

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Cylinder-Piston Fit Inspection

Page 8.2

Series LDW 2204/T Engine Section 8

Cylinder Roughness

The angles for cross hatch lines to intersect should be included between 115° and 140°. Cross hatch lines should be smooth and sharp in both directions.

Average roughness should be between 0.5 and 1 µm.

The entire cylinder surface that is affected by the contact with piston rings should be honed with special plateau finish.

Warning: It is forbidden to manually finish the cylinder inner surfaces with an emery cloth.

Piston Class

According to their diametrical values, pistons are subdivided into classes: A, B, C and R. These references, along with the logotype, are marked inside the piston.

Important: Class R piston rings have oversized dimensions in comparison with class A, B and C rings.

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Cylinder-Piston Fit Inspection

Page 8.3

Series LDW 2204/T Engine Section 8

Dimensions (in mm): Classes – ∅Cylinders – ∅Pistons – Clearance

A B C

88.00 – 88.01

87.96

87.967

88.01 – 88.02

87.97

87.977

88.02 – 88.03

87.98

87.987

R

88.10 – 88.11 - 88.06 – 88.067

0.033 – 0.05

Measure the diameter Q at height A from the base of the skirt (A = 12 mm).

Important: Available oversizes are of 0.5 and 1.00 mm.

The piston of LDW 2204/T engine is different from the one of LDW/2004 in a few details: the cooling spray nozzle through niche and the insert in the slot of the first piston ring.

Piston supply: Only class A and R pistons are supplied with diameters higher than the rated value.

Only class A pistons, oversized by 0.50 and 1.00 mm, are supplied.

Their oversize reference is marked on the crown.

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Cylinder-Piston Fit Inspection

Page 8.4

Series LDW 2204/T Engine Section 8

Piston Weight To avoid unbalances, pistons need to be weighed before being replaced.

The difference between them should not be higher than 6 g.

Piston Rings – Centre-to-centre distance (in mm)

Put the piston rings into the cylinder and measure the distance between centres A by means of a feeler gauge.

1° ring A = 0.30 – 0.50 mm 2° ring A = 0.30 – 0.50 mm 3° ring A = 0.25 – 0.50 mm

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Cylinder-Piston Fit Inspection

Page 8.5

Series LDW 2204/T Engine Section 8

Piston Rings – Clearance between slots (in mm)

B = 0.07 – 0.10 C = 0.05 – 0.08

Piston Rings – Order of Assembly A = 1st piston ring (trapezoidal section) B = 2nd piston ring (cone-shaped inner section and torsion) C = 3rd oil scraper (chromium-plated)

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Cylinder-Piston Fit Inspection

ring

Page 8.6

Series LDW 2204/T Engine Section 8

A) Trapezoidal section piston ring.

This shape is used for boosted engines. It ensures a higher tightness than conventional piston rings, as it tilts on one side according to the running direction, thus reducing the bearing surface on the barrel.

B) Piston ring having a conical inner section with torsion.

Bevelled inner upper corner shape.

This section asymmetry causes a slight torsion upwards, when the piston is fitted inside the cylinder and the piston ring is compressed.

This kind of rings (torsional) is characterized by a remarkable speed of running in, as well as by an excellent tightness due to the high specific pressure.

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Cylinder-Piston Fit Inspection

Page 8.7

Series LDW 2204/T Engine Section 8

C) Oil scraper ring (chromiumplated).

It is designed to remove all the oil from the barrel surface “during the downstroke”. It is made up of two details: the sheer ring and the spiral, which needs to be placed inside it, in its relevant seat.

Expansion spiral having a metallic wire (1) inside that is placed just next to the joint.

1

C) Assembled oil scraper ring.

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Cylinder-Piston Fit Inspection

Page 8.8

Series LDW 2204/T Engine Section 8

Attention: In case one of the piston ring surfaces bears an inscription, it needs to be assembled upwards.

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Cylinder-Piston Fit Inspection

Page 8.9

Series LDW 2204/T Engine Section 9

Connecting Rod Dimensional Sizes of the Connecting Rod complete with Bearings and Piston Pin

Dimensions (in mm): A = 148 ± 0.2 B = 28.02 ÷ 28.03 (with driven and machined bearing) C = 50.035 ÷ 50.066 (with cap tightened at 70 Nm) E = 65.8 (B-D) = 0.02 ÷ 0.03 (B-D) = limit = 0.06

Note: The connecting rod big end bearing is supplied both at rated value and undersized by 0.25 and 0.50 mm.

Edition July 2002 Revision July 2002

Connecting Rod

Page 9.1

Series LDW 2204/T Engine Section 9

Connecting Rod Alignment

Use a surface gauge or a dial gauge, as shown in the drawing.

Check the alignment of the axes.

Gap A = 0.02 mm.

Limit = 0.05 mm.

Small deformations can be adjusted, by placing it under a press and gradually pressing.

Connecting Rod Weight To avoid unbalances, the connecting rods need to be weighed before being replaced.

The weight difference between them should not be higher than 10 g.

Edition July 2002 Revision July 2002

Connecting Rod

Page 9.2

Series LDW 2204/T Engine Section 10

Piston Assembly

Couple the piston to the connecting rod, by inserting the piston pin with a simple pressure of the thumb greased with motor oil.

Insert the two retaining rings of the piston pin and make sure that they are properly housed in their seats.

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Piston Assembling

Page 10.1

Series LDW 2204/T Engine Section 10

Starting from the third ring (oil scraper ring), place the piston rings in their relevant seats.

The picture shows the assembled piston rings.

The position of piston rings shall be modified afterwards, when fitting the piston in.

The open space between the two ends of a ring should not be aligned to the open spaces of the other rings.

Edition July 2002 Revision July 2002

Piston Assembling

Page 10.2

Series LDW 2204/T Engine Section 11

Connecting Rod and Piston Weight It is possible to weigh the preassembled connecting rod, piston and piston pin.

The weight difference should not be higher than 14 g.

Connecting rod/piston units should be put back in their proper cylinders.

To avoid any mistake, we suggest you to place some reference marks.

The cylinder that is considered to be the first is the one on flywheel side.

Edition July 2002 Revision July 2002

Connecting Rod and Piston Weight

Page 11.1

Series LDW 2204/T Engine Section 12

Piston Cooling Spray Nozzle

Piston cooling spray nozzles are assembled in boosted engines.

Blow them with compressed air, then check that inside they are free from impurities.

Re-assemble them in their seats, retaining the inclination of axis A of the spray nozzle to axis B, as shown in the drawing.

In any case, the correct orientation is given by the clamping screw, which is used to fasten the piston to the cylinder block.

A = 3° A¹= 28° D = 28 mm

Edition July 2002 Revision July 2002

Piston Cooling Spray Nozzle

Page 12.1

Series LDW 2204/T Engine Section 13

Shoulder Half Rings

FLYWHEEL SIDE

Shoulder half rings are designed to limit the driving shaft end float during its normal operation. They are placed in the side main bearing, on flywheel side.

Axial Direction

To make them remain in their seats during the assembly, use a small quantity of grease.

Half rings should be assembled with grooves A, as shown in the drawing.

Half ring thickness = 2.31 ÷ 2.36 mm.

Edition July 2002 Revision July 2002

Shoulder Half Rings

Page 13.1

Series LDW 2204/T Engine Section 13

Shoulder half rings are supplied as spare parts, also with thickness oversizes of 0.1 and 0.2 mm.

The driving shaft in the working zone of half rings is hardened, so as to avoid any wear of the shaft itself.

In such a case, half rings are made of a red-coloured silicone material.

On currently produced engines, half rings made of a browncoloured viton material are assembled instead. In this case, driving shafts do not need to be hardened.

It follows that red-coloured half rings cannot be assembled in place of brown-coloured ones; whereas brown-coloured half rings can be assembled to both driving shafts.

Edition July 2002 Revision July 2002

Shoulder Half Rings

Page 13.2

Series LDW 2204/T Engine Section 13

Shoulder Half Rings and Oversizes

Dimensions (in mm):

Standard 1 Oversize 2 Oversize 3 Oversize

C 27.77/27.92 27.97/28.12 28.07/28.22 28.17/28.32

B** 28.00/28.06 28.20/28.25 28.30/28.35 28.40/28.45

A* 0.08/0.28

1) Grinding B according to the table, the following half rings can be assembled: 2) Oversize. Half rings 1 and 2, +0.10 mm on both sides of the support.

3) Oversize. Half rings 1 and 2, +0.10 mm on one side of the support and +0.20 mm on the other side.

4) Oversize. Half rings 1 and 2, +0.20 mm on both sides of the support.

Edition July 2002 Revision July 2002

Shoulder Half Rings

Page 13.3

Series LDW 2204/T Engine Section 14

Driving Shaft Assembly Crankshaft Bearing Positioning 1

2

4

Edition July 2002 Revision July 2002

3

The crankshaft bearing is made up of two half bearings.

Each half bearing has a reference notch (2), which should match the notch (3) made in the cylinder block.

Only one of the two half bearings has a hole (1).

This half bearing shall be housed on the cylinder block, so that the oil coming out of the hole (4), which is made in the cylinder block, can find a passage so as to lubricate the crankshaft bearings.

Driving Shaft Assembly

Page 14.1

Series LDW 2204/T Engine Section 14

Fitting in of the Driving Shaft

After having greased the driving shaft with motor oil, gently put it in place, paying attention that no jamming occurs.

The driving shaft should be correctly positioned with the flywheel coupling flange turned towards the side of the shoulder half rings.

Edition July 2002 Revision July 2002

Driving Shaft Assembly

Page 14.2

Series LDW 2204/T Engine Section 14

Rear and Front Main Bearings When re-assembling the rear main bearing on flywheel side, replace the side rubber gaskets, considering that they should stand 0.5 ÷ 1.0 mm out of the bearing.

Repeat the same operation for the front bearing.

To make the insertion of the bearings into the cylinder block easier, two 01-mm thick foils can be interposed between the two surfaces.

Note: During the detail coupling operation, use your finger pressure only.

Edition July 2002 Revision July 2002

Driving Shaft Assembly

Page 14.3

Series LDW 2204/T Engine Section 14

Check of the clearance between crankshaft bearings and main journals.

Use a sized wire (A) of the “Perfect Cicle Plasticage” type, grease it and place it in the middle of the half bearings.

Tighten the screws at 117.6 Nm (12Kg).

Measure the clearance value, by checking the deflection of the wire by means of the suitable graduated scale, which is supplied in the kit and, otherwise, may be easily found on sale.

For the correct values of the clearance between main journals, connecting rod big end pins and relevant bearings, see page…

Insert the fastening screws.

Edition July 2002 Revision July 2002

Driving Shaft Assembly

Page 14.4

Series LDW 2204/T Engine Section 14

To make the insertion of the bearings into the cylinder block easier, two 01-mm thick foils can be interposed between the two surfaces.

Fit in the main bearing on timing side.

This side is different from the flywheel one, as there are no housings for the shoulder rings.

Insert the clamping screws.

Edition July 2002 Revision July 2002

Driving Shaft Assembly

Page 14.5

Series LDW 2204/T Engine Section 14

(Central) Main Bearings

3

1

2

Edition July 2002 Revision July 2002

1

2

The caps of central main bearings are marked by some references.

Similar references are marked on the cylinder block.

Match the caps with the same references and on the same side.

In any case, refer to the two notches 1 and 2 for the centering of the half bearings, which should be placed on the same side.

Driving Shaft Assembly

Page 14.6

Series LDW 2204/T Engine Section 14

In the event of replacement of the bearings, pay attention not to invert the lower half bearing with the upper one.

Check of the clearance between crankshaft bearings and main journals.

Use a sized wire (A) of the “Perfect Cicle Plasticage” type, grease it and place it in the middle of the half bearings.

Tighten the screws at 117.6 Nm (12Kg).

Measure the clearance value, by checking the deflection of the wire by means of the suitable graduated scale, which is supplied in the kit and, otherwise, may be easily found on sale.

For the correct values of the clearance between main journals, connecting rod big end pins and relevant bearings, see page…

Edition July 2002 Revision July 2002

Driving Shaft Assembly

Page 14.7

Series LDW 2204/T Engine Section 14

Tighten all the screws of the main bearing caps at 120 Nm.

Once the tightening is completed, trim the gasket in excess.

Trim the gasket in excess also on the side of the cylinder block.

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Driving Shaft Assembly

Page 14.8

Series LDW 2204/T Engine Section 14

Attention: The gasket should not protrude.

Edition July 2002 Revision July 2002

Driving Shaft Assembly

Page 14.9

Series LDW 2204/T Engine Section 14

Inspection of the Driving Shaft End Float Once the main bearings have been assembled, measure the end float reading (A) between the driving shaft shoulder on flywheel side and the main bearing half rings.

A = 0.08 ÷ 0.28 mm

In case the end float is not included in the specified value range, check again the driving shaft reading and, if necessary, assemble oversized half rings.

Edition July 2002 Revision July 2002

Driving Shaft Assembly

Page 14.10