OM PIMESPO LDW 2204T CHD ENGINE WORKSHOP MANUAL - PDF DOWNLOAD

LDW 2204/T CHD ENGINE

60424180 GB Ed: 05/2004 Rev: 01-05/2004

LDW 2204/T CHD engine

LDW 2204/T CHD ENGINE

INDEX

1 - DISASSEMBLY / REASSEMBLY. ....................................................................... 2 Cylinder head ........................................................................................................ 5 Cylinders ............................................................................................................. 11 Pistons ................................................................................................................ 12 Connecting rod ................................................................................................... 15 Drive shaft ........................................................................................................... 17 Valvetrain control gear ........................................................................................ 21 Camshaft ............................................................................................................ 25 2 - TURBOSUPERCHANGER................................................................................. 29 3 - LUBRICATION SYSTEM. .................................................................................. 31 Oil pump.............................................................................................................. 32 4 - COOLING SYSTEM. .......................................................................................... 34 Engine cooling .................................................................................................... 34 5 - INJECTION / FEEDING SYSTEM. ..................................................................... 36 Injection pump .................................................................................................... 37 Injection valve ..................................................................................................... 45 6 - ELECTRIC EQUIPMENT. .................................................................................. 46 Alternator ............................................................................................................ 46 Starter ................................................................................................................. 47 7 - SETTINGS. ......................................................................................................... 50 8 - TORQUE WRENCH SETTING. .......................................................................... 52

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LDW 2204/T CHD engine

1 - DISASSEMBLY / REASSEMBLY Intake manifold The sealing surface should be smooth and free of any scoring.

Replace the A gasket.

Tighten nuts to 25 Nm

Nm

.

Exhaust manifold Check the sealing surface for smoothness and clean accurately the inner part.

Replace the A gaskets.

Tighten nuts to 25 Nm

Nm

.

V-belt Tension adjustment: The tension is adjusted at the 1 screw.

Stretch the belt so that a 100 Nm strength applied at the middle point between both pulleys causes a 10÷15 mm flexure.

Cooling fan Pull the fan off and check the fan blades for wear and tear; should a single blade turn out to be worn or torn, replace the whole fan.

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LDW 2204/T CHD engine

Drive pulley The pulley controls the alternator and the water pump. Moreover, it represents the second engine PTO. To loose the bolt 1 turn clockwise When reassembling, tighten it to 352 Nm

Nm

.

8

Flywheel Loosen the bolts securing the flywheel to the drive Nm shaft; when refitting, tighten them to 140 Nm after checking the reference pin to be in its seat.

To replace the starter ring gear heat slowly for 15÷20 minutes up to 300°C. Insert the ring gear in its seat making sure that it bottoms homogeneously against the seat shoulder.

Cool down gradually.

9

Rocker arm cap 1. Oil top up plug 2. Gasket

Vacuum control valve The pressure relief valve, integrated in the rocket arms cover, is an engine safety device in the oil fumes recovery circuit.

Its function is to limit the vacuum, whenever it begins increasing.

10

Should this vacuum control valve be missing, with the air filter clogged, the oil contained in the housing might be sucked thorough the intake manifold and the engine reach a runaway speed rate.

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LDW 2204/T CHD engine

Rocker arm journal or shaft Loosen the screws securing the rocker arm bearings to the head; when reassembling tighten to 50 Nm Nm .

The journal inner is hollow to permit lubrication. The journal ends are closed through two screws.

Check the journal and the rocker arm bearings for wear and tear.

Remove both screws from the ends and clear accurately the inner part.

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12

When reassembling, apply a drop of Loctite 270 on the screws.

Dimensions in mm: A= 14,032 ÷ 14,050 when the bearing fitted on the rocker arm and reamed B= 13,982 ÷ 14,000.

(A-B)= 0,03 ÷ 0,07.

(A-B) wear limit value = 0,14.

ATTENTION The hydraulic tappets installed make necessary to carry out the procedure described below whenever the rocker arm shaft is disassembled.

1. Before fitting the rocker arm shaft, drive all pistons to ~ 1/2 a stroke.

2. Fill oil in the tappet seat through the stem ducts to supply oil to the tappets.

3. Fit the rocker arm shaft.

4. Wait approx. ~1/2 hour prior to start the engine, for the tappets to reach their optimal fill-in level.

5. Turn the engine manually by a couple of revolutions and check it for seizing or other failures.

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CYLINDER HEAD Do not disassemble when hot to avoid deformation.

Check the cylinder head for flatness with a metal rule and a thickness gauge.

Should the deviation exceed 0,10 mm level by grinding and removing maximum 0,20 mm.

For head tightening see fig. 50.

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Valve disassemble 1. Valve.

2. Spring ring.

3. Oil seal gasket.

4. Spring.

5. Upper spring ring.

6. Cotter.

To remove the cotters depress firmly as shown in the figure.

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15

Valves Stem and head are of two different materials.

Exhaust valve A: 3. Chromium coated section.

4. X 45 Cr Si 8 UNI 3992 section. .

5. X 70 Cr Mn N 216 UNI 3992 section. = 45°30’/45°45’.

D = 35,30/35,50 mm.

Intake valve B: 1. Chromium coated section 4. X 45 Cr Si 8 UNI 3992 section..

5. X 70 Cr Mn N 216 UNI 3992 section.

1 = 60°30’/60°45’.

C = 40,30/40,50 mm.

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LDW 2204/T CHD engine

Valve guides and seats Both intake and exhaust valve guides are made of grey cast iron with pearlitic and phosphoric matrix.

1. Exhaust valve guide 2. Intake valve guide Dimensions (mm): A=36,5.

C=12,020 ÷ 12,038.

D=12,048 ÷ 12,058.

Valve guides with D outer diameter oversized by 0,5 mm are provided; in such cases, when assembling, the C sat must be oversized by 0,5 mm.

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Valve guide fitting Press the guides using a driftpin considering the A and B distances or E and F, respectively from the head lower surface G. Dimensions (mm) A= 36,5 ± 0,2.

B= 36,5 ± 0,2.

C= 7,020 ÷ 7,035.

D= 6,985 ÷ 7,000.

E= 10,5 ÷ 11,0.

F= 6,5 ÷ 7,0.

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Backlashes (mm) (C-D)= 0,020 ÷ 0,050.

(C-D) wear limit value= 0,10.

Fitting the oil seal gasket onto the valve guide When fitting the gasket 1 onto the valve guide 3, insert it in the special tool 2 not to deform it and proceed as shown in the picture, making sure that the gasket 1 bottoms at the end position.

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6

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LDW 2204/T CHD engine

Seats valve and sockets Dimensions (mm) A= 41,500 ÷ 41,520.

B= 41,575 ÷ 41,590.

C= 36,500 ÷ 36,520.

D= 36,575 ÷ 36,590. = 44,53’ ÷ 45°.

1= 59,53 ÷ 60°.

Press fit the seats in their sockets and mill them considering the angles a and a1.

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Valve embedding and seat sealing surfaces Valve embedding and seat sealing surfaces S= Exhaust seat sealing width S1= Intake seat sealing width D=Valve recess with reference to the head plane

S 1,27 ÷ 1,55

S1 1,20 ÷ 1,60

D 0,95 ÷ 1,2 22

23

24

25

Wear limit values for S and S1 = 2.00 mm.

D wear limit value = 1,3 mm.

Pre-combustion chamber Tap with a driftpin on the injector housing side to remove the pre-combustion chamber.

When removing the pre-combustion chamber it might undergo deformation.

For this reason replace it with a new one when reassembling.

Insert the pre-combustion chamber by overlapping dowel 1 with the notch 2 and press it homogeneously.

The interference between the pre-chamber and its socket on the cylinder head is 0.5 mm.

Use a micrometer to check that pre-combustion chamber plane does not hang over the cylinder head plane by over 0,04 mm and does not stay behind the head plane by over 0.02 mm.

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LDW 2204/T CHD engine

Injection pump control tappet Insert the tappet in its socket and tighten by hand the screw 3 as long as it enters the notch 2.

Before locking the screw 3 make sure that the tappet can move freely also in vertical direction by inserting a finger.

The nut 1 shall be introduced in the tappet with the place surface upward.

IMPORTANT: 26

27

The screws 3 have all the same length except for the screw on the distributor side, located inside the cover of the throttle valve, which is shorter.

Take care not to confuse this screw with the longer ones.

Valve control hydraulic tappet 1. Retainer.

2. Body.

3. Plunger.

4. Check ball.

5. Single-acting valve.

6. Check ball spring.

7. Plunger spring.

The unit in collapsed position 28

The clearance arising between the cam and the tappet allows the spring 1 to release, thus causing a vacuum in the chamber A and the single-acting valve open and let the oil fill in the chamber A as long as no clearance is left.

29

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LDW 2204/T CHD engine

The following benefits can be obtained: • Less noise • Less fuel consumption • Temperature and wear do not have any impact on the operation.

• Valve retaining springs smoother.

• Larger valve stroke and valve operation “closer” to the cam profile.

• No adjustment or maintenance.

Oil inlet Rocker ann

Rod

Drainage lubrication

Valve

and

Hydraulic tappet

Camshaff

30

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LDW 2204/T CHD engine

ATTENTION When removing the rocker shaft or whenever “cutting off” the contact between the elements in Fig. 30, the spring 1 (Fig. 29) releases and lets oil in, so that the length of the tappets increases over the normal working measure.

In this condition, switching on the engine might cause cracking or function failure.

To restore the normal operation conditions, before reassembling any dismounted component, drive the pistons to approx. half stroke.

Prior to start the engine, wait approx. 30 minutes, for the valve springs to be loaded enough to bring the tappets again to their optimal fill-in level, then turn the engine manually by a couple of revolutions, as to check it for any sticking point or other troubles.

L. Operation length.

L1. Length with no load.

P. Tappet push rod causing the valve spring “dischar-ging” the exceeding oil from the tappet.

31

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LDW 2204/T CHD engine

CYLINDERS Reset the dial gauge with a calibrated ring.

Check the diameter D in the points 1, 2 and 3.

Repeat the same measurement at the same heights after turning the dial gauge by 90°: Check the X area where pistons rings are operated for wear.

Dimensions (mm) D = 88,00 ÷ 88,01

wear limit value = 88,100

The diameter sizes indicated above refer to cylinders of class A and shall be matched with pistons of the same class (see fig 38).

Measure the diameter in the area Z of each cylinder along the axis perpendicular to the drive shaft, to check the coupling clearance with the pistons.

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33

Cylinder class The piston class references (A, B, C, R) are indicated on the piston (see figure 38/39).

The cylinder class references are indicated by the point E.

34

Cylinder roughness The inclination of the crossed-hatched marks left by machining shall range between 115° ÷ 140°. The marks shall be homogeneous and clearly visible in both directions.

The average roughness shall range between 0.5 and 1 µm.

The whole cylinder surface coming in contact with the piston rings shall be machined with the plateau method.

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WARNING: Manual re-grinding of the cylinder inner surfaces by emery cloth is not allowed.

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LDW 2204/T CHD engine

PISTONS Remove retaining clips and piston pin.

Remove the piston rings and clean the grooves.

Measure the diameter Q at a distance A from the skirt bottom (A = 12 mm).

Should the diameters present a wear exceeding the value indicated as a minimum by 0.05 mm, replace the piston and the piston rings.

NOTE Oversized versions by 0,50 and 1,00 mm are available.

The LDW 2204/T piston is different from the LDW 2004 one because of the cooling nozzle throughput recess and because of an insert in the groove of the first piston ring.

36

37

38

39

Piston classes The pistons are divided into the classes. A, B, C and R, according to their diameter sizes.

These references are stamped on the inner part of the piston together with the firm trademark (fig. 38/39).

Dimensions (mm).

Classes Ø cilinders A B C R

88,00÷88,01 88,01÷88,02 88,02÷88,03 88,10÷88,11

Ø pistons

Backlash

87,96÷87,967 87,97÷87,977 87,98÷87,987 88,06÷88,067

0,033÷0,050

IMPORTANT: The piston rings of the class R present oversized di-mensions in comparison with the classes A, B and C.

Piston availability: Pistons with rated diameter size are available only in the classes A and R. Oversized pistons 0,50 and 1,00 mm are available only in the class A. The oversize indication is stamped on the crown (fig.

38).

Piston weight Weight pistons before replacing them to prevent unbalance.

Weight differences should not exceed 6 g.

40

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LDW 2204/T CHD engine

Piston rings - end gaps (mm) Insert the piston rings in the cylinder and measure the end gaps A. 1° piston ring 2° piston ring 3° piston ring

A = 0,30 ÷ 0,50 mm.

A = 0,30 ÷ 0,50 mm.

A = 0,25 ÷ 0,50 mm

41

Piston rings - Groove clearances (mm) B = 0,07 ÷ 0,10 C = 0,05 ÷ 0,08

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Piston rings - Fitting sequence A = 1° (trapezoidal section) piston ring.

B = 2° (inner tapered, torsional) piston ring.

C = 3° piston scraper ring (chromium-coated).

NOTE: If the piston ring surface presents an inscription, that surface shall be fitted in upward position.

44

Piston - Reassembling Attach the piston the connecting rod after lubricating the piston pin by simply pressing with your thumb.

Insert both rings retaining the piston pin and make sure that they seat properly in their sockets.

Use a ring compressor to insert the piston in the cylinder with the combustion chamber facing the injection pump surface.

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LDW 2204/T CHD engine

Piston position and clearance volume To obtain the clearance volume (0.67 ÷ 0.90 mm), measure the distance A from each piston to the cylinder plane and consider the larger A value.

Perform the measurement along the engine axis.

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Cylinder head gasket In the point B of the gasket some small, half-circular notches are provided, indicating the gasket thickness.

Choose a suitable gasket considering that each A value range in the table is matched with a gasket (no notch, one notch, two notches).

A mm.

Notch amount

Clearance volume in mm 48

0,60 ÷ 0,83

0,67 ÷ 0,90

0,84 ÷ 0,98

0,67 ÷ 0,84

0,99 ÷ 1,10

NOTE: The notches pictured above hang over the cylinder head plane.

This circumstance enables the identification of the gasket thickness before disassembling the cylinder head.

Cylinder head tightening Use a torque wrench equipped with a tool for angular tightening.

Do not re-tighten the cylinder head after the running test.

Bolt replacement is recommended according to their elongation caused through tightening.

The bolt length is 126.40/126.60 mm.

49

Should an elongation by 2 mm be ascertained, replace the bolts.

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LDW 2204/T CHD engine

Cylinder head tightening steps The bolts shall be tightened in four steps with the following torque wrench settings and according to the following sequence: Nm 1ª step = 40 Nm Nm 2ª step = 70 Nm Nm 3ª step = 100 Nm 4ª step = Perform a further revolution of the spanner by further 270° (in three separate steps: 90°+90°+90°) Nm

50

Connecting rod Remove the oil sump and the oil pump suction pipe.

Detach the connecting rod from the drive shaft and perform the following checks.

When reassembling, both centering notches A and B shall be located on the same side.

Tighten the connecting rod cap at 70 Nm

Nm

.

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52

53

54

Connecting rod weight Weight the connecting rods before replacing them to prevent unbalance.

Weight differences should not exceed 10 g.

Connecting rod, piston and pin can be weighted together in pre-assembled condition.

In this cas the weight difference should not exceed 14 g.

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LDW 2204/T CHD engine

Connecting rod including bearings and piston pin Dimensions mm A= 148 ± 0,2.

B= 28,02 ÷ 28,03 (with bearing press fitted and machined).

C= 50,035 ÷ 50,066 (with cap tightened to 70 Nm).

D= 27,995 ÷ 28,000.

E= 65,8.

(B-D)= 0,02 ÷ 0,03.

(B-D) Wear limit value= 0,06.

NOTE:

55

The connecting rod head bearing is available in both versions, with rated value and undersized: 0,25 mm and 0,50 mm.

Connecting rod alignment Use a gauge with surface plate or a dial gauge as shown in the picture.

Check the axis for alignment.

Deviation A = 0,02 mm Wear limit value 0,05 mm.

Little deformations can be rectified under a press applying gradual efforts.

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57

58

59

60

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Piston cooling nozzles They are installed in the supercharged engine.

Blow them up with pressurised air and check the inner part for any impurity.

Refit the nozzles in their seats ensuring the same inclination of the A spray axis to the B spray axis as shown in the picture; anyway, the correct orientation is ensured through the screw securing the nozzle to the cylinder block. = 3° 1 = 28° D = 28 mm

Connecting rod - pistons reassembling The connecting rods / pistons assemblies shall be refitted in the original cylinders.

To avoid any mistake, mark references.

NOTE: Under first cylinder is understood the cylinder on the flywheel side.

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LDW 2204/T CHD engine

DRIVE SHAFT

Middle main bearings The middle main bearings caps are marked with references.

The same references are indicated on the cylinder block.

Refit the caps with the corresponding numbers and on the same side.

Refer to both centering notches of the bearing halfshells that must be placed on the same side.

Tighten the bolt to 120 Nm

Nm

.

62

Rear and front main bearings When refitting the rear main bearing 1, replace the side rubber gaskets 2 making sure that the bearing shall overhang by 0,5 ÷ 1,0 mm (A and B distances).

Cut off any exceeding section.

Proceed in the same way with the front main bearing.

When inserting the bearings in the cylinder block put in-between the surfaces two metal sheets C and D 0,1 mm thick.

Tighten the bolt to 120 Nm

Nm

63

64

65

66

.

Checking the clearance between bearings and main journals Use a scaled wire A type “Perfect Circle Plasticage” and place with some grease in the bearing half-shell Nm . middle. Tighten the bolts with 120 Nm Measure the clearance value by checking the wire deformation using the scale supplied in the same package and commonly available on the market.

For the clearance values between main journals, connecting rod head journals and relevant bearings see Fig. 77.

NOTE: When replacing bearings, make sure not to confuse the lower and the upper bearing-halfshells.

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LDW 2204/T CHD engine

Ring half-shells Apply some grease to keep the shaft segments in their seats during the assembly.

The ring half-shells shall be fitted with the A grooves as shown in the picture.

Ring half-shell thickness = 2,31 ÷ 2,36 mm Oversized rings 0,1 and 0,2 mm are available.

67

68

69

70

71

72

Drive shaft end play After tightening the main bearings, measure the A end play between drive shaft shoulder on the flywheel side and the main bearings half-shells.

A = 0,08 ÷ 0,28 mm B = 28,00 ÷ 28,05 mm Should the end play do not match the theoretical value, check the B value and insert the oversized halfshells if required.

Oversized ring half-shells

Dimensions (mm) C

B**

Standard

27.77/27.92 28.00/28.05

1 Oversize

27.97/28.12 28.20/28.25

2 Oversize

28.07/28.22 28.30/28.35

3 Oversize

28.17/28.32 28.40/28.45

A*

(0.08/0.28)

* A in the fig. 69 ** B in the fig. 70 To re-adjust B according to the table the following half-shells can be fitted: 1ª Oversize.

Ring half-shells 1 and 2, +0.10 mm on both sides of the bearing.

2ª Oversize.

Ring half-shells 1 and 2, +0.10 mm on one side of the bearing and +0.20 mm on the opposite side.

3ª Oversize.

Ring half-shells 1 and 2, +0.20 mm on both sides of the bearing.

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LDW 2204/T CHD engine

Front and rear drive shaft oil seal rings The front oil seal ring A is fitted in the oil pump cover.

The rear oil seal ring B is located in the flange on flywheel side.

Replace the rings if they are warped, hardened or torn.

For replacing the rings: • Clear accurately the ring seat.

• Plunge the ring in engine oil for approx. half an hour.

• Press fit the ring in its seat with a driftpin applying a homogeneous pressure on the whole front surface.

• Fill-in the inner space with grease and lubricate the seal lip with thick oil.

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NOTE: Before overhauling the engine, should an oil leakage from the seal ring area be ascertained, you can remove this failure by pressing the ring to the inner by approx. 2 mm.

ATTENTION At room temperature lower that –35°C the seal rings might be damaged.

NOTE: Generally the drive shaft is hardened in the seal ring area to prevent drive shaft wear.

In such a case the ring are of silicon and red-coloured.

In the engines currently manufactured and equipped with “Viton” (brown-coloured) rings, the drive shafts are not hardened in this area.

As a consequence, brown-coloured rings cannot be replaced through red-coloured ones.

On the opposite, brown-coloured rings can be installed on both drive shaft versions.

Valve train control gear Should you replace the gear A perform the following the procedure: To remove the gear, use a bearing extractor tool.

To refit the gear, pre-heat it to a temperature 180° ÷ 200°C and the press fit the gear as long as it bottoms up perfectly with its contact surface.

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LDW 2204/T CHD engine

Drive shaft lubrication ducts Plunge the drive shaft in petroleum.

Remove the caps and clear the ducts with a pin.

Blow them up with pressurised air.

Refit the caps and caulk them in their seats.

Check them for tightness.

75

Checking diameters of the journals and the cranks Use a micrometer for outer parts.

76

Main journals and connecting rod head diameters Dimensions (mm) A = 59.981 ÷ 60.000 B = 49.984 ÷ 50.000 The drive shaft is in cast iron with globular graphite. In the operation area of the oil seal rings 1 and 2 the drive shaft is hardened: hardness 55 hrc hardness depth 0.5 ÷1.5 mm.

NOTE 77

If using “Viton” rings the areas 1 and 2 are eliminated.

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LDW 2204/T CHD engine

Main bearings and connecting rod head bearings inner diameters Dimensions (mm) E = 50,035 ÷ 50,066 F = 58,041 ÷ 58,091 The dimensions indicated are referred to tightened bearings.

Clearances between bearings and relevant journals (mm) (E-B) = 0,035 ÷ 0,077 (E-B) Wear limit value = 0,150 (F-A) = 0,041 ÷ 0,111 (F-A) Wear limit value = 0,200 For checking see fig. 55.

78

NOTE: For both main bearings and connecting rod head bearings, undersized inner diameters 0,25 and 0,50 mm are available.

VALVE TRAIN CONTROL GEAR Distributor cover For removing the cover remove the accelerator cover 2 and release the spring 3.

Drive the piston 1 or 4 to the TDC. Turn in anticlockwise direction by 90° (looking toward the valve train control gear).

When reassembling, replace the gaskets 4 and 5.

Tighten the screws securing the cover 1 with 25 Nm Nm and loose the cover 2 with 10 Nm Nm .

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LDW 2204/T CHD engine

Intermediate gear and hub 1. Intermediate gear 2. Hub 3. Thrust ring 4. Union 5. Oil seal ring 6. Bush lubrication hole Dimensions (mm): A = 36,00 ÷ 36,02 B = 35,959 ÷ 35,975 C = 1,95 ÷ 2,05 D = 0,96 ÷ 1,00 Clearances (mm): (A-B) = 0,025 ÷ 0,061 (A-B) wear limit value = 0,120 End play = 0,10 ÷ 0,30 (Maximum limit value 0,6)

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82

83

84

NOTE: To loosen the joint 4 turn it in counter clockwise direction.

When reassembling, tighten with 200 Nm

Nm

.

Speed governor 1. Gear.

2. Removable housing.

3. Counterweights.

4. Adjust screw.

5. Accelerator control engage tie rod.

6. Adjuster spring.

7. Injection pump flow rate adjust rod control yoke.

8. Injection pump flow rate adjust rod.

9. Adjust cam of yoke 7.

10. Bush.

11. Lever.

12. Bolt.

The yoke 7 is pre-adjusted by means of the screw 4 and the cam 9. Do not loosen it (see hereafter).

When reassembling the gear for the camshaft 1 and Nm . tighten the bolt 12 with 80 Nm.

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LDW 2204/T CHD engine

Adjustment of the injection pump flow rate control yoke (mm) A= 10,8.

B= 20,6.

C= 13,4.

D= 88.

4. Adjust screw.

7. Injection pump flow rate adjust rod control yoke.

10. Bush.

11. Lever.

13. Reference surface and contact surface for bearing 14.

14. Lever bearing.

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NOTE: If the adjust screw 4 has been loosened by mistake, restore the adjustment of the yoke 7 considering the dimensions A, B, C and D. When replacing, the lever assembly 11 with preadjusted yoke 7 is supplied.

Throttle valve spring The device is automatic: with the engine off, the throttle valve spring 1 brings the injection pump control lever 2 back to its maximum flow rate position as long as the speed governor is actuated.

86

Auto-choke valve This device excludes the throttle valve when starting the engine, if the engine is already warmed up (lever 4 in position A).

When the temperature decreases under 0°C the lever 4 turns (due to the thermostat groove 3) as long as it reaches the position B, thus allowing the rod 5 to reach the fuel overfeeding position during the starting of the engine.

The position of the adjust screw 1 may not be changed.

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LDW 2204/T CHD engine

If, for any reason, the adjust screw is mislaid, perform the following procedure to re-adjust the throttle valve: a) Run the engine to the rated power and rpm. b) Loosen the lock nut 2. c) Loosen the adjust screw 1 (as to bring the lever 4 closed to the rod 5), as long as the engine rpm begins decrea-sing. d) Tighten the adjust screw 1 by 1/2 + 3/4 revolution as to detach the lever 4 from the rod 5 by 1.2 + 1.8 mm e) Tighten the lock nut 2.

Speed governor counterweights and springs The counterweights 3 for the speed governor, located inside the camshaft gear have different dimensions according to the various engine adjustments.

If the adjustment deviates from the standard the springs 6 are different as well.

88

Frame with idle speed governor spring If the engine application requires a certain power at a low rpm, the frame 5 complete with idle speed spring is installed.

This device fulfils the application requirements without the engine shows a tendency to stop.

1. Adjuster 2. Max speed adjustment 3. Idle speed adjustment 4. Camshaft gear and speed governor 5. Frame for idle speed governor spring 6. Rocker arm with speed governor springs

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LDW 2204/T CHD engine

CAMSHAFT Camshaft pull-off To pull off the camshaft remove the valve control tappets 1, the injection pump control tappets 2, the bearing retaining metal sheet 3 and the feeding pump drive rod 5.

NOTE: For pulling-off the tappets 2 you have to turn the screws 4 by three or four revolutions.

90

Checking the inner diameter of the camshaft bushes Use a dial gauge for inner parts.

Should the measured diameter values do not match the theoretic ones, pull the bushes off with the special tool (Fig. 93 and 94) and replace them.

91

Camshaft journals and bushes Dimensionsi (mm): A = 44,000 ÷ 44,025 B = 43,94 ÷ 43,96 C = 43,000 ÷ 43,025 D = 42,94 ÷ 42,96 E = 42,000 ÷ 42,025 F = 41,94 ÷ 41,96 Clearances (mm): (A-B) (C-D)

0,040 ÷ 0,085 (wear limit value 0,16 max)

92

(E-F)

NOTE: The values A, C, E are referred to bushes press fitted and reamed.

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LDW 2204/T CHD engine

Camshaft bush replacement Bush replacement tool 1. Spindle 2. Centering bush 3. Bush diameter 44 mm 4. Bush diameter 43 mm 5. Bush diameter 42 mm NOTE: 93

When positioning the bush for press fitting, the bush shall be faced as to overlap the lubrication hole and the seat hole.

94

Intake, exhaust and injection cam heights Dimensions (mm): Intake = 35,438 ÷ 35,500 Exhaust = 35,138 ÷ 35,200 Injection = 33,950 ÷ 34,000

Intake

1st cylinder

Exhaust

2nd cylinder 3th cylinder

Injection

3th cylinder

95

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LDW 2204/T CHD engine

Valve train timing Fit the intermediate gear B by matching the references 2 and 1 of the camshaft control gear A with the references 3 and 4 or the train valve control gear C.

96

Valve train timing without references Place the piston 1 (flywheel side) on the top dead centre.

Place two rods A with the same length on the tappets.

Turn the camshaft as long as the cams of the cylinder 1 cross together (intake open and exhaust closed).

Check with a metal rule B the rods A for the same height.

Engage the intermediate gear in the camshaft gear and in the valve train gear.

97

Checking the valve train timing The check is performed on the drive shaft.

The values indicated are measured on the circumference: with flywheel diameter 330, 1° is equal to 2.87 mm.

Reset the dial gauge on the intake valve ball.

By turning the drive shaft in its revolution direction (intake valve opening timing referred to the top dead centre S) and (intake valve closing timing referred to the bottom dead centre I can be determined.

98

Proceed in the same way with the exhaust valves checking them for (exhaust valve opening time) and (exhaust valve closing timing).

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27

LDW 2204/T CHD engine

Operation timing angles = 12° (corresponding to 34.54 mm on flywheel). = 48° (corresponding to 138.16 mm on flywheel). = 58° (corresponding to 166.94 mm on flywheel). = 14° (corresponding to 40.29 mm on flywheel).

the the the the

99

Camshaft end play Measure the camshaft end after dismounting the engine head and the injection and feeding pumps.

Make sure that the plate 1 is tightened.

Place the dial gauge on the camshaft front surface.

Push to the inner and pull to the outer side the camshaft.

The end play value is the ball bearing play (0,008 mm).

100

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LDW 2204/T CHD engine

2 - TURBOSUPERCHARGER For checking the supercharger air pressure tighten the pressure gauge in the M8 hole A or B, provided for both versions with air inlet on flywheel side (Fig. 101) and with air inlet on fan side (Fig. 102).

102

103

Turbosupercharger components 1.

Hose.

2.

“Waste gate” valve actuator.

3.

Clamp.

4.

Turbine housing.

5.

Snap ring.

6.

Turbosupercharger scroll.

7.

Shim.

8.

Nut. 9.

Lock nut.

10. Turbine shaft.

11. Piston ring.

12. Spark arrester.

13. Bearing.

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14. Snap ring.

15. Shim.

16. Piston rig.

17. Oil baffle plate.

18. Thrust coupling.

19. O-ring.

20. Thrust bearing.

21. Thrust ring.

22. Bearing.

23. Snap ring.

24. Snap ring.

25. Bearing holder.

29

LDW 2204/T CHD engine

Turbosupercharger function test Provide a pressure gauge scaled from 0 to 2 bar.

Connect it according to Fig. 101 or 102.

Start the engine, warm it up for few minutes and run it to 2500 rpm N-power.

The supercharger air pressure to be detected is 89/93 KPa (0.89/0.93 bar).

If the set air pressure does not match the values required, an adjustment of the (Wastegate) C valve stem stroke is needed, see hereafter.

104

Checking the adjustment of the actuator.

Stroke governor of the “Wastegate” valve control stem.

The check shall be performed with engine off.

Detach the hose 7 on the supercharger side.

Use a T-union and connect the pressure gauge 4 (scaled from 0 to 2 bar) and with the pressurised air system hose including throttle valve 5.

The pressurised system air pressure shall be 1.5/2 up to bar.

105

Drill a B hole with diameter 1.5 mm in the pressure gauge hose.

Through this hole, a certain air flow rate will be breathed out, which was intended to stabilised the pressure inside the pressure gauge.

Operate the throttle valve 5 to feed air to the actuator as to pull forward the terminal 2 by A (A = 1 mm).

Adjust the dial gauge 6 for the feeler to get in contact with the terminal 2.

The pressure detected through the pressure gauge must be 830/890 mm Hg (1.11/1.19 bar).

Should the pressure be lower than the value specified, proceed as follows: - Loosen the lock nut 1.

- Remove the split pin 9 and detach the rod 8.

- Keep the rod in its position as you tighten the terminal 2 as long as the setting pressure is reached.

As the terminal is turned the rod may not be warped.

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LDW 2204/T CHD engine

3 - LUBRICATION SYSTEM

8

1

2 15 9 10 3 11 4 12 5

6 13 14

7

106

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Oil fill-in plug.

Rocker arm journal.

Cartridge filter.

Main journal.

Connecting rod head journal Oil dipstick Exhaust plug Breather Camshaft Oil pressure indicator Oil pump Drive shaft Oil pressure relief valve Intake mesh net Turbosupercharger

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31

LDW 2204/T CHD engine

OIL PUMP

1. Intake duct.

2. Delivery duct.

3. Oil pressure relief valve duct.

4. Gasket.

5. Outer rotor.

6. Inner rotor.

7. Spline.

The oil pump is driven through the drive shaft by means of the spline 7.

The rotor 6 is locked in the circumference direction, but not in the axial direction, thus allowing the drive shaft to move axially without the rotors 5 and 6 wear the pump seal surfaces.

107

108

109

110

111

112

Oil pump rotor clearances Measure the clearance A between the teeth on the spine axis (as shown in the picture).

Its value is 0,150 mm Wear limit clearance 0,280 mm.

Oil pressure adjust valve 1. Valve 2. Spring 3. Gasket 4. Plug Dimensions: (mm) A = 45,5 ÷ 46,0 Blow the pressurised air the valve seat and clear accurately all components.

Use a gauge to check the length of the spring A.

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LDW 2204/T CHD engine

Oil filter cartridge 1. Gasket.

2. Plates.

3. Gasket.

4. Blade.

5. Filtering material.

6. By-pass valve.

Specification: - Maximum operation pressure: 7 bar.

- Maximum discharge pressure: 20 bar.

- Cold resistance: – 35°C. - By-pass valve adjustment: 2,1 ÷ 2,8 bar.

- Total filtering surface: 2000 cm2.

- Filtering rate: 15 µ.

113

Oil pressure check After assembling, top up the engine with oil and fuel; connect a pressure gauge scaled to 10 bar to the pressure switch union.

Start up the engine and check the pressure trend according to the oil temperature, see hereafter.

114

Oil pressure curve with engine at idle speed The curve was detected on the oil filter at a speed of 850 rpm in unladen condition.

115

Oil pressure curve with engine at highest speed The curve was detected on the oil filter at a speed of 2500 rpm at N-power.

116

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33

LDW 2204/T CHD engine

4 - COOLING SYSTEM

11

10

8 6

7 1

9 2

11 4

5

3

10 10 11 117

ENGINE COOLING 1. Expansion tank.

2. Cooler 3. Fan 4. Circulating pump.

5. Heat exchanger 6. Coolant temperature warning lamp.

34

7.

8.

9.

10.

11.

Thermostat.

Plug on the cooler.

Cylinder block.

To transmission.

From transmission.

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LDW 2204/T CHD engine

Expansion tank and plug The expansion vessel A is detached from the radiator and includes the coolant fill-in plug.

The plug on the radiator B is equipped with a vacuum valve and a pressure relief valve.

Pressure relief valve opening pressure 1,0 bar.

118

Checking the cooler for tightness Replace the cooler plug with a plug equipped with an union for manually operated air pumps, see picture.

Pressurize air to 1 bar for approx. 2 minutes.

Check the radiator for leakages

119

Coolant circulation pump The impeller 3 and the hub 5 are fitted on the shaft per negative allowance.

On the shaft a front sealing gasket is put in- between bearing and impeller.

Should this gasket be worn or torn, a leakage from the hole 1 would be ascertained.

The pump flow rate at 2500 rpm is ~ 115 l/1’.

121_1

121_2

Thermostat 1. Stainless steel or brass body 2. Breather valve 3. Wax bulb

Specification: - Actuation temperature: 77° ÷ 81° C. - Maximum stroke 94° C≥ 7 mm.

- Fluid drainage with thermostat and valve closed: 15 l/h con P = 1 bar.

122

Ed. 05/2004 • Rev. 01-05/2004

123

35

LDW 2204/T CHD engine

5 - INJECTION / FEEDING SYSTEM

124

1. Tank.

2. Feeding pump.

3. Fuel strainer.

4. Feeding pipe.

5. Exhaust pipe.

6. Injection pump.

7. Fuel delivery pip.

8. Injector.

9. Injector return pipe.

10. Fuel interception solenoid valve.

Fuel filter 1. Bleed screw 2. Cover 3. Gasket 4. Union 5. Cartridge Cartridge specification: - Filtering paper: - Filtering surface: - Filtering rate: - Maximum operation pressure:

PF 904 5000 cm2 2/3 4 bar 125

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LDW 2204/T CHD engine

Feeding pump 1. Feeding pump 2. Drive rod 3. Seal ring The feeding pump is a membrane pump. It is operated through a cam of the camshaft by means of a drive rod.

The pump is equipped with an outer lever for manual operation.

Specification: with the control cam at 1500 rpm, the minimum flow rate is 64 l/h.

The self-adjusting pressure is 5 ÷ 6 m water column.

126

Feeding pump drive rod overhanging The overhanging measure A o the drive rod 2 from the cylinder block is 1,5 ÷ 1,9 mm.

The check must be performed with the cam 1 in standby position.

Drive rod length = 32,5 ÷ 32,7 mm.

Check the drive rod for the right length and replace it, if necessary.

127

INJECTION PUMP The injection pump installed in the engines type CHD is a simplified version of the type Q. The injection system consists of four different pumps, each pump feeding a cylinder.

The pumps, located on the cylinder block in the position matching the relevant cylinder, are operated directly through the camshaft.

The A fuel feed hoses have the same shape and dimensions.

They have a short length.

128

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37

LDW 2204/T CHD engine

Injection pump disassembly After releasing the spring from the retaining ball, disassemble the piston.

The upper ball is kept closed to the pump housing through two pins.

For disassembling the pump place a tool between the pump housing and the ball.

129

Injection pump components 1.

Delivery union.

2.

Filler-in.

3.

Spring.

4.

Gasket.

5.

Delivery valve.

6.

Gasket.

7.

Retainer ball.

8.

Spring.

9.

Upper ball.

10. Piston.

11. Lever.

12. Pin. 13. Body.

A. B. C. D. E.

Fuel intake coupling.

Fuel exhaust coupling.

Pump securing flange.

Cylinder.

Fuel regulation blade.

NOTE:

The A and B couplings as well as the C flange and the D cylinder are integrated with the pump housing.

130

Injection pump reassembling The piston shall be fitted with the E blade facing the B exhaust coupling.

Should the piston be fitted by mistake with the blade facing the A intake coupling, the feeding pump does not work (there is no danger for the engine to operate at runaway speed rate).

Complete the assembly according to Fig. 130 and 131.

Tighten the delivery union with 35 Nm

Nm

.

131

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LDW 2204/T CHD engine

Injection pump non-return valve In the exhaust coupling a non-return valve A is installed.

This valve aims an injection improvement by bleeding the air contained in the fuel as well as a quick engine switch off whenever the stop switch is operated.

132

Injection pump control rod The rod 1, operated by the accelerator and controlled by the speed governor, controls the injection pumps.

The ring nut 2 keeps the rod 1 in its guide by means of the groove 3.

NOTE: Do not loosen the ring nut 2 before pulling off the rod 1.

133

134

135

136

Injection pump feeding hose removal Cut the nylon hose in the point A and in the direction pictured.

Remove the hose piece left in the coupling by means of standard pliers.

Shape and remove the nylon ring without damaging the coupling sealing, see picture.

Re-use the same feeding hoses, if enough length is left; replace the hose, if this is not the case.

IMPORTANT: Do not cut the hose in the direction opposite to the arrow A (horizontally), otherwise the pump coupling might be damaged and fuel drain out.

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LDW 2204/T CHD engine

Injection pump feeding hoses refitting 1. Pinchcock for hoses with diameter 6 mm.

2. Pinchcock for hoses with diameter 8 mm.

The intake and exhaust hoses are made of nylon.

The hoses are press fitted in the injection pump couplings by means of suitable pinchcocks and a rubber hammer

137

138

Injection pump flow rate balance device 1. Tank.

2. Test tube.

3. Bearing.

4. Knob.

5. Injection pump exhaust pipe on-off valve.

6. Injection pump intake pipe on-off valve A. Connection pipe with injection pump intake coupling.

B. Connection pipe with injection pump exhaust coupling.

•

Remove the feeding hoses from each injection pump and insert the hoses of the measurement instrument making sure to connect each pump with the relevant intake and exhaust hose; connect A of the instrument with A of the engine as well as B of the instrument with B the engine, referring to the Fig. 139 and 140.

•

Open completely the valves 5 and 6 of each hose and fill up the measurement device with fresh fuel.

•

Start up the engine and run it at 2000 rpm in unladen condition.

The maximum balance deviation between the test tube levels may not exceed 2 cm3 in a minute.

40

139

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LDW 2204/T CHD engine

Injection pump flow rate balance Place the measurement device, duly connected and filled-at least 20 cm higher than the injection pump level.

Run the engine to 2000 rpm in unladen condition Use the knob 4 in the Fig. 139 to interrupt the feeding flow from the measurement device tank to the engine and check the test tube level.

If the level of a test tube decreases more than the others, the flow rate of the relevant pump shall be reduced.

Considering that all holes for the pump flange screws are slotted, proceed as follows: - Loosen the screws securing the relevant pump to the cylinder block by 1/4 revolution.

- Tap the pump housing with a driftpin and a hammer for the pump housing to rotate slightly.

Turn in clockwise direction to increase the flow rate, turn in anticlockwise direction to reduce the flow rate.

Nm .

- Tighten the screws with 25 Nm

140

Flywheel side

Distributor side

Whenever the injection pump is replaced, the injection pump flow rates shall be balanced to each other.

IMPORTANT:

141

When disassembling one or more pumps you intend to reassemble, observe the following procedure: • If there are none, mark some references between the pump flanges and the contact surfaces on the cylinder block.

• Do not alter the injection timing adjust shims under each pump.

• Each pump shall be re-fit in its seat. Line up the reference marks on the flange of each pump with the cylinder block marks.

Pumping element 1. Pump housing 2. Cylinder 3. Piston Dimensions (mm) A = 2,00 ÷ 2,03 B = 1,50 ÷ 1,53 C = 7,000 D = 26,00 IMPORTANT: The cylinder 2 is integrated with the pump housing 1. For this reason, there is no way of replacing the cylinder and the piston 3.

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142

41

LDW 2204/T CHD engine

Checking of low pressure injection timing Injection timing 9° ± 1°.

Fill-in the tank (you can use the one pictured in Fig. 139 or an equivalent one), and connect it to the input union 2 of the injection pump you want to check (cylinder no. 1), Fig. 143.

Make sure that the fuel level in the tank is exceeds the injection pump level by at least 20 cm.

If this condition cannot be realised, excite the solenoid valve by the ignition switch and operate the feeding pump.

Detach the back-feeding pipe from the output union 2 (Fig. 143) and fit on the same union a hose piece.

Insert a wire making sure it comes out by approx. 1 cm and check any dropping.

Bring the first cylinder to the compression TDC by turning the drive pulley in the engine revolution direction (clockwise) and pull it back by 1/4 revolution.

Some fuel will come out of the output hose 1 of the injection pump.

Continue turning the pulley slowly in clockwise direction, making sure to stop as soon as the fuel stops dropping: this is the static injection timing.

143

Should the 1st cylinder TDC reference on the pulley D not match the reference injection timing reference Fig. 144, remove the injection pump and replace the shim with another one with proper thickness (Fig. 146), (see hereafter “TIMING ADJUSTMENT”) Proceed in the same way for the injection pumps left taking care of the TDC references for each cylinder marked on the pulley.

Injection timing references and cylinder top dead centre: A = TDC on the distributor cover B = Injection timing reference referred to TDC = 10°/12°.

C = Injection timing reference referred to TDC 1 = 12°/14°.

144

Pulley references D = TDC of the 1° and 4° cylinder.

E = Reference for other application.

F = TDC of the 3° and 2° cylinder.

G = Reference for other application.

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LDW 2204/T CHD engine

Checking of low pressure injection timing with reference to the piston descent relevant to the TDC NOTE: When performing the operation according to Fig. 145, the valve collapsing causes the valve fill-up completely, since there is no load on the hydraulic tappet. In this condition the engine cannot turn for approx. 1/2 h (the time needed for the tappet to discharge completely).

To gain time and operate on the four pumps contemporaneously, detach the tappet push rods from the rocker arms by removing and putting them away, and check the timing in this condition.

145

After finishing the check, refit the rods, keeping to the procedure and operation instructions of the paragraph relevant to hydraulic tappets. grades If you cannot pass through and reach the pulley because there is not place enough, you can check the injection timing by means of the tool 1 (Fig. 145). In this way you would benefit of more precise values than with the check described before.

Remove the rocker arm cover, the intake manifold and install the tool 1 (Fig. 145).

Drive the piston in the TDC (to be verified with the tool 1). Operate the lever 2 for the intake valve to get in contact with the piston and reset the dial gauge.

Feed in the injection pump to be checked as illustrated above. Turn the engine in anticlockwise direction by 1/ 4 revolution.

Then turn it clockwise slowly and observe the dropping from the hose 3 (Fig. 145).

Stop as soon as the fuel stops dropping out.

15° 14° 13° 12° 11° 10° 9° 8° 7° 6° 5°

TIMING 9°± 1° (mm) 1.866 1.627 1.405 1.198 1.008 0.834 0.676 0.534 0.409 0.301 0.209

To adjust the injection timing, replace the shim inside the injection tappet with another one with different thickness (Fig. 149).

(See “INJECTION TIMING ADJUSTMENT”).

This is the static injection timing according to the description in Fig. 144.

Operate again the lever 2 to bring the valve in contact with the piston and re-measure the piston down-stroke in comparison with the previous measurement: PMS When referring to the table aside, you can see that injection timing 9° corresponds to a piston downstroke by 0,676 mm (a deviation by ± 1°is allowed, i.e. a piston down-stroke from 0,534 to 0,834 mm).

If you happen to measure different values, this would mean that the injection timing is too early or too late in comparison with the specified timing: a correction is required.

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43

LDW 2204/T CHD engine

Injection timing adjustment by inserting different shims The system require only one gasket A located under the injection pump flange preventing any oil leakage.

Besides the thickness of the gasket A, another factor determining the injection timing is the thickness of the shim located inside the injection tappet.

To pull the shim B off, use a rod with a suction cup C or a magnet on one end.

The shims provided as spare parts are available in 9 different thickness sizes (from 4.0 up to 4.8 mm).

The thickness is stamped on the lower part of the shim.

146

147

IMPORTANT: A variation by 0.1 mm of the B shim causes a injection timing variation by approx. 1°.

Is the injection too late, increase the B shim.

If the injection too early, decrease the B shim.

In case the rocker arm shaft is disassembled or the tappet push rods are detached from the rocker arms, before reassembling them, perform the following procedure: 1. Drive all pistons up to ~ 1/2 stroke.

2. Feed the tappets by filling in oil in the tappet seats through the rod ducts.

3. Refit the rocker arm shaft or replace the rods.

4. Wait ~ 1/2 hour before starting the engine for the tappets to reach their optimum fill-in level.

5. Turn the engine manually by a couple of revolutions and check it for seizing or other failures.

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LDW 2204/T CHD engine

INJECTION VALVE

Whenever servicing the injector, clear the spark arrester and replace it, if you notice any failure.

Insert the spark arrester 1 in the injector socket with the sealing surface facing upwards, as shown in the picture.

Tighten the injector head with 70 Nm.

148

Injection valve adjustment Connect the injector to a manually operated pump and check the setting pressure for a value 140/150 bar; adjust, if required, by changing the shim placed over the spring.

Eleven different thickness sizes, from 1 up to 2 mm, are provided.

When replacing the spring, the setting must be performed at a pressure higher than 10 bar (160 bar) to compensate any operation settlement.

149

Check the tightness with a pin by maintaining the pressure at 120 bar for 10 seconds.

If you notice any dropping, replace the fuel nozzle.

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45

LDW 2204/T CHD engine

6 - ELECTRIC EQUIPMENT

Alternator alternator type aa125 r - 14v - 65a with terminal w.

Specification: - Rated voltage = 14 V. - Rated current = 65 A. - Maximum speed = 14000 giri/1’.

- Maximum discontinuous speed ( for 15’) = 15000 giri/1’.

- Tension governor = RTT 119 C. - Clockwise turning direction.

Nm .

- Nut 1 tightening = 60 Nm 150

IMPORTANT: Lubricate both bearings with high-temperature grease.

Characteristic curve for the alternator The curves have been measured with an electronic voltage regulator after heat stabilisation at 25°C and test voltage 13,5V.

P1 = Power in KW I = Current in Ampere = Alternator efficiency

X 1000 rpm 151

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LDW 2204/T CHD engine

Characteristic curve for the voltage governor RTT 119 AC The electronic voltage regulator is integrated in the alternator.

The curve changes as the temperature does.

A = Maximum voltage curve B = Minimum voltage curve.

152

STARTER Starter type EV 12V - 2 kW Clockwise turning direction.

153

Characteristic curve for the starter The continuous lined curves have been detected at a temperature +20°C; the section-lined curves have been detected at a temperature -20°C.

rpm

Battery used: 110 Ah 450 A. U = Starter terminal voltage in Volt n = Starter speed.

A = Input current in Ampere.

P = Power in kW. M = Torque in N/m.

154

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47

LDW 2204/T CHD engine

Coolant temperature light thermostat Specification: - System: single-pole system.

- Input voltage: 6/24V. - Input power: 3W. - Contact actuation temperature: 107/113°C. When reassembling, tighten with 25 Nm

Nm

.

155

Pre-heating glow plug Specification: - Rated voltage = 11V. - Input = 12 ÷ 14A after 5 seconds.

- Sheath outer temperature = 850° C after 5 seconds.

1. Sheath.

2. Control filament.

3. Heating filament.

IMPORTANT: 157

Should the engine do not start in 15 seconds preheating is interrupted so as to prevent any damage to the glow plug due to prolonged operation time.

Glow plug control unit with engine compartment temperature sensor The temperature sensor determines the glow plug ignition time according to the curves detected (Fig. 160).

ELECTRIC SYSTEM + Batt.

+ 50

+ Batt.

Glow plug Optical indicator

159

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LDW 2204/T CHD engine

Pre-heating time characteristic curve

sec

160

Operation The area A corresponds to the period in which the optical indicator is on and the pre-heating device switched on.

The hatched area B represents the tolerance range in which the optical indicator is switched off, whereas the preheating device is still on.

The area C represents the period in which the optical indicator is switched off and the pre-heating device is on.

This phase, characterized by 8 ÷ 14 sec. long, continuous operation time, is counted down from the optical indicator switch off.

The area D corresponds to the period of time in which the optical indicator and the pre-heating device are off.

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49

LDW 2204/T CHD engine

7 - SETTINGS (Standard) idle speed adjustment in unladen condition) After filling in the engine with oil, fuel and coolant, start it up and warm it up for 10 minutes Adjust the idle speed at ~ 850 ÷ 900 rpm by means of the setscrew 1. Tighten the lock nut.

NOTA: The rpm rate decreases by loosening the screw 1 and increases by turning the screw in the opposite direction.

161

(Standard) highest speed adjustment in unladen condition After setting the idle speed, adjust the highest speed at 2650 ÷ 2700 rpm in unladen condition by means of the screw 2 and tighten the lock nut.

As soon as the engine reaches the specified power, the highest speed will be adjusted at 2500 rpm’.

NOTE: The rpm rate increases by loosening the screw 2 and decreases by tightening the screw 2.

162

Injection pump flow rate standard adjustment without water brake This adjustment should be carried out with the engine connected to a water brake otherwise the adjustment is only approximate.

In this case proceed as follows: - Loosen the flow rate regulator C by 5 revolutions.

- Run the engine up to the maximum speed in unladen condition, i.e. up to 2650 ÷ 2700 rpm.

- Re-screw the regulator C as far as the engine speed begins decreasing - Loosen the regulator C by one and half revolution.

- Tighten the ring nut.

163

NOTE: If too much smoke comes out of the engine in the maximum load condition tighten C. Loosen C if no smoke is visible when discharging and the engine cannot develop its maximum power.

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LDW 2204/T CHD engine

Injection pump flow rate regulator and torque adjuster The regulator C limits the injection pump maximum flow rate.

The same device acts as a torque adjuster.

In fact, in the maximum torque range, the springs N prevail on the resistance of the spring M inserted in the piston by means of the lever L. The lever L is allowed by the torque adjuster to run a stroke H of 1,0 ÷ 1,1 mm.

As a consequence, the injection pump flow rate will increase and the torque will reach its maximum value.

164

Auto-choke valve When starting the engine, the auto-choke valve prevents too much smoke coming out of the exhaust pipe.

It operates the injection pump flow rate regulation rod 5 (Fig. 166) continuously when the room temperature exceeds 15°C. As long as the temperature decreases, this device is released gradually and is finally completely switched off then the temperature reaches 0 °C.

165

Auto-choke valve adjustment - Run the engine to the specified rpm and torque - Loosen the lock nut 2.

- Loosen the screw 1 for the lever 4 get closer to the rod 5 as long as the engine rpm begins decreasing.

- Tighten the screw by 1/2 ÷ max. 1/4 revolutions for the lever 4 be detached from the rod 5 by 1,2 ÷1,8 mm.

- Tighten the lock nut 2.

- As soon as the temperature decreases under 0°C, thelever A turns (the pin 6 of the thermostat 3 goes back) as long as it reaches the position B and the rod 5 rea-ches the throttle position.

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166

51

LDW 2204/T CHD engine

8 - TORQUE WRENCH SETTINGS MAJOR TORQUE WRENCH SETTINGS

Item

Diameter and inch mm

Torque Nm

Caps

10 x 1.5

70

Flywheel housing

10 x 1.5

50

Pre-heating glow plug

12 x 1.25

50

Rocker arm caps

8 x 1.25

20

Main bearing cap

12 x 1.25

120

Intake manifold

8 x 1.25

25

Exhaust manifold

8 x 1.25

25

Cover

6x1

10

Oil pump cover

6x1

10

1P Fluid pump flange cover

6x1

10

Oil pressure gauge

12 x 1.5

35

Camshaft gear

10 x 1.5

80

Head injector

24 x 2

70

Starter

10 x 1.5

45

Distributor cover

8 x 1.25

25

Feed pump stud bolts

8 x 1.25

-

Drive pulley

16 x 1.5

352

Oil filter cartridge union

UNF 3/4

-

Injection pump union

12 x 1.5

35

Intermediate gear thrust block union

22 x 1.5

200

Fuel inlet union pipe

12 x 1.5

25

Water back-feeding brass unions

14 x 1.5

-

Rocker arm bearing

10 x 1.5

50

Cylinder block lubrication nipple plug

14 x 1.25

-

Water drain plug

14 x 1.5

40

Oil drain plug

14 x 1.5

50

Bleed plug under the oil sump

14 x 1.5

40

Bleed tube under the oil sump

12 x 1.5

35

Flywheel

12 x 1.5

140

52

Torque Loctite, type

270

270 270 270 554 554

270

Ed. 05/2004 • Rev. 01-05/2004

Series LDW 2204/T Engine Section 41

Place the washer.

Insert the screw.

Edition July 2002 Revision July 2002

Tightening of the Head

Page 41.2

Series LDW 2204/T Engine Section 41

Following the numerical order shown in the picture, tighten the screws in four consecutive phases with the following torques.

Using a wrench:

dynamometric

1st phase = 40 Nm 2nd phase = 70 Nm 3rd phase = 100 Nm

4th phase = Using an angle tightening tool, rotate the wrench of 270° further.

(In 3 times, 90°+90°+90°)

Edition July 2002 Revision July 2002

Tightening of the Head

Page 41.3

Engine series LDW 2204/T CHD Section 42

Valve Control Tappets Less noise; Less fuel consumption; Operation not affected by wear and temperature; Softer valve springs; Valves have higher rise and their operation is more ‘faithful’ to the cam shape; No adjustment or maintenance required.

Oil intake

Drainage and lubrication

Camshaft

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.1

Engine series LDW 2204/T CHD Section 42

Transmission Rods

Transmission rods are hollowed out to allow the movement of oil from the rocker arm shaft to the tappets.

The tappets eliminate the mechanical play, which occurs in the kinematic motion due to temperature shift and usage.

The tappet transmission rods are characterized by their symmetry; therefore, it is possible to assemble them in many ways.

The spherical fitting on the two ends enables a good oil seal.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.2

Engine series LDW 2204/T CHD Section 42

Insert the rods in those head compartments that communicate with the tappets.

(The rods inserted.).

Edition July 2002 Revision July 2002

Valve Control Tappets

have

been

Pag. 42.3

Engine series LDW 2204/T CHD Section 42

Rocker Arm Pin Assembly

Before carrying out the assembly, thoroughly clean the interior of the rocker arm shaft and lubricate all the fitting surfaces between the shaft and the rocker arm with motor oil.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.4

Engine series LDW 2204/T CHD Section 42

Check the wear condition of the bearings and replace them, if necessary.

Dimensions (in mm): A = 14.032 ÷ 14.050 for each bearing, which is assembled to the rocker arm and bored.

B = 13.982 ÷ 14.00 (A-B) = 0.03 ÷ 0.07 (A-B) = wear limit = 0.14

Check the wear condition of the rocker arm pin.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.5

Engine series LDW 2204/T CHD Section 42

Insert the head retaining ring on the opposite side from the oil intake (1).

Insert the washer.

1

Insert the rocker arm.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.6

Engine series LDW 2204/T CHD Section 42

Insert the shaft bearing.

In case of doubt about the direction of the assembly, see the exploded view at the beginning of this section.

Insert the second rocker arm.

Insert the spring.

Repeat the sequence.

Edition July 2002 Revision July 2002

Valve Control Tappets

assembly

Pag. 42.7

Engine series LDW 2204/T CHD Section 42

1

The last bearing to be inserted has the purpose of centering the hole (1) with the shaft threaded hole for “lubricant intake” (2).

2

Insert the oil intake nozzle.

It takes oil from the engine casing and is also designed to create an assembly reference mark for the whole unit.

Screw until it stops.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.8

Engine series LDW 2204/T CHD Section 42

Insert the washer.

Put the retaining ring in place.

Put some drops of Loctite 270 on the thread of both dowels.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.9

Engine series LDW 2204/T CHD Section 42

Tighten them in opposite directions at 20 Nm.

The assembled rocker arm shaft is as shown in the picture beside.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.10

Engine series LDW 2204/T CHD Section 42

Oil intake nozzle:

1

Through this hole 1, the oil flows into the shaft and is then distributed to the bearings.

2

Oil delivery to the hydraulic tappets (2) by means of hollow transmission rods.

This is a hole (3), through which a certain quantity of oil is released for continuous lubrication of the valve stem.

3

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.11

Engine series LDW 2204/T CHD Section 42

Important: Before carrying out the assembly, follow the instructions below: 1 Bring all the pistons to ~ ½ stroke.

2 Put oil in the tappet housing through the rod lines, in order to feed the tappets.

3 Assemble the rocker arm shaft.

4 Wait ~ ½ hour before starting the engine, so that the tappets can reach their ideal filling level.

5 Manually operate the engine and let it perform a few revolutions, so as to check that there is no jamming or other faults.

Insert the stud bolts into the rocker arm shaft.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.12

Engine series LDW 2204/T CHD Section 42

Tighten each stud bolt three turns, so as to avoid shaft deformations due to the valve spring strain.

Tighten them at 50 Nm.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.13

Series LDW 2204/T Engine Section 43

Exhaust Manifold (The exhaust manifold is made of one single piece of cast iron).

(The four metallic).

gaskets

are

Insert the new gaskets onto the head, as shown in the picture beside.

Edition July 2002 Revision July 2002

Exhaust manifold

Page 43.1

Series LDW 2204/T Engine Section 43

After checking that the seal plane is even, thoroughly clean the interior.

Insert the exhaust manifold into the stud bolts.

Tighten the screw nuts at 25 Nm.

Edition July 2002 Revision July 2002

Exhaust manifold

Page 43.2

Series LDW 2204/T Engine Section 44

Feeding / Injection Circuit

1) 2) 3) 4) 5) 6) 7) 8) 9) 10)

Tank Feeding pump Fuel filter Feeding pipe Exhaust pipe Injection pump Diesel oil thrust pipe Injector Injector waste pipe Solenoid valve

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.1

Series LDW 2204/T Engine Section 44

Injector Assembly The injector has been designed to spray a certain quantity of fuel in the combustion chamber.

The components that make it up are very precise and delicate.

Always remember to work in a condition of maximum cleanliness.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.2

Series LDW 2204/T Engine Section 44

1

2

The nebulizer is formed by the needle (1) and by the nozzle (2). They are supplied together because of the extreme precision of the mechanical machining.

Attention: Never replace only one of the two components.

Insert the needle in the suitable hole of the nozzle.

Insert the partition disk, as shown in the picture beside.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.3

Series LDW 2204/T Engine Section 44

Insert ring.

the

spring-holding

Insert the nozzle, complete with all its components, inside the lower injector casing.

Then, take the upper injector casing and insert a lining having any value.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.4

Series LDW 2204/T Engine Section 44

Insert the spring.

Assemble the pump barrel.

Tighten it at 60 Nm.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.5

Series LDW 2204/T Engine Section 44

Calibration of the Injectors.

Connect the injector with a hand pump and check that the calibration pressure is 140/150 bars, and, if necessary, adjust it by changing the lining, which is placed on top of the spring. Eleven different linings, having various dimensions between 1 and 2 mm, are supplied as spare parts.

Lining

When replacing the spring, the calibration should be done with a pressure higher than 10 bars (160 bars), so as to counterbalance any adjustment during operation.

Check the needle tightness, by keeping the pressure at 120 bars for 10 seconds.

Replace the nozzle if it drips.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.6

Series LDW 2204/T Engine Section 44

Assembly of the Injectors During the maintenance of the injector, clean the fireproof partition and replace it in case faults are detected.

Seal Plane

Edition July 2002 Revision July 2002

Insert the fireproof partition in the injector housing with its seal plane turned upwards.

Feeding_Injection Circuit

Page 44.7

Series LDW 2204/T Engine Section 44

Place the injectors in their housings and tighten them at 70 Nm to the head.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.8

Series LDW 2204/T Engine Section 45

Injection Pump

Injection Pump The injection pump, which is installed in series CHD engines, is of the streamlined Q type.

The injection system is made up of four different pumps, with each pump feeding one cylinder. The pumps are housed inside the cylinder block close to their relevant cylinder and are directly operated by the camshaft.

Non-Return Valve A small non-return valve (A) is inserted in the exhaust clutch. This valve is designed to improve the injection, by expelling the air that forms in the fuel and to quickly bring the engine to a stop every time that the stop signal is operated.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.1

Series LDW 2204/T Engine Section 45

Injection Pump Assembly

Injection Components

Pump

1) Delivery fitting 2) Filler 3) Spring 4) Gasket 5) Delivery valve 6) Gasket 7) Stop disk 8) Pump spring 9) Upper disk 10) Piston 11) Lever 12) Pin 13) Pump barrel A Fuel intake clutch B Fuel exhaust clutch C Pump securing flange D Small cylinder E Fuel control propeller Note: the clutch tubes A and B, the flange C and the small cylinder D are all integral parts of the pump barrel.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.2

Series LDW 2204/T Engine Section 45

1

Insert the filler 1 in the delivery fitting 2.

2

Insert the spring.

Place the metallic gasket inside the pump barrel.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.3

Series LDW 2204/T Engine Section 45

Insert the delivery valve.

Put on top of the other metallic gasket.

Place the delivery fitting, complete with all its components inside, onto the pump barrel, and tighten it at 35 Nm.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.4

Series LDW 2204/T Engine Section 45

Assemble the lever to the piston.

1

2

Edition July 2002 Revision July 2002

Pay attention to place the control pin (1) of the lever on the same side as the horizontal groove for fuel exhaust (2).

Injection Pump

Page 45.5

Series LDW 2204/T Engine Section 45

Assemble the lever as well as the small cylinder to the pump barrel, with the control pin (2) turned towards the diesel oil passage clutches (3, 1).

Attention: If any jamming should occur during this assembly stage, it is imperative not to force it.

2

3

1

Pumping Element

Note: In case the piston is assembled with the propeller turned towards the intake clutch (3) by mistake, the injection pump will not work (there is no danger that the engine will rev up).

1) Pump casing 2) Cylinder 3) Piston Dimensions (in mm): A = 2.00 ÷ 2.03 B = 1.50 ÷ 1.53 C = 7.000 D = 26.00 Important: The cylinder (2) is an integral part of the pump barrel (1), therefore we exclude all possibility of replacing the cylinder and the piston (3).

Edition July 2002 Revision July 2002

Injection Pump

Page 45.6

Series LDW 2204/T Engine Section 45

2

Place the upper disk, making the two pins (2) match the holes that are made in the disk itself.

Attention: In case of disassembly, lever by means of a flat screwdriver that can be inserted between the pump barrel and the disk itself.

Insert the piston spring.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.7

Series LDW 2204/T Engine Section 45

Pre-compress the spring and house the stop disk.

Repeat the same operation for all the pumping elements.

Installing the Pumps on the Engine Unlike previous series, here the gasket between the pumping element and the engine is made of a metal material that is equipped with an O-ring, and only has one thickness.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.8

Series LDW 2204/T Engine Section 45

House the gasket on the pump plane.

1

As shown in the picture beside, the pump driving tappet is equipped with a roller (1), which works in direct contact with the cam.

1

Then, place any lining on the bottom of the tappet, with its hollow surface (1) turned towards the roller.

Otherwise the lining itself would scrape against the roller and damage it.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.9

Series LDW 2204/T Engine Section 45

(Correct assembly of the lining).

House the injection pump inside its compartment.

As a precaution, apply finger pressure on the pump, so as to check that it rests on the cylinder block plane.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.10

Series LDW 2204/T Engine Section 45

In case it should not rest on the cylinder block plane, check that the pump delivery control pin is properly seated within the sliding rod.

Coupling inside Cylinder Block

In the event of incorrect assembly, if the pump fastening nuts were tightened, the pump delivery control pin (1) will succeed in deforming the rod that controls them.

1

1

Edition July 2002 Revision July 2002

the

When the assembly is correctly carried out, the pin (1) is free to slide in the axial direction within its housing.

Injection Pump

Page 45.11

Series LDW 2204/T Engine Section 45

Insert the washers.

Put the nuts in place.

Tighten the nuts at 25 Nm. Repeat the same operation for all the pumping elements.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.12

Series LDW 2204/T Engine Section 45

Attention: When disassembling one or more pumps with the intention of re-assembling the same ones, proceed as follows: 1. If there is none, place a reference mark between the pump flanges and the bearing surfaces on the cylinder block.

2. Leave unchanged the advance injection setting linings under each pump.

3. Each pump should be placed inside its housing.

Align the delivery reference notches, which are made in the flange of each pump, with the reference notches on the cylinder block.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.13

Series LDW 2204/T Engine Section 46

Installing the Thermostat Unit

1

Replace the gasket (1).

Place the gasket in its proper seat (1), which is made in the bearing surface.

Position the thermostat unit in the seat to the left of the water pump.

Edition July 2002 Revision July 2002

Installing the Thermostat Unit

Page 46.1

Series LDW 2204/T Engine Section 46

Inspect all screws before torque tightening, to avoid any deformation of the aluminium fusion.

Tighten them at 28 Nm.

Edition July 2002 Revision July 2002

Installing the Thermostat Unit

Page 46.2

Series LDW 2204/T Engine Section 47

Placing the Oil Dipstick Guide Pipe and the Fuel Stop Solenoid Valve Check and replace the Orings, if necessary.

Insert the pipe suitable hole (1).

in

the

1

Make the holes of the pipe support bracket match the threaded holes in the cylinder block.

Edition July 2002 Revision July

Oil Dipstick Pipe

Page 47.1

Series LDW 2204/T Engine Section 47

The solenoid valve is designed to interrupt the diesel oil flow to the engine, so as to stop it.

Place the solenoid valve in front of the pipe support bracket, using the two threaded holes.

Tighten the two screws of the solenoid valve and of the bracket at 20 Nm.

(Correct positioning).

Edition July 2002 Revision July

Oil Dipstick Pipe

Page 47.2

Series LDW 2204/T Engine Section 47

Insert the oil dipstick.

(Oil dipstick push rod).

Edition July 2002 Revision July

Oil Dipstick Pipe

Page 47.3

Series LDW 2204/T Engine Section 48

Check of Advanced regards the TDC

Injection

Timing

as

In case of disassembly of the injection pump feeding pipes, cut the nylon tube along point A. Using a standard pair of pliers, remove the section of the pipe that is left inside the clutch.

Deform the nylon pipe without damaging the clutch gasket, see picture beside.

Reuse the same feeding pipes if the remaining sections are long enough; otherwise replace them.

Attention: Cutting the pipe in the opposite direction as to arrow A (horizontally) will damage the pump clutch and cause a fuel leakage.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.1

Series LDW 2204/T Engine Section 48

Reassembly of the Fuel Pump Feeding Pipes 1) Pliers for pipes having a diameter of 6 mm.

2) Pliers for pipes having a diameter of 8 mm.

Outlet and inlet pipes are made of nylon.

They are inserted in the clutches of the pressure injection pump by means of a special pair of pliers and of a plastic hammer.

1

Prepare the pumping element, by connecting the fuel inlet clutch (1) to a small tank, which contains a certain quantity of diesel oil and which is placed at least 20 cm higher than the pumping element itself.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.2

Series LDW 2204/T Engine Section 48

Connect a small pipe (2) of about 15 cm. in length to the fuel exhaust clutch.

Make the small pipe slightly curve upwards before letting it bend down.

This is done so that, during the advanced timing operation, the pipe will never be completely drained.

At the outlet of the small pipe, insert a metallic wire letting it protrude of about 1 cm. so as to check that it does not drip.

2

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.3

Series LDW 2204/T Engine Section 48

Leave the transmission disconnected.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

tappet rods

Page 48.4

Series LDW 2204/T Engine Section 48

Install two hand levers on the flywheel, as shown in the picture beside, to help in the advanced timing operation…

…placing them at 180°...

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.5

Series LDW 2204/T Engine Section 48

…so as to be able to operate the flywheel with both hands.

Position the measuring instrument.

It is composed of a frame, which lowers the valves, and is equipped with a support to house the dial gauge.

This tool is designed to measure the height variation of the valves.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.6

Series LDW 2204/T Engine Section 48

1

A

Edition July 2002 Revision July 2002

Position the cylinder piston to be controlled at the top dead centre, during the compression stage.

For greater accuracy, keep the lever pushed down, so as to ensure the contact between the valve and the piston.

At the piston reverse motion, the dial gauge pointer will reverse its rotation direction and that moment will represent the actual TDC. Zero-adjust the dial gauge.

Slowly release the frame lever (1) and read the measure in mm that is given by the valve recession.

At this moment, the reading obtained A represents the measure between the surface of the piston that is placed at TDC and the valve stop.

Check of Advanced Injection Timing

Page 48.7

Series LDW 2204/T Engine Section 48

Rotate the flywheel of about 90° in a clockwise direction until the exhaust pipe of the pumping element starts to drip.

At this point, turn the flywheel in an anticlockwise direction (operation direction) until the exhaust pipe stops dripping. At that time, stop rotating the flywheel.

Press on the lever until the valve is in direct contact with the piston.

B

Edition July 2002 Revision July 2002

Slowly release the lever (1) and read on the dial gauge the measure that is given by the valve return.

Now, work out the piston height difference from the moment when the injection to TDC starts.

B – A = Advanced timing expressed in mm.

Check of Advanced Injection Timing

Page 48.8

Series LDW 2204/T Engine Section 48

Adjustment of Advanced Injection Timing ADVANCED TIMING 9° ± 1° mm 0.3 6° 0.409 7° 0.534 8° 0.675 9° 0.833 10° 1.007 11° 1.189 12° 1.404 13° 1.627 14° 1.865 15°

The chart shows equivalence between and degrees ( ).

As shown, the standard advanced timing injection is with = 9° and it corresponds to a lowering of the piston of 0.675 mm.

A

B

Edition July 2002 Revision July 2002

the mm

The new system includes one single gasket (A) under the injection pump flange and it also has the purpose to avoid any oil leakage.

The advanced injection timing is determined by the thickness of gasket A, as well as by the thickness of the pad, which is placed inside the injection tappet.

To pull out pad B, use a rod equipped with a magnet on one of its ends.

The spare pads supplied have 8 different levels of thickness (from 4.0 to 4.7 mm), and their thickness value is marked on the lower part of the pad.

Check of Advanced Injection Timing

Page 48.9

Series LDW 2204/T Engine Section 48

To correct the advanced injection timing, replace the thickness of the pad that is placed inside the injection tappet.

Important: When changing B thickness by 0.1 mm, advanced timing is changed by 1°.

- In case of delayed injection timing, increase B thickness.

- In case of advanced injection timing, decrease B thickness.

Whenever the disassembly of the rocker arm shaft is carried out, follow the steps below before reassemblying it: 1) Bring all the pistons to ~½ stroke; 2) Put some oil in the tappet housing through the rod lines, so as to feed the tappets; 3) Install the rocker arm shaft; 4) Wait ~½ hour before starting the engine so that the tappets can reach their ideal filling level; 5) Manually operate the engine and let it perform a few revolutions, so as to check that there is no jamming or other faults.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.10

Series LDW 2204/T Engine Section 49

Rocker Arm Cap Replace the gasket of the rocker arm cap.

Check that the lines are not clogged with solid residual oil sludge.

Place the cap onto the head plane and screw in the special nuts with the relevant rubber washers.

Edition July 2002 Revision July 2002

Rocker Arm Cap

Page 49.1

Series LDW 2204/T Engine Section 49

Tighten the nuts at 20 Nm.

Pressure Relief Valve Before closing the oil gas recovery tank, check that the lines do not have any scaling.

Edition July 2002 Revision July 2002

Rocker Arm Cap

Page 49.2

Series LDW 2204/T Engine Section 49

Insert the diaphragm return spring.

Check and replace the diaphragm, if necessary.

Position the diaphragm as shown in the picture beside.

The pressure relief valve (1), which is integrated in the rocker arm cover, is a safety device of the engine.

It is designed to limit the depression whenever it tends to increase. Without this device, should there be a clogged up air filter, the oil contained in the case could be sucked up in the intake manifold and rev up the engine.

Edition July 2002 Revision July 2002

Rocker Arm Cap

Page 49.3

Series LDW 2204/T Engine Section 49

Close everything.

Edition July 2002 Revision July 2002

Rocker Arm Cap

Page 49.4

Series LDW 2204/T Engine Section 50

Intake Manifold After having checked that the seal plane is free from scratches, place the paper gasket on the coupling plane.

Put the intake manifold in place.

Tighten the screws at 25 Nm.

Edition July 2002 Revision July 2002

Intake Manifold

Page 50.1

Series LDW 2204/T Engine Section 51

Oil Vapour Recovery Line The components that make up the oil vapour recovery line from the cylinder block.

Replace the o-ring of the oil vapour recovery pipe running from the cylinder block to the head.

Edition July 2002 Revision July 2002

Oil Vapour Recovery Line

Page 51.1

Series LDW 2204/T Engine Section 51

Assemble the pipe to the head; its o-ring should be housed inside the hole.

Edition July 2002 Revision July 2002

Oil Vapour Recovery Line

Page 51.2

Series LDW 2204/T Engine Section 26

(Inserting the longer screw).

Tighten at 30 Nm.

(Completed assembly).

Tighten the screws at 25 Nm.

Edition July 2002 Revision July 2002

Cooling System

Page 26.8

Series LDW 2204/T Engine Section 26

Complete the assembly of the pump by inserting the plug.

This component cannot be assembled beforehand, as its dimensions would not allow the tightening of the pump sealing screw.

Tighten the plug at 35 Nm.

Edition July 2002 Revision July 2002

Cooling System

Page 26.9

Series LDW 2204/T Engine Section 27

Motor Oil Pressure Switch

(Oil pressure switch).

Tighten it at 35 Nm.

Edition July 2002 Revision July 2002

Motor Oil Pressure Switch

Page 27.1

Series LDW 2204/T Engine Section 28

Thermostat (Components making up the thermostatic unit).

Thermostat Stainless steel or brass body.

The thermostat is equipped with a small air bleeding valve (1) and has a wax bulb.

1

Specifications: Opening temperature: 77° ÷ 81° C. Maximum stroke at 90° C 7 mm.

Liquid blow-by with closed thermostat and small valve = 15 l/h with P=1bar.

Edition July 2002 Revision July 2002

Thermostat

Page 28.1

Series LDW 2204/T Engine Section 28

Thermostat for the Pilot Light of the Coolant Temperature Specifications: - Unipolar circuit - Power supply voltage: 6/24V - Absorbed power: 3W - Contact closing temperature: 107/113°C.

Place the thermostat inside its housing, as shown in the picture beside.

Edition July 2002 Revision July 2002

Thermostat

Page 28.2

Series LDW 2204/T Engine Section 28

Push it with your fingers, and then check its proper sealing.

Assemble the cover that will prevent any movement of the thermostat.

Insert the fastening screws.

Edition July 2002 Revision July 2002

Thermostat

Page 28.3

Series LDW 2204/T Engine Section 28

(The two fastening screws).

Tighten them at 20Nm.

Insert the plug.

(The previous engine series was equipped with two bulbs). Then, tighten the plug at 25 Nm.

Assemble the coolant overtemperature warning bulb to the pilot light of the instrument panel.

Tighten the bulb at 25Nm.

Edition July 2002 Revision July 2002

Thermostat

Page 28.4

Series LDW 2204/T Engine Section 28

Insert the bleeding screw.

Insert the plug and tighten it at 28 Nm.

(Assembled unit).

Edition July 2002 Revision July 2002

Thermostat

Page 28.5

Series LDW 2204/T Engine Section 29

Oil Filter Support with Heat Exchanger (Components).

(Oil heat exchanger support).

(Fastening and oil flow pin).

Edition July 2002 Revision July 2002

Oil Filter Support with Heat Exchanger

Page 29.1

Series LDW 2204/T Engine Section 29

Heat exchanger (face in contact with the support…

…and face in contact with the oil filter).

(Stud bolt).

Edition July 2002 Revision July 2002

Oil Filter Support with Heat Exchanger

Page 29.2

Series LDW 2204/T Engine Section 29

(Oil filter).

Assemble the support to the heat exchanger.

Apply some Loctite 270 on the thread of the stud bolt.

Edition July 2002 Revision July 2002

Oil Filter Support with Heat Exchanger

Page 29.3

Series LDW 2204/T Engine Section 29

Insert it as shown in the picture beside…

…and tighten it at 32 Nm.

Close with the threaded plug.

Edition July 2002 Revision July 2002

Oil Filter Support with Heat Exchanger

special

Page 29.4

Series LDW 2204/T Engine Section 29

Tighten the plug at 30 Nm.

Insert the fastening pin.

Install the assembled unit.

Edition July 2002 Revision July 2002

Oil Filter Support with Heat Exchanger

Page 29.5

Series LDW 2204/T Engine Section 29

Tighten the unit at 55 Nm.

Lubricate the gasket of the filter cartridge with motor oil, then fit it in…

…and tighten it by hand pressure only.

Edition July 2002 Revision July 2002

Oil Filter Support with Heat Exchanger

Page 29.6

Series LDW 2204/T Engine Section 29

A

Connect the engine water flow pipe to its suitable fittings (A).

Tighten both ends of the pipe with metallic rings.

Edition July 2002 Revision July 2002

Oil Filter Support with Heat Exchanger

Page 29.7

Series LDW 2204/T Engine Section 30

Alternator Support (Alternator support).

Insert the screws…

…screw them in place…

Edition July 2002 Revision July 2002

Alternator Support

Page 30.1

Series LDW 2204/T Engine Section 30

…and tighten them at 28 Nm.

Edition July 2002 Revision July 2002

Alternator Support

Page 30.2

Series LDW 2204/T Engine Section 31

Accelerator Control Assembly A

Hook the frame by means of the special hook (A), so as to connect the accelerator to the engine.

Insert the other end of the hook in the accelerator control transmission bracket.

After having replaced the gasket, put the cover of the accelerator compartment in place.

Edition July 2002 Revision July 2002

Accelerator Control Assembly

Page 31.1

Series LDW 2204/T Engine Section 31

Insert the screws…

…and tighten them at 0.8 Nm.

Edition July 2002 Revision July 2002

Accelerator Control Assembly

Page 31.2

Series LDW 2204/T Engine Section 32

Hydraulic Tappets Assembly of the Hydraulic Tappets 5

4

3

2

1

1) External cylinder 2) Spring 3) Inner casing 4) Transmission rod bearing 5) Clip

Place the spring inside the tappet external cylinder and subsequently insert the inner casing

…then fit the rod bearing to the inner casing.

Assemble the clip.

Edition July 2002 Revision July 2002

Hydraulic Tappets

Page 32.1

Series LDW 2204/T Engine Section 32

Observe the position of the clip.

This position of the tappet corresponds to the assembly position.

(On the opposite end of the tappet, there is the surface of contact with the camshaft).

Edition July 2002 Revision July 2002

Hydraulic Tappets

Page 32.2

Series LDW 2204/T Engine Section 32

Positioning of the Hydraulic Tappets After having lubricated the slip holes with motor oil, insert the 8 tappets.

When inserting the tappets, make sure they come in direct contact with the cams.

(Completed assembly).

Edition July 2002 Revision July 2002

Hydraulic Tappets

Page 32.3

Series LDW 2204/T Engine Section 33

Driving Pulley Put the pulley in place, paying attention to the reference pin, which must match the hole that is made in the pulley.

Insert the suitable screw.

Tighten it at 352 Nm in an anticlockwise direction.

Edition July 2002 Revision July 2002

Driving Pulley

Page 33.1

Series LDW 2204/T Engine Section 34

Fuel Pump Measure the length of the cap and replace if it does not correspond to the correct measure.

Length of the cap: 32.5 ÷ 32.7 mm.

Insert the cap into the proper hole with groove 1 turned towards the camshaft.

1

Fuel Pump Projection

Cap

The projection A of cap 2 from the cylinder block plane is 1.5 ÷ 1.9 mm.

An inspection should be carried out with the eccentric cam 1 at rest, as shown in the picture beside.

Edition July 2002 Revision July 2002

Fuel Pump

Page 34.1

Series LDW 2204/T Engine Section 34

After having measured the thickness of the block…

…measure the distance between the surface of the cap and the block surface.

By a simple subtraction, you will obtain the cap projection relative to the motor plane.

Replace the O-ring (1) that is placed on the pump contact surface.

1

Edition July 2002 Revision July 2002

Fuel Pump

Page 34.2

Series LDW 2204/T Engine Section 34

Insert the pump into its housing.

Tighten the nuts of the pump support at 20 Nm.

This is a diaphragm fuel pump, which is driven by an eccentric cam of the camshaft by means of a cap.

It is equipped with a lever (1) for manual coupling.

Specifications: When the eccentric control cam reaches 1500 revolutions/1’, the minimum rate is 64 l/h and the automatic adjustment pressure is a column of water of 5 ÷ 1.9 m.

1

Edition July 2002 Revision July 2002

Fuel Pump

Page 34.3

Series LDW 2204/T Engine Section 35

Flywheel Bell Housing Check that the surface of contact and the reference pins are in good working order.

Check that the coupling flange is in good working order.

Place the flange in the suitable compartment that is made in the flywheel housing box.

Edition July 2002 Revision July 2002

Flywheel Bell Housing

Page 35.1

Series LDW 2204/T Engine Section 35

Once the screws have been properly inserted, tighten them at 30 Nm.

Fit the housing…

flywheel

bell

…making the reference pins (A) match together.

A

A

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Flywheel Bell Housing

Page 35.2

Series LDW 2204/T Engine Section 35

Insert the screws…

fastening

…and tighten them at 50 Nm.

(Once the assembly completed).

Edition July 2002 Revision July 2002

Flywheel Bell Housing

is

Page 35.3

Series LDW 2204/T Engine Section 36

Driving Shaft Gasket on Flywheel Side When gasket:

replacing

the

Thoroughly clean its housing.

Keep the ring immersed in motor oil for approximately half an hour.

Ram it in place, using a stopper and evenly pressing on the whole front surface.

Fill the inner compartment with grease and lubricate the sealing lip with thick oil.

Attention: If an oil leak in the ring gasket area should occur, you can remedy this inconvenience by pushing the ring itself inward of about 2mm.

An ambient temperature below –35° could damage the rings.

Edition July 2002 Revision July 2002

Driving Shaft Gasket on Flywheel Side

Page 36.1

Series LDW 2204/T Engine Section 36

Gently place the oil splash guard onto the driving shaft.

Push with your thumbs until it comes to a stop.

Once the screws have been inserted, tighten them at 10 Nm.

Edition July 2002 Revision July 2002

Driving Shaft Gasket on Flywheel Side

Page 36.2

Series LDW 2204/T Engine Section 37

Flywheel To replace the starting crown wheel, slowly heat it up to 300°C for 15 to 20 minutes.

Insert the crown wheel in the flywheel housing, making sure that it rests evenly on the shoulder of the housing itself.

Let it slowly cool down.

1

When reassembling, make sure that the reference pin 1 is inserted inside its housing.

Flywheel Positioning Put the flywheel in place, making sure that the reference pin is properly fitted.

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Flywheel

Page 37.1

Series LDW 2204/T Engine Section 37

Insert the screws.

Tighten the screws at 140 Nm.

Assemble the guide cover.

Edition July 2002 Revision July 2002

Flywheel

converter

Page 37.2

Series LDW 2204/T Engine Section 37

Insert the screws.

Tighten them at 30 Nm.

Edition July 2002 Revision July 2002

Flywheel

Page 37.3

Series LDW 2004/T Engine Section 38

Starter (Starter).

(Terminal block connections).

for

the

Assemble the starter to the coupling flange.

Edition July 2002 Revision July 2002

Starter

Page 38.1

Series LDW 2004/T Engine Section 38

Insert the fastening screws.

Tighten them at 50 Nm.

Edition July 2002 Revision July 2002

Starter

Page 38.2

Series LDW 2204/T Engine Section 39

Head To avoid any deformation, never disassemble the head when it is still hot.

Using a metallic ruler and a feeler gauge, check the uniformity of the head plane; should a deformation greater than 0.10 mm be detected, level it off by grinding, removing no more than 0.20 mm.

Precombustion Chamber 1

2

Edition July 2002 Revision July 2002

3

In order to pull the precombustion chamber out, use a punch to strike the side of the injector housing (1), and then replace it, as it could buckle during extraction.

Head

Pag. 39.1

Series LDW 2204/T Engine Section 39

Precombustion Chamber Panel The negative allowance between the precombustion chamber and its housing on the head is 0.5 mm.

Before inserting the new panel, measure such diameter gap by means of a micrometer gauge.

1

Insert the new panel, by making dowel 1 match notch 2, then evenly press it.

2

Edition July 2002 Revision July 2002

Head

Pag. 39.2

Series LDW 2204/T Engine Section 39

Before going on fastening the precombustion chamber, check that the head plane is parallel to the precombustion chamber plane.

Hit by means of a plastic hammer, paying attention that no jamming occurs…

Edition July 2002 Revision July 2002

Head

Pag. 39.3

Series LDW 2204/T Engine Section 39

…until the surfaces of the precombustion chamber and of the head are flush.

Using a micrometer gauge, check that the plane of the precombustion chamber does not come out of the head plane more than 0.04 mm and that it is not indented more than 0.02 mm.

Edition July 2002 Revision July 2002

Head

Pag. 39.4

Series LDW 2204/T Engine Section 39

Valve Seats and Housings

1

Valve seats (1) and valve guides are made of a metal that is different from the head material, so as to increase the resistance to wear.

In order to achieve this, they are driven into suitable housings, which are made in the head.

Valve Seats and Housings Dimensions (in mm): A = 41.500 ÷ 41.520 B = 41.575 ÷ 41.590 C = 36.500 ÷ 36.520 D = 36.575 ÷ 36.590 = 44.53’ ÷ 45° 1 = 49.53 ÷ 60° Drive the seats into their housings and mill them, taking into account and 1.

Edition July 2002 Revision July 2002

Head

Pag. 39.5

Series LDW 2204/T Engine Section 39

Valve Guides and Housings

The exhaust and intake guides are identical: both are made of grey cast iron with a phosphorous pearlitic matrix.

1 Guide for exhaust valve 2 Guide for intake valve Dimensions (in mm): A = 36.5 C = 12.020 ÷ 12.038 D = 12.048 ÷ 12.058 Valve guides, having an external diameter D that is oversized of 0.5 mm, are provided for. In such a case, it is necessary to widen housing C by 0.5 mm in order to assembly them.

Edition July 2002 Revision July 2002

Head

Pag. 39.6

Series LDW 2204/T Engine Section 39

Valve Guide Assembly Drive the guides by means of a punch, taking into account the values of A and B with reference to the lower head plane G or of E and F. Dimensions (in mm): A = 36.5 ± 0.2 B = 36.5 ± 0.2 C = 7.020 ÷ 7.035 D = 6.985 ÷ 7.000 E = 10.5 ÷ 11.0 F = 6.5 ÷ 7.0 Clearance (in mm): (C-D) = 0.020 ÷ 0.050 (C-D) = wear limit = 0.10

1

Edition July 2002 Revision July 2002

As you can see, valve (1) is the exhaust valve, since its diameter is oversized when compared to the intake valve (2).

This difference in diameter has the purpose of facilitating the elimination of the exhaust gases.

2

Head

Pag. 39.7

Series LDW 2204/T Engine Section 39

Valves Exhaust valve A: Stem and head are made with two different kinds of material.

3) Chromium-plated section.

4) Section with material: X 45 Cr Si 8 UNI 3992.

5) Section with material: X 70 Cr MnN216 UNI 3992.

1 45°30’/45°45’ D = 35.35/35.50 mm.

Intake valve B: 1) Chromium-plated section.

4) Section with material: X 45 Cr Si 8 UNI 3992.

5) Section with material: X 70 Cr MnN 216 UNI 3992.

1 60°30’/60°45’ C = 40.30/40.50 mm.

Attention: Once the couplings have been located, stick some reference marks onto the components.

Edition July 2002 Revision July 2002

Head

Pag. 39.8

Series LDW 2204/T Engine Section 39

Valve Embedding and Bearing Surfaces of Seats

Once the seats have been milled, hone them with fine emery paste or diamond compound in an oil suspension.

S = Width of the exhaust seat.

S1 = Width of the intake seat.

D = Embedding of the valves relative to the head plane.

Wear limit for S and S1 = 2.00 mm.

Wear limit for D = 1.3 mm.

Oil Seal Ring in the Valve Guide To avoid any deformation of the oil seal ring (1) during its assembly to the valve guide (3), insert the seal ring inside the suitable tool (2) and proceed as shown in the picture beside, making sure to bring the seal ring (1) to a stop.

Edition July 2002 Revision July 2002

Head

Pag. 39.9

Series LDW 2204/T Engine Section 39

(Completed assembly).

Valve Assembly

Edition July 2002 Revision July 2002

Head

Pag. 39.10

Series LDW 2204/T Engine Section 39

After having lubricated the stem of the valve and the hole of the valve guide with motor oil, insert the exhaust valve into its seat.

Paying special attention that no jamming occur, push the valve in until it reaches its bed.

Repeat the same procedure for the intake valve.

Edition July 2002 Revision July 2002

Head

Pag. 39.11

Series LDW 2204/T Engine Section 39

(This is how the opposite side of the head looks like. Notice the two stems).

Assemble the “lower spring-holding ring” washers, whose purpose is to enable the whole valve unit to rotate thanks to the inclined contact plane, between the rocker arm and the stem valve.

The purpose is to obtain a uniform wear of all diameters.

Edition July 2002 Revision July 2002

Head

Pag. 39.12

Series LDW 2204/T Engine Section 39

Inclined Plane Fitting It offers the advantage of setting the valve into rotation every time that it is brought into the opening

Spring Check Inspect the Valve Springs Using a gauge, measure the free length.

(Free length: 52 mm).

Position the valve springs.

Attention: All valve springs identical.

Edition July 2002 Revision July 2002

Head

are

Pag. 39.13

Series LDW 2204/T Engine Section 39

Assemble the upper spring–holding ring.

Half Cones Prepare the half cones for the assembly.

1 2

Edition July 2002 Revision July 2002

Head

The half cones are designed to couple the valve stem to the springholding ring by means of the grooved fitting (1) between the valve stem and the half cone, as well as of the conical fitting between the upper springholding ring and the half cone (2).

Pag. 39.14

Series LDW 2204/T Engine Section 39

In order to enable the insertion the half cones, you should use a tool similar to the one that is shown in the picture beside.

The sprag is equipped with a terminal that allows the upper spring-holding ring to compress until it overcomes the spring load.

Edition July 2002 Revision July 2002

Head

Pag. 39.15

Series LDW 2204/T Engine Section 39

Constrain the press, using the threaded holes that are made on the surface of the head.

This is how the installation will look like (as shown in the picture beside).

Edition July 2002 Revision July 2002

Head

Pag. 39.16

Series LDW 2204/T Engine Section 39

Apply a downward pressure, to overcome the spring load.

Edition July 2002 Revision July 2002

Head

Pag. 39.17

Series LDW 2204/T Engine Section 39

Insert the first cotter…

…and subsequently the other one.

Interrupting the pressure on the valve spring will produce a certain force between the spring-holding ring and the cotter.

Because of the cotter external shape, it will receive a radial thrust that will keep it adherent to the stem.

This is how the head will look like, once the assembly is completed.

Edition July 2002 Revision July 2002

Head

Pag. 39.18

Series LDW 2204/T Engine Section 39

(Assembled head).

Edition July 2002 Revision July 2002

Head

Pag. 39.19

Series LDW 2204/T Engine Section 40

Head Gasket Piston Clearance Volume Inspection Using a magnetically supported dial gauge, check the actual position of the piston top dead centre.

In order to determine the clearance volume (0.67 ÷ 0.90 mm), it is necessary to measure the projection A of all the pistons in respect to the cylinder plane and to consider the value A of the piston that protrudes the most.

Attention: Carry out the measurement along the axis of the engine.

Edition July 2002 Revision July 2002

Head Gasket

Page 40.1

Series LDW 2204/T Engine Section 40

Determining the Thickness of the Head Gasket

In point B of the gasket, there are some small semicircular notches that show the gasket thickness.

Number mm

Resulting Clearance Volume (mm.)

Choose the proper gasket, bearing in mind that to every A value of the table corresponds a gasket having: - no notches, - one notch, - two notches.

(Example).

Edition July 2002 Revision July 2002

Head Gasket

Page 40.2

Series LDW 2204/T Engine Section 40

Positioning of the Gasket Once the head gasket has been determined, place it on the plane.

As you may notice, it is impossible to position it unless it is correctly put in place.

Hole + Bushing

This happens because of the presence of two bushings, having different diameters, which are on the cylinder block plane.

They must match the two holes that are made in the head gasket.

Attention: The gasket should be replaced every time that the head of the cylinder block is removed.

Such a replacement is required, otherwise ideal gasket tightness cannot be guaranteed.

Edition July 2002 Revision July 2002

Head Gasket

Page 40.3

Series LDW 2204/T Engine Section 40

Positioning of the Head Put the head in place, as shown in the picture beside.

Note: The two centering bushings that have been previously used for the gasket will also be used for a correct positioning of the head.

Note: The notches, which are shown in the picture beside, protrude from the head plane. In this way, the thickness of the gasket can be determined before disassembling the head.

This is useful if there are no operations that can bring about a variation in the projection of the pistons.

Edition July 2002 Revision July 2002

Head Gasket

Page 40.4

Series LDW 2204/T Engine Section 41

Tightening of the Head

Before proceeding to tighten the head, the length of the screws should be measured, since the tightening is carried out to the limit and it can leave permanent deformations in the screws.

The length of the screws is 126.40/126.60 mm.

Attention: Replace the screws in case an elongation of 2 mm is detected.

Edition July 2002 Revision July 2002

Tightening of the Head

Page 41.1

Series LDW 2204/T Engine Section 41

Place the washer.

Insert the screw.

Edition July 2002 Revision July 2002

Tightening of the Head

Page 41.2

Series LDW 2204/T Engine Section 41

Following the numerical order shown in the picture, tighten the screws in four consecutive phases with the following torques.

Using a wrench:

dynamometric

1st phase = 40 Nm 2nd phase = 70 Nm 3rd phase = 100 Nm

4th phase = Using an angle tightening tool, rotate the wrench of 270° further.

(In 3 times, 90°+90°+90°)

Edition July 2002 Revision July 2002

Tightening of the Head

Page 41.3

Engine series LDW 2204/T CHD Section 42

Valve Control Tappets Less noise; Less fuel consumption; Operation not affected by wear and temperature; Softer valve springs; Valves have higher rise and their operation is more ‘faithful’ to the cam shape; No adjustment or maintenance required.

Oil intake

Drainage and lubrication

Camshaft

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.1

Engine series LDW 2204/T CHD Section 42

Transmission Rods

Transmission rods are hollowed out to allow the movement of oil from the rocker arm shaft to the tappets.

The tappets eliminate the mechanical play, which occurs in the kinematic motion due to temperature shift and usage.

The tappet transmission rods are characterized by their symmetry; therefore, it is possible to assemble them in many ways.

The spherical fitting on the two ends enables a good oil seal.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.2

Engine series LDW 2204/T CHD Section 42

Insert the rods in those head compartments that communicate with the tappets.

(The rods inserted.).

Edition July 2002 Revision July 2002

Valve Control Tappets

have

been

Pag. 42.3

Engine series LDW 2204/T CHD Section 42

Rocker Arm Pin Assembly

Before carrying out the assembly, thoroughly clean the interior of the rocker arm shaft and lubricate all the fitting surfaces between the shaft and the rocker arm with motor oil.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.4

Engine series LDW 2204/T CHD Section 42

Check the wear condition of the bearings and replace them, if necessary.

Dimensions (in mm): A = 14.032 ÷ 14.050 for each bearing, which is assembled to the rocker arm and bored.

B = 13.982 ÷ 14.00 (A-B) = 0.03 ÷ 0.07 (A-B) = wear limit = 0.14

Check the wear condition of the rocker arm pin.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.5

Engine series LDW 2204/T CHD Section 42

Insert the head retaining ring on the opposite side from the oil intake (1).

Insert the washer.

1

Insert the rocker arm.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.6

Engine series LDW 2204/T CHD Section 42

Insert the shaft bearing.

In case of doubt about the direction of the assembly, see the exploded view at the beginning of this section.

Insert the second rocker arm.

Insert the spring.

Repeat the sequence.

Edition July 2002 Revision July 2002

Valve Control Tappets

assembly

Pag. 42.7

Engine series LDW 2204/T CHD Section 42

1

The last bearing to be inserted has the purpose of centering the hole (1) with the shaft threaded hole for “lubricant intake” (2).

2

Insert the oil intake nozzle.

It takes oil from the engine casing and is also designed to create an assembly reference mark for the whole unit.

Screw until it stops.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.8

Engine series LDW 2204/T CHD Section 42

Insert the washer.

Put the retaining ring in place.

Put some drops of Loctite 270 on the thread of both dowels.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.9

Engine series LDW 2204/T CHD Section 42

Tighten them in opposite directions at 20 Nm.

The assembled rocker arm shaft is as shown in the picture beside.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.10

Engine series LDW 2204/T CHD Section 42

Oil intake nozzle:

1

Through this hole 1, the oil flows into the shaft and is then distributed to the bearings.

2

Oil delivery to the hydraulic tappets (2) by means of hollow transmission rods.

This is a hole (3), through which a certain quantity of oil is released for continuous lubrication of the valve stem.

3

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.11

Engine series LDW 2204/T CHD Section 42

Important: Before carrying out the assembly, follow the instructions below: 1 Bring all the pistons to ~ ½ stroke.

2 Put oil in the tappet housing through the rod lines, in order to feed the tappets.

3 Assemble the rocker arm shaft.

4 Wait ~ ½ hour before starting the engine, so that the tappets can reach their ideal filling level.

5 Manually operate the engine and let it perform a few revolutions, so as to check that there is no jamming or other faults.

Insert the stud bolts into the rocker arm shaft.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.12

Engine series LDW 2204/T CHD Section 42

Tighten each stud bolt three turns, so as to avoid shaft deformations due to the valve spring strain.

Tighten them at 50 Nm.

Edition July 2002 Revision July 2002

Valve Control Tappets

Pag. 42.13

Series LDW 2204/T Engine Section 43

Exhaust Manifold (The exhaust manifold is made of one single piece of cast iron).

(The four metallic).

gaskets

are

Insert the new gaskets onto the head, as shown in the picture beside.

Edition July 2002 Revision July 2002

Exhaust manifold

Page 43.1

Series LDW 2204/T Engine Section 43

After checking that the seal plane is even, thoroughly clean the interior.

Insert the exhaust manifold into the stud bolts.

Tighten the screw nuts at 25 Nm.

Edition July 2002 Revision July 2002

Exhaust manifold

Page 43.2

Series LDW 2204/T Engine Section 44

Feeding / Injection Circuit

1) 2) 3) 4) 5) 6) 7) 8) 9) 10)

Tank Feeding pump Fuel filter Feeding pipe Exhaust pipe Injection pump Diesel oil thrust pipe Injector Injector waste pipe Solenoid valve

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.1

Series LDW 2204/T Engine Section 44

Injector Assembly The injector has been designed to spray a certain quantity of fuel in the combustion chamber.

The components that make it up are very precise and delicate.

Always remember to work in a condition of maximum cleanliness.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.2

Series LDW 2204/T Engine Section 44

1

2

The nebulizer is formed by the needle (1) and by the nozzle (2). They are supplied together because of the extreme precision of the mechanical machining.

Attention: Never replace only one of the two components.

Insert the needle in the suitable hole of the nozzle.

Insert the partition disk, as shown in the picture beside.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.3

Series LDW 2204/T Engine Section 44

Insert ring.

the

spring-holding

Insert the nozzle, complete with all its components, inside the lower injector casing.

Then, take the upper injector casing and insert a lining having any value.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.4

Series LDW 2204/T Engine Section 44

Insert the spring.

Assemble the pump barrel.

Tighten it at 60 Nm.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.5

Series LDW 2204/T Engine Section 44

Calibration of the Injectors.

Connect the injector with a hand pump and check that the calibration pressure is 140/150 bars, and, if necessary, adjust it by changing the lining, which is placed on top of the spring. Eleven different linings, having various dimensions between 1 and 2 mm, are supplied as spare parts.

Lining

When replacing the spring, the calibration should be done with a pressure higher than 10 bars (160 bars), so as to counterbalance any adjustment during operation.

Check the needle tightness, by keeping the pressure at 120 bars for 10 seconds.

Replace the nozzle if it drips.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.6

Series LDW 2204/T Engine Section 44

Assembly of the Injectors During the maintenance of the injector, clean the fireproof partition and replace it in case faults are detected.

Seal Plane

Edition July 2002 Revision July 2002

Insert the fireproof partition in the injector housing with its seal plane turned upwards.

Feeding_Injection Circuit

Page 44.7

Series LDW 2204/T Engine Section 44

Place the injectors in their housings and tighten them at 70 Nm to the head.

Edition July 2002 Revision July 2002

Feeding_Injection Circuit

Page 44.8

Series LDW 2204/T Engine Section 45

Injection Pump

Injection Pump The injection pump, which is installed in series CHD engines, is of the streamlined Q type.

The injection system is made up of four different pumps, with each pump feeding one cylinder. The pumps are housed inside the cylinder block close to their relevant cylinder and are directly operated by the camshaft.

Non-Return Valve A small non-return valve (A) is inserted in the exhaust clutch. This valve is designed to improve the injection, by expelling the air that forms in the fuel and to quickly bring the engine to a stop every time that the stop signal is operated.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.1

Series LDW 2204/T Engine Section 45

Injection Pump Assembly

Injection Components

Pump

1) Delivery fitting 2) Filler 3) Spring 4) Gasket 5) Delivery valve 6) Gasket 7) Stop disk 8) Pump spring 9) Upper disk 10) Piston 11) Lever 12) Pin 13) Pump barrel A Fuel intake clutch B Fuel exhaust clutch C Pump securing flange D Small cylinder E Fuel control propeller Note: the clutch tubes A and B, the flange C and the small cylinder D are all integral parts of the pump barrel.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.2

Series LDW 2204/T Engine Section 45

1

Insert the filler 1 in the delivery fitting 2.

2

Insert the spring.

Place the metallic gasket inside the pump barrel.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.3

Series LDW 2204/T Engine Section 45

Insert the delivery valve.

Put on top of the other metallic gasket.

Place the delivery fitting, complete with all its components inside, onto the pump barrel, and tighten it at 35 Nm.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.4

Series LDW 2204/T Engine Section 45

Assemble the lever to the piston.

1

2

Edition July 2002 Revision July 2002

Pay attention to place the control pin (1) of the lever on the same side as the horizontal groove for fuel exhaust (2).

Injection Pump

Page 45.5

Series LDW 2204/T Engine Section 45

Assemble the lever as well as the small cylinder to the pump barrel, with the control pin (2) turned towards the diesel oil passage clutches (3, 1).

Attention: If any jamming should occur during this assembly stage, it is imperative not to force it.

2

3

1

Pumping Element

Note: In case the piston is assembled with the propeller turned towards the intake clutch (3) by mistake, the injection pump will not work (there is no danger that the engine will rev up).

1) Pump casing 2) Cylinder 3) Piston Dimensions (in mm): A = 2.00 ÷ 2.03 B = 1.50 ÷ 1.53 C = 7.000 D = 26.00 Important: The cylinder (2) is an integral part of the pump barrel (1), therefore we exclude all possibility of replacing the cylinder and the piston (3).

Edition July 2002 Revision July 2002

Injection Pump

Page 45.6

Series LDW 2204/T Engine Section 45

2

Place the upper disk, making the two pins (2) match the holes that are made in the disk itself.

Attention: In case of disassembly, lever by means of a flat screwdriver that can be inserted between the pump barrel and the disk itself.

Insert the piston spring.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.7

Series LDW 2204/T Engine Section 45

Pre-compress the spring and house the stop disk.

Repeat the same operation for all the pumping elements.

Installing the Pumps on the Engine Unlike previous series, here the gasket between the pumping element and the engine is made of a metal material that is equipped with an O-ring, and only has one thickness.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.8

Series LDW 2204/T Engine Section 45

House the gasket on the pump plane.

1

As shown in the picture beside, the pump driving tappet is equipped with a roller (1), which works in direct contact with the cam.

1

Then, place any lining on the bottom of the tappet, with its hollow surface (1) turned towards the roller.

Otherwise the lining itself would scrape against the roller and damage it.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.9

Series LDW 2204/T Engine Section 45

(Correct assembly of the lining).

House the injection pump inside its compartment.

As a precaution, apply finger pressure on the pump, so as to check that it rests on the cylinder block plane.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.10

Series LDW 2204/T Engine Section 45

In case it should not rest on the cylinder block plane, check that the pump delivery control pin is properly seated within the sliding rod.

Coupling inside Cylinder Block

In the event of incorrect assembly, if the pump fastening nuts were tightened, the pump delivery control pin (1) will succeed in deforming the rod that controls them.

1

1

Edition July 2002 Revision July 2002

the

When the assembly is correctly carried out, the pin (1) is free to slide in the axial direction within its housing.

Injection Pump

Page 45.11

Series LDW 2204/T Engine Section 45

Insert the washers.

Put the nuts in place.

Tighten the nuts at 25 Nm. Repeat the same operation for all the pumping elements.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.12

Series LDW 2204/T Engine Section 45

Attention: When disassembling one or more pumps with the intention of re-assembling the same ones, proceed as follows: 1. If there is none, place a reference mark between the pump flanges and the bearing surfaces on the cylinder block.

2. Leave unchanged the advance injection setting linings under each pump.

3. Each pump should be placed inside its housing.

Align the delivery reference notches, which are made in the flange of each pump, with the reference notches on the cylinder block.

Edition July 2002 Revision July 2002

Injection Pump

Page 45.13

Series LDW 2204/T Engine Section 46

Installing the Thermostat Unit

1

Replace the gasket (1).

Place the gasket in its proper seat (1), which is made in the bearing surface.

Position the thermostat unit in the seat to the left of the water pump.

Edition July 2002 Revision July 2002

Installing the Thermostat Unit

Page 46.1

Series LDW 2204/T Engine Section 46

Inspect all screws before torque tightening, to avoid any deformation of the aluminium fusion.

Tighten them at 28 Nm.

Edition July 2002 Revision July 2002

Installing the Thermostat Unit

Page 46.2

Series LDW 2204/T Engine Section 47

Placing the Oil Dipstick Guide Pipe and the Fuel Stop Solenoid Valve Check and replace the Orings, if necessary.

Insert the pipe suitable hole (1).

in

the

1

Make the holes of the pipe support bracket match the threaded holes in the cylinder block.

Edition July 2002 Revision July

Oil Dipstick Pipe

Page 47.1

Series LDW 2204/T Engine Section 47

The solenoid valve is designed to interrupt the diesel oil flow to the engine, so as to stop it.

Place the solenoid valve in front of the pipe support bracket, using the two threaded holes.

Tighten the two screws of the solenoid valve and of the bracket at 20 Nm.

(Correct positioning).

Edition July 2002 Revision July

Oil Dipstick Pipe

Page 47.2

Series LDW 2204/T Engine Section 47

Insert the oil dipstick.

(Oil dipstick push rod).

Edition July 2002 Revision July

Oil Dipstick Pipe

Page 47.3

Series LDW 2204/T Engine Section 48

Check of Advanced regards the TDC

Injection

Timing

as

In case of disassembly of the injection pump feeding pipes, cut the nylon tube along point A. Using a standard pair of pliers, remove the section of the pipe that is left inside the clutch.

Deform the nylon pipe without damaging the clutch gasket, see picture beside.

Reuse the same feeding pipes if the remaining sections are long enough; otherwise replace them.

Attention: Cutting the pipe in the opposite direction as to arrow A (horizontally) will damage the pump clutch and cause a fuel leakage.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.1

Series LDW 2204/T Engine Section 48

Reassembly of the Fuel Pump Feeding Pipes 1) Pliers for pipes having a diameter of 6 mm.

2) Pliers for pipes having a diameter of 8 mm.

Outlet and inlet pipes are made of nylon.

They are inserted in the clutches of the pressure injection pump by means of a special pair of pliers and of a plastic hammer.

1

Prepare the pumping element, by connecting the fuel inlet clutch (1) to a small tank, which contains a certain quantity of diesel oil and which is placed at least 20 cm higher than the pumping element itself.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.2

Series LDW 2204/T Engine Section 48

Connect a small pipe (2) of about 15 cm. in length to the fuel exhaust clutch.

Make the small pipe slightly curve upwards before letting it bend down.

This is done so that, during the advanced timing operation, the pipe will never be completely drained.

At the outlet of the small pipe, insert a metallic wire letting it protrude of about 1 cm. so as to check that it does not drip.

2

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.3

Series LDW 2204/T Engine Section 48

Leave the transmission disconnected.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

tappet rods

Page 48.4

Series LDW 2204/T Engine Section 48

Install two hand levers on the flywheel, as shown in the picture beside, to help in the advanced timing operation…

…placing them at 180°...

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.5

Series LDW 2204/T Engine Section 48

…so as to be able to operate the flywheel with both hands.

Position the measuring instrument.

It is composed of a frame, which lowers the valves, and is equipped with a support to house the dial gauge.

This tool is designed to measure the height variation of the valves.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.6

Series LDW 2204/T Engine Section 48

1

A

Edition July 2002 Revision July 2002

Position the cylinder piston to be controlled at the top dead centre, during the compression stage.

For greater accuracy, keep the lever pushed down, so as to ensure the contact between the valve and the piston.

At the piston reverse motion, the dial gauge pointer will reverse its rotation direction and that moment will represent the actual TDC. Zero-adjust the dial gauge.

Slowly release the frame lever (1) and read the measure in mm that is given by the valve recession.

At this moment, the reading obtained A represents the measure between the surface of the piston that is placed at TDC and the valve stop.

Check of Advanced Injection Timing

Page 48.7

Series LDW 2204/T Engine Section 48

Rotate the flywheel of about 90° in a clockwise direction until the exhaust pipe of the pumping element starts to drip.

At this point, turn the flywheel in an anticlockwise direction (operation direction) until the exhaust pipe stops dripping. At that time, stop rotating the flywheel.

Press on the lever until the valve is in direct contact with the piston.

B

Edition July 2002 Revision July 2002

Slowly release the lever (1) and read on the dial gauge the measure that is given by the valve return.

Now, work out the piston height difference from the moment when the injection to TDC starts.

B – A = Advanced timing expressed in mm.

Check of Advanced Injection Timing

Page 48.8

Series LDW 2204/T Engine Section 48

Adjustment of Advanced Injection Timing ADVANCED TIMING 9° ± 1° mm 0.3 6° 0.409 7° 0.534 8° 0.675 9° 0.833 10° 1.007 11° 1.189 12° 1.404 13° 1.627 14° 1.865 15°

The chart shows equivalence between and degrees ( ).

As shown, the standard advanced timing injection is with = 9° and it corresponds to a lowering of the piston of 0.675 mm.

A

B

Edition July 2002 Revision July 2002

the mm

The new system includes one single gasket (A) under the injection pump flange and it also has the purpose to avoid any oil leakage.

The advanced injection timing is determined by the thickness of gasket A, as well as by the thickness of the pad, which is placed inside the injection tappet.

To pull out pad B, use a rod equipped with a magnet on one of its ends.

The spare pads supplied have 8 different levels of thickness (from 4.0 to 4.7 mm), and their thickness value is marked on the lower part of the pad.

Check of Advanced Injection Timing

Page 48.9

Series LDW 2204/T Engine Section 48

To correct the advanced injection timing, replace the thickness of the pad that is placed inside the injection tappet.

Important: When changing B thickness by 0.1 mm, advanced timing is changed by 1°.

- In case of delayed injection timing, increase B thickness.

- In case of advanced injection timing, decrease B thickness.

Whenever the disassembly of the rocker arm shaft is carried out, follow the steps below before reassemblying it: 1) Bring all the pistons to ~½ stroke; 2) Put some oil in the tappet housing through the rod lines, so as to feed the tappets; 3) Install the rocker arm shaft; 4) Wait ~½ hour before starting the engine so that the tappets can reach their ideal filling level; 5) Manually operate the engine and let it perform a few revolutions, so as to check that there is no jamming or other faults.

Edition July 2002 Revision July 2002

Check of Advanced Injection Timing

Page 48.10

Series LDW 2204/T Engine Section 49

Rocker Arm Cap Replace the gasket of the rocker arm cap.

Check that the lines are not clogged with solid residual oil sludge.

Place the cap onto the head plane and screw in the special nuts with the relevant rubber washers.

Edition July 2002 Revision July 2002

Rocker Arm Cap

Page 49.1

Series LDW 2204/T Engine Section 49

Tighten the nuts at 20 Nm.

Pressure Relief Valve Before closing the oil gas recovery tank, check that the lines do not have any scaling.

Edition July 2002 Revision July 2002

Rocker Arm Cap

Page 49.2

Series LDW 2204/T Engine Section 49

Insert the diaphragm return spring.

Check and replace the diaphragm, if necessary.

Position the diaphragm as shown in the picture beside.

The pressure relief valve (1), which is integrated in the rocker arm cover, is a safety device of the engine.

It is designed to limit the depression whenever it tends to increase. Without this device, should there be a clogged up air filter, the oil contained in the case could be sucked up in the intake manifold and rev up the engine.

Edition July 2002 Revision July 2002

Rocker Arm Cap

Page 49.3

Series LDW 2204/T Engine Section 49

Close everything.

Edition July 2002 Revision July 2002

Rocker Arm Cap

Page 49.4

Series LDW 2204/T Engine Section 50

Intake Manifold After having checked that the seal plane is free from scratches, place the paper gasket on the coupling plane.

Put the intake manifold in place.

Tighten the screws at 25 Nm.

Edition July 2002 Revision July 2002

Intake Manifold

Page 50.1

Series LDW 2204/T Engine Section 51

Oil Vapour Recovery Line The components that make up the oil vapour recovery line from the cylinder block.

Replace the o-ring of the oil vapour recovery pipe running from the cylinder block to the head.

Edition July 2002 Revision July 2002

Oil Vapour Recovery Line

Page 51.1

Series LDW 2204/T Engine Section 51

Assemble the pipe to the head; its o-ring should be housed inside the hole.

Edition July 2002 Revision July 2002

Oil Vapour Recovery Line

Page 51.2

Series LDW 2204/T Engine Section 51

Tighten the pipe fitting to the cylinder block at 35 Nm.

(Once the completed).

Edition July 2002 Revision July 2002

Oil Vapour Recovery Line

assembly

is

Page 51.3

Series LDW 2204/T Engine Section 52

Multistage Centrifugal Blower

(Components that make up the multistage centrifugal blower).

Assemble the oil exhaust pipe to the centrifugal blower.

Edition July2002 Revision July 2002

Multistage Centrifugal Blower

Page 52.1

Series LDW 2204/T Engine Section 52

Assemble the centrifugal blower to the exhaust manifold.

Assemble the motor oil delivery pipe fitting to the centrifugal blower.

Edition July2002 Revision July 2002

Multistage Centrifugal Blower

Page 52.2

Series LDW 2204/T Engine Section 52

Manually screw one pipe fitting screw…

…then, the other one.

Tighten them at 20 Nm.

Edition July2002 Revision July 2002

Multistage Centrifugal Blower

Page 52.3

Series LDW 2204/T Engine Section 52

Tighten at 20 Nm.

Tighten at 25 Nm.

Tighten at 20 Nm.

Edition July2002 Revision July 2002

Multistage Centrifugal Blower

Page 52.4

Series LDW 2204/T Engine Section 52

Assemble the sealing fitting to the intake manifold.

Place two metallic clamps around it.

A

Edition July2002 Revision July 2002

B

Prepare the elbow (A) and its relevant gasket (B) for fitting…

Multistage Centrifugal Blower

Page 52.5

Series LDW 2204/T Engine Section 52

…position it and tighten the clamps.

(Completed assembly).

Edition July2002 Revision July 2002

Multistage Centrifugal Blower

Page 52.6

Series LDW 2204/T Engine Section 53

Pre-Heating Glow Plugs

Specifications:

4

- Rated voltage: 11V. - Absorption: 12 ÷14° after 5 seconds.

- Temperature of the sheath surface = 850°C after 5 seconds.

- By a temperature of 0°C with a voltage of 11V, the rated preheating time is 7 seconds.

1) Sheath.

2) Regulation filament.

3) Heating filament.

4) Metallic seal.

Important: If the engine does not start up in 15 seconds, preheating is interrupted; the glow plug will not be damaged because of extended insertion time.

Edition July 2002 Revision July 2002

Pre-Heating Glow Plugs

Page 53.1

Series LDW 2204/T Engine Section 53

Insert the glow plugs…

…and tighten them at 20 Nm.

Connect the glow plugs with the suitable cables in parallel.

Edition July 2002 Revision July 2002

Pre-Heating Glow Plugs

Page 53.2

Series LDW 2204/T Engine Section 54

Assembly of the Diesel Oil Thrust Pipes

A

All diesel oil thrust pipes (A) are equal in shape and dimensions and they are of proportionate length.

Tighten the lower fittings of the diesel oil thrust pipes at 25 Nm.

Tighten the upper fittings of the diesel oil thrust pipes at 25 Nm.

Edition July 2002 Revision July 2002

Assembly of the Diesel Oil Thrust Pipes

Page 54.1

Series LDW 2004/T Engine Section 55

Anti-Supplement Device

Edition July 2002 Revision July 2002

This device enables to cut out the fuel supplement during start-up, when the engine is warmed up (lever 4 in position A).

When the temperature drops below 0°C, the lever A turns (causing the recession of thermostat 3) until it reaches position B, thus enabling rod 5 to shift into supplement position during the start-up of the engine.

The position of the adjustment screw 1 should never be changed.

In the event that an unintentional manoeuvring should displace the adjustment screw, you need to calibrate the device, as described below.

A) Set the required calibration power and number of revolutions of the engine.

B) Loosen the lock nut.

C) Unscrew the adjustment screw 1 (so as to bring lever 4 close to rod 5) until the number of revolutions of the engine starts to decrease.

D) Screw the adjustment screw 1 of 1/2 +3/4 of a turn, so as to bring lever 4 away from rod 5 of 1.2+1.8 mm.

Tighten the lock nut.

E)

Anti-Supplement Device

Page 55.1

Series LDW 2004/T Engine Section 55

2

After having checked the perfect working order of the gasket (1), place the antisupplement device in its housing, paying attention that the arm (2), which is inside the engine compartment, does not jam with the pump control rod.

1

Tighten the screws at 10 Nm.

Edition July 2002 Revision July 2002

Anti-Supplement Device

Page 55.2

Series LDW 2004/T Engine Section 56

Oil Sump Put the oil sump in place and tighten the screws at 30 Nm.

Note:

1

Edition July 2002 Revision July 2002

Oil Sump

The oil sump has a protrusion underneath (1).

Such a protrusion is designed to ensure a certain level of oil to the oil pump suction rose pipe, which draws oil out of the bottom of this protrusion.

Page 56.1

Series LDW 2204/T Engine Section 57

Alternator Assembly

1

House the alternator as shown in the picture beside, using screw 1 as the axis, on which to rotate.

Insert screw 2 in the slot and make it turn a few times.

2

Edition July 2002 Revision July 2002

Aternator Assembly

Page 57.1

Series LDW 2204/T Engine Section 57

After having assembled the driving belt, check its pull strength by means of a dynamometer.

Its tension should be such that when a 10-kg load is placed between the two pulleys, it should cause a bending of 10/15 mm.

Edition July 2002 Revision July 2002

Aternator Assembly

Page 57.2

Series LDW 2204/T Engine Section 57

Finally tighten it at 35 Nm.

Completed assembly.

Edition July 2002 Revision July 2002

Aternator Assembly

Page 57.3

Series LDW 2204/T Engine Section 58

Pipe Assembly Assemble the fuel distribution fittings and tighten them at 20 Nm.

As shown in the picture beside, insert the water pump and thermostat connection pipe.

Put the oil vapour recovery pipe in place.

Edition July 2002 Revision July 2002

Pipe Assembly

Page 58.1

Series LDW 2204/T Engine Section 58

Edition July 2002 Revision July 2002

Pipe Assembly

Page 58.2

Series LDW 2204/T Engine Section 59

Calibrations Tool for the Injection Pump Delivery Trimming 1) Tank 2) Test tube 3) Support 4) Knob 5) Injection pump exhaust pipe on-off valve 6) Injection pump inlet pipe onoff valve A) Connection pipe to the injection pump inlet clutch B) Connection pipe to the injection pump exhaust clutch

Edition July 2002 Revision July 2002

Calibrations

Page 59.1

Series LDW 2204/T Engine Section 59

Injection Pump Delivery Trimming

1

Remove the feeding pipes from all the injection pumps and in place of them insert the pipes of the device, carefully connecting each pump to its relevant inlet and exhaust pipes.

Referring to the picture beside, connect the pipe that is equipped with one filter to the pumping element exhaust outlet and the other pipe without filter to the inlet.

The filter that is installed on the pipe is designed to damp the shockwave produced by the pump, thus reducing diesel oil height variations inside the graduated test tubes.

The knob (1), which is placed on the side, serves for refilling the test tubes with fuel, so as to get an equal fuel level in all four test tubes.

Once the device has been connected and fueled, place it on a plane that is at least 20 cm. higher than the injection pumps.

Edition July 2002 Revision July 2002

Calibrations

Page 59.2

Series LDW 2204/T Engine Section 59

Trim the fuel level in the test tubes by operating the knob…

1

…slightly turning it, as shown in the picture beside.

This operation will connect the four test tubes to the tank, which is installed inside the device.

2

Edition July 2002 Revision July 2002

Calibrations

Page 59.3

Series LDW 2204/T Engine Section 59

Then, reset the knob in its starting position.

Now, each test tube is connected to one pump.

3

Open the pump delivery cock.

Then, bring the engine to 2000 idling revolutions/1’ for about 1 minute.

Edition July 2002 Revision July 2002

Calibrations

Page 59.4

Series LDW 2204/T Engine Section 59

In case the fuel level in one test tube should drop more than in the others, it is necessary to reduce the delivery of the relevant pump.

Keep in mind that the screw holes on the pump flange are slotted; therefore proceed as follows.

Turn the engine off, by closing all fuel oil delivery cocks of the pumps.

Edition July 2002 Revision July 2002

Calibrations

Page 59.5

Series LDW 2204/T Engine Section 59

Loosen the lower fitting of the fuel thrust pipe, paying attention not to loosen also the fitting that is placed on the pump casing.

Loosen by one fourth turn the pump retaining screw nuts.

Using a flat head screwdriver, slightly rotate the pump casing.

By turning in a clockwise direction the delivery increases, while in the opposite direction it decreases.

Tighten the pump retaining screws at 25 Nm and the lower fitting of the fuel thrust pipe at 25 Nm. Attention: A few degrees of rotation are enough to cause great delivery variations.

Edition July 2002 Revision July 2002

Calibrations

Page 59.6

Series LDW 2204/T Engine Section 59

Calibration of the Stroke Adjustment Actuator of the “Wastegate” Valve Control Rod

The test should be performed when the engine is not running.

Disconnect pipe 7 from the compressor side.

Using a T-shaped clutch, connect it to a pressure gauge 4 (scale from 0 to 2 bars), as well as to the compressed air pipe network that is equipped with a pressure-reducing valve 5.

The air pressure should be between 1.5 and 2.0 bars.

In the pressure gauge pipe drill a 1.5-mm diameter hole (B), from where some air will come out, so as to stabilize the pressure in the pressure gauge.

- By operating the pressure-reducing valve 5, send some air to the actuator so that terminal 2 will be shifted forward of an A distance (A= 1mm).

- Put a dial gauge 6 in place, so that the feeler pin rests on terminal 2.

- The pressure reading displayed on the pressure gauge should be 830/890 mm Hg (1.11/1.19 bars). If it is lower than the required reading, proceed as follows: - Unscrew the lock nut 1.

- Remove the split pin 9 and disconnect the rod 8.

- Holding the rod still, screw terminal 2 until the correct calibration pressure is reached.

- During the rotation of the terminal, the rod should not stand any torsional stress.

Edition July 2002 Revision July 2002

Calibrations

Page 59.7

Series LDW 2204/T Engine Section 59

Test of the Multistage Centrifugal Blower

Take a pressure gauge equipped with a scale from 0 to 2 bars and connect it to seat 1, as shown in the picture beside.

Start the engine, let it warm up for a few minutes, then bring it to 3,000 revolutions/1’ at NB power.

The pressure reading of the boosting air should be 89/93 KPa (0.89/0.93 bars).

1

If the calibration pressure does not fall within the required value range, it is necessary to adjust the stroke of the control rod of valve C (Wastegate).

Attention: Seat 1, which is made in the intake manifold for the pressure gauge, has an M8 thread.

C

Edition July 2002 Revision July 2002

Calibrations

Page 59.8

Series LDW 2204/T Engine Section 59

Adjustment of Idling Speed (Standard)

After having supplied oil, fuel and coolant to the engine, start the engine and let it warm up for 10 minutes.

Then, release screw 1 by loosening lock nut 2.

2

Operating the adjustment screw 1, adjust the idling speed at ~800 revolutions/1’; then block lock nut 2.

1

Note: By unscrewing screw 1 in an anticlockwise direction, the revolutions decrease, while in the opposite direction they increase.

Edition July 2002 Revision July 2002

Calibrations

Page 59.9

Series LDW 2204/T Engine Section 59

Adjustment of Maximum Speed (Standard)

3

4

After having adjusted the idling speed, loosen lock nut 3.

Operating screw 4, adjust the maximum speed at 2,550 ÷ 2,600 revolutions/1’; then block the lock nut.

When the engine reaches the adjustment power, the maximum speed will be set at 2,400 revolutions/1’.

Note: By unscrewing screw 4 in an anticlockwise direction, the revolutions decrease, while in the opposite direction they increase.

Edition July 2002 Revision July 2002

Calibrations

Page 59.10

Series LDW 2204/T Engine Section 59

Standard Adjustment of the Brakeless Injection Pump Delivery Note: This adjustment should be performed with the engine at water brake, otherwise this calibration will be inaccurate.

C

In this case, proceed as follows: - Loosen lock nut 3.

- Loosen the delivery limiting device C of 5 turns.

- Bring the engine to the maximum number of idling revolutions, that is to say 2,550 ÷2,600 revolutions/1’.

- Keep re-tightening the delivery limiting device C until the engine starts to rev down.

- Loosen the speed limiting device C of one and a half turn.

- Block lock nut 3.

3

Edition July 2002 Revision July 2002

Calibrations

Page 59.11

Series LDW 2204/T Engine Section 59

Note: In the event that the engine gives off too much smoke under maximum load conditions, screw C in.

Unscrew C if no smoke is sent out of the exhaust pipe and if the engine is not able to reach its maximum power.

Edition July 2002 Revision July 2002

Calibrations

Page 59.12

Series LDW 2204/T Engine Section 59

Limiting Device of the Injection Pump Delivery and Torque Trimmer The limiting device C is designed to limit the maximum delivery of the injection pump.

At the same time, this device is also a torque trimmer, in fact, at torque running, the springs N, operating on lever L, win the resistance of spring M, which is placed inside the cylinder.

The stroke H that the torque trimmer enables lever L to perform is of 1.0 ÷ 1.1 mm; therefore, the delivery of the injection pump will increase and the torque will reach its maximum value.

Edition July 2002 Revision July 2002

Calibrations

Page 59.13

Series LDW 2204/T Engine Section 59

Anti-Supplement Device

During the starting phase of the engine, the antisupplement device has the purpose to avoid excessive smoke from the exhaust pipe.

It operates on the injection pump delivery adjustment rod 5, working continously when the ambient temperature is over 15°C. As temperature drops, this device gradually decreases its operation until it cuts it off at zero degrees.

Edition July 2002 Revision July 2002

Calibrations

Page 59.14

Series LDW 2204/T Engine Section 59

Adjustment of the Anti-Supplement Device

1) Bring the engine to calibration power and revolutions.

2) Loosen lock nut 2.

3) Unscrew screw 1, so as to approach lever 4 to rod 5 until the engine starts to rev down.

4) Screw the screw of ½ ÷ ¾ max of a turn, so as to push lever 4 1.2 ÷ 1.8 mm away from rod 5.

5) Screw lock nut 2.

When the temperature drops below zero degrees, lever A rotates (pin 6 of the thermostat 3 folds in) until it reaches position B, so as to enable rod 5 to reach the supplement position.

Edition July 2002 Revision July 2002

Calibrations

Page 59.15

Series LDW 2204/T Engine Section 60

Expansion Tank and Plug

1

Edition July 2002 Revision July 2002

The expansion tank is separated from the radiator and is equipped with a coolant filling plug.

The plug is equipped with one vacuum valve and one overpressure escape valve 1.

Opening pressure of the overpressure escape valve: 1 bar.

Expansion Tank and Plug

Page 60.1

Series LDW 2204/T Engine Section 61

Radiator Tightness Check Remove the plug from the expansion tank and check that the coolant is at level.

Replace the plug with a temporary plug, which should be equipped with a pipe connection for a manually operated air pump. See picture below.

Bring the air to the pressure of 1 bar for about 2 minutes.

Check that there are no leakages inside the radiator.

Edition July 2002 Revision July 2002

Radiator Tightness Check

Page 61.1

Series LDW 2204/T Engine Section 62

Oil Pressure Check Once the assembly is completed, supply the engine with fuel and oil. Then, connect a 10-bar pressure gauge to the pressure switch fitting.

Start up the engine and check how pressure works as oil temperature changes.

See below.

Oil Pressure Curve with Idling Running Engine Curve measured on the oil filter when the idling speed is of 850 revolutions/1’.

Oil Pressure Curve with Maximum Running Engine Curve measured on the oil filter at a speed of 2500 revolutions/1’ at N power.

Note: The maximum temperature of the lubrication oil should be lower than the addition: ambient temperature + 95°C.

Edition July 2002 Revision July 2002

Oil Pressure Check

Page 62.1

Series LDW 2204/T Engine Section 63

Operating Features Fuel Filter Attention: In case of replacement of the fuel filter cartridge, wet the gasket of the component to be assembled with fuel and tighten it by hand pressure only.

Cartridge Specifications: - Filtering paper: PF904 - Filtering surface: 5,000 cm2 - Filtering degree: 2/3 m Maximum working pressure: 4 bars.

Edition July 2002 Revision July 2002

Operating Features

Page 63.1

Series LDW 2204/T Engine Section 63

Oil Filter Cartridge 1) 2) 3) 4) 5) 6)

Gasket Plates Gasket Reed Filtering material By-pass valve

Specifications: - Max working pressure: 7 bars.

- Max exhaust pressure: 20 bars.

Resistance to cold temperatures: -35°C. - By-pass valve calibration: 2.1 ÷ 2.8 bars.

- Total filtering surface: 200 cm2.

- Filtering degree: 15µ.

Attention.

In case of replacement of the fuel filter cartridge, wet the gasket of the component to be assembled with fuel and tighten it by hand pressure only.

Edition July 2002 Revision July 2002

Operating Features

Page 63.2

Series LDW 2204/T Engine Section 63

Alternator

Type AA125R-65A Alternator with W Clamp Specifications: - Rated voltage = 14V. - Rated current = 65A. - Maximum speed = 14,000 revolutions/1’.

- Maximum peak speed (for 15’) = 15,000 revolutions/1’.

- Bearing on control side = 6203-2Z. - Bearing on manifold side = 6201-2Z/C3.

-Voltage regulator = RTT 119 C. - Clockwise direction rotation.

- Screw nut tightening: 1 = 60Nm. Important: Lubricate the two bearings with grease for high temperatures.

Edition July 2002 Revision July 2002

Operating Features

Page 63.3

Series LDW 2204/T Engine Section 63

Characteristic Curves of the A125 R – 14V – 65A Alternator The curves have been measured by means of an electronic voltage regulator after thermal stabilization at 25°C; test voltage 13.5 V. P1 = Power expressed in KW. I = Current expressed in ampere. = Alternator performance.

Important: The revolutions/1’ shown on the table beside, when multiplied by 1000 give the alternator revolutions/1’.

Engine/alternator revolution ratio: 1:1.8.

Voltage Characteristic Curve of the RTT 119 AC Regulator The electronic voltage regulator is integrated in the alternator.

The curve varies as the temperature changes.

A = Maximum voltage curve B = Minimum voltage curve Edition July 2002 Revision July 2002

Operating Features

Page 63.4

Series LDW 2204/T Engine Section 63

Starter

Type EV12V-2KW Starter Clockwise direction rotation.

Characteristic the Starter

Curve

of

The continuous line curves have been measured at a temperature of +20°; dashed line curves have been measured at a temperature of –20°.

U = Voltage at the starter clamps, expressed in Volts n = Starter speed A = Absorbed current, expressed in Amperes P = Absorbed power, expressed in KW M = Torque, expressed in N/m.

Edition July 2002 Revision July 2002

Operating Features

Page 63.5

Series LDW 2204/T Engine Section 63

Control Unit Glow plug control unit with temperature sensor for the engine compartment.

Wiring Diagram

Edition July 2002 Revision July 2002

Operating Features

Page 63.6

Series LDW 2204/T Engine Section 63

Features of Pre-Heating Time

Operation: Area A corresponds to the time with optical indicator on and plugged-in pre-heater.

Area B (dashed) shows the tolerance field, where the optical indicator switches off when the pre-heater is plugged in.

Area C shows the time with plugged-in pre-heater and open optical indicator. This stage is characterized by 8 + 14 seconds of constant operation; the time is counted from the moment when the optical indicator is switched off.

Area D corresponds to the time with switched-off optical indicator and unplugged pre-heater.

Edition July 2002 Revision July 2002

Operating Features

Page 63.7

Series LDW 2204/T Engine Section 64

Special Equipment

SPECIAL EQUIPMENT NAME Injection Pump Delivery Trimming Tool

191551

Glass Column for Injection Pump Delivery Trimming Tool

191552

Tool for Camshaft Bearing Replacement

191553

Tester for Injection Pump Static Advanced Injection Timing Tool for Valve Lowering to Check the Static Advanced Injection Timing

Pairs of Pliers for Injection Pump Feeding Pipes 1) For 6-mm Diameter Pipes 2) For 8-mm Diameter Pipes

Edition July 2002 Revision July 2002

CODE

Special Equipment

191554

191555

1) 191556 2) 191557

Page 64.1

Series LDW 2204/T Engine Section 64

Tool designed to Compress the Valve Springs 16

Ø8 42

8

16

Ø 14

Edition July 2002 Revision July 2002

Special Equipment

Page 64.2

Series LDW 2204/T Engine Section 64

M8

Edition July 2002 Revision July 2002

Special Equipment

Page 64.3

Series LDW 2204/T Engine Section 64

M8

Edition July 2002 Revision July 2002

Special Equipment

Page 64.4

Series LDW 2204/T Engine Section 64

62

130 8

68

5

31

8

Edition July 2002 Revision July 2002

Special Equipment

Page 64.5

Series LDW 2204/T Engine Section 64

Ø31

Ø17

160

M8

Edition July 2002 Revision July 2002

Special Equipment

Page 64.6

Series LDW 2204/T Engine Section 64

Ø 10

8

62

Ø 20

Ø8

30

Edition July 2002 Revision July 2002

Special Equipment

Page 64.7

Series LDW 2204/T Engine Section 64

30

M8

M8

Edition July 2002 Revision July 2002

Special Equipment

Page 64.8

Series LDW 2204/T Engine Section 64

20

40

Ø7

10

100

Edition July 2002 Revision July 2002

170

Special Equipment

Page 64.9

Series LDW 2204/T Engine Section 64

Edition July 2002 Revision July 2002

Special Equipment

Page 64.10

Series LDW 2204/T Engine Section 64

Edition July 2002 Revision July 2002

Special Equipment

Page 64.11

Series LDW 2204/T Engine Section 64

Edition July 2002 Revision July 2002

Special Equipment

Page 64.12