WORKSHOP MANUAL Series LGW 523-627 and LGW 627 GPL engines code 1-5302-509 LGW 523 LGW 627 1st Edition SERVICE COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
FOREWORD We have done all in our power to give up to date and accurate technical information in this manual. Lombardini engines are, however, constantly developing thus the data in this publication may be liable to modification without prior notice. The information in this manual is the exclusive property of Lombardini. Neither partial nor total duplications or reprints are therefore permitted without the express authorization of Lombardini.
WARRANTY CLAUSE WARRANTY CLAUSE Lombardini S.r.l., guarantees its engines for a period of 12 months from the date of delivery to the first user, and no later than 24 months from the date of delivery to the manufacturer or building site. Of the two alternatives, the one that occurs first shall be considered valid. Stationary assemblies (with use at constant load and constant speed and/or with load and speed that slightly vary within the regulating limits) are not covered by this clause.
TABLE OF CONTENTS This manual contains information on how to repair LOMBARDINI LGW 523, LGW 627 gasoline fuelled engines and LOMBARDINI LGW 627 LPG fuelled engines and is up to date as of 10.06.1999.
TABLE OF CONTENTS LGW 523 bleed LGW 523 dry air filter LGW 523 rocker cap LGW 523-627 head torquing phases LGW 627 air filter support LGW 627 dry air filter LGW 627 rocker cap LGW 627 speed governor LGW 627 speed governor components LGW 627 speed governor levers Oil pump Oil retainer seal in valve guide, removal Oil sump, removal Operative timing system tuning angles (valve clearance = 0.26 mm) for LGW Operative timing system tuning angles (valve clearance = 0.
TABLE OF CONTENTS X COOLING CIRCUIT Page 48 Cooling circuit Cooling fluid pump, components Radiator and compensation chamber plug - Inspections and tightness Thermostatic valve ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ XI ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 48 49 49 49 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
TABLE OF CONTENTS Battery recharging curve for 12V 30A alternator Characteristic curve of alternator Marelli AA 125 R 14V 45A Characteristic curve of starter motor Bosch type DW 12V 1.1 kW Characteristic curve of the Iskra 14V 33A alternator Ignition module of gasoline (petrol) and LPG fuelled engine LGW 627 with spark lead variation device serial N° 122.2193.114 Ignition module of gasoline (petrol) fuelled engine LGW 523 with idling back-up device serial N° 122.2193.
TABLE OF CONTENTS XVI MAIN DRIVING TORQUES 90 Driving torques for standard screws Main driving torques Use of sealing agents ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ XVII SPECIFI
TROUBLESHOOTING I PROBABLE CAUSES AND THEIR REMEDIES The table gives the causes of some of the faults that may occur during operation. Proceed systematically with the simplest inspections before removing or replacing any parts.
II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS SAFETY AND WARNING DECALS DANGER CAUTION Failure to comply with the instructions could result in damage to persons and property Failure to comply with the instructions could lead to technical damage to the machine and/or system SAFETY INSTRUCTIONS · Lombardini Engines are built to supply their performances in a safe and long-lasting way.
SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS II · The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is dust that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been certified for the machine. · To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.
CODE AND IDENTIFICATION III Max speed setting (r/min) Type of engine Serial N° N° of version (K modulus) é Performance approval Note: Exhaust approvals The Performance Approval and Exhaust Approvals are only stamped for Diesel engines ç 12 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-509 50778 10.06.99 REVISION 00 DATE 10.06.
IV TECHNICAL SPECIFICATIONS LGW 523-627 SPECIFICATIONS TYPE OF ENGINE Cylinders Bore Stroke Displacement Compression ratio r/min N 80/1269/EEC - 88/195/EEC - ISO 1585 Power kW/HP NB 80/1269/EEC - ISO 1585 NA ISO 3946/1 - ICXN Maximum torque No-load idling speed r/min Water pump flow rate Max.
CHARACTERISTIC CURVES V CHARACTERISTIC POWER, DRIVING TORQUE AND SPECIFIC CONSUMPTION CURVES LGW 627 LGW 523 N (80/1269/CEE - ISO 1585) SELF-DRIVING POWER: Discontinuous service at variable rates and loads. NB (ISO 3046 - 1 IFN) NON-OVERLOADABLE POWER: Continuous light service at constant rate and with variable loads. NA (ISO 3046 - 1 ICXN) CONTINUOUS OVERLOADABLE POWER: Continuous heavy-duty service at constant rates and loads.
OVERALL DIMENSIONS VI LGW 523 LGW 627 Note : The values are in mm COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
VII MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system LGW 523 ENGINE MAINTENANCE FREQUENCY HOURS OPERATION INSPECTION REPLACEMENT OVERHAUL (*) (**) (***) (****) PART 10 50 80 100 175 250 350 500 1000 2000 5000 SUMP OIL LEVEL RADIATOR FINS ALTERNATOR BELT TENSION VALVE AND TAPPET PLAY AIR FILTER CARBURETOR SUMP OIL LEVEL ANTI-FREEZE (****) OIL FILTER CARTRIDGE FUEL
MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS VII The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed. Use a suitable oil in order to protect the engine. The lubrication oil influences the performances and life of the engine in an incredible way.
VII MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS The fluid coolant circuit is pressurized. Inspections must only be made when the engine has cooled and even in this case, the radiator or expansion chamber plug must be unscrewed with the utmost caution. If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the engine is at a standstill. Coolant fluid is polluting. It must therefore be disposed of in the correct way.
DISASSEMBLY/REASSEMBLY VIII DISASSEMBLY AND REASSEMBLY Always wear protective goggles during repair Besides describing how to dismantle and reassemble the various work, when compressed air is used parts, this chapter also includes instructions on how to check and tune the engines, dimensions, repairs and hints on operation. Always use genuine LOMBARDINI spares to correctly repair the engines.
VIII DISASSEMBLY/REASSEMBLY When engines LGW 523 and LGW 627 are being installed, remember that any variation to the intake system (type of air filter, length and diameters of the pipes leading from the intake manifold to the air filter) will involve a modification to the carburation. The carburation must be tested beforehand in the Lombardini test department.
DISASSEMBLY/REASSEMBLY VIII Before demounting the cooling fan, disconnect the positive battery cable to prevent accidental short-circuits which could consequently energize the starter motor. Cooling fan Thoroughly clean the cooling fan and make sure that all its blades are in a good condition. Replace the fan if even only one of its blades is damaged. 7 Only check the belt tension when the engine is at a standstill Cooling fan and alternator belt Tension adjustment. Slacken off screws 1 and 2.
VIII DISASSEMBLY/REASSEMBLY Transmission pulley Remove the pulley by taking out screw 1 of fig. 12. Components: 1 Screw 2 Washer 3 Centering bush 4 Pulley 5 Circlip 6 Ball bearing 7 Spacer 8 Ball bearing 9 Circlip Note: To remount, thoroughly clean the thread of screw 1 and torque to 25 Nm. 12 13 Always lock the crank shaft and not the other engine components to loosen or tighten screw 1 to the required torque value.
DISASSEMBLY/REASSEMBLY VIII If the timing belt is removed, it must be replaced even though it has not terminated its forecast period of use. Always make sure that the battery + is well disconnected. Removing the timing belt Unscrew the screw of the tightening pulley 1 and remove the belt by pulling it from the timing pulley on the camshaft. Consult page 16 for the frequency with which the belt must be replaced. Consult page 16 when remounting.
VIII DISASSEMBLY/REASSEMBLY Timing pulley - Timing system tuning reference marks 1 Timing system tuning reference mark for LGW 523 and LGW 627 2 Timing system tuning reference mark for LGW 523 3 Timing system tuning reference mark for LGW 627. 23 Only remove the timing belt from its protective casing just before assembly. Tuning the timing system - Refitting the timing belt 24 Match the reference marks on both the timing pulley fig. 23 and driving pulley fig. 21. Insert the timing belt as shown in fig.
DISASSEMBLY/REASSEMBLY VIII Tuning the timing system - Inspection A = Intake valve B = Exhaust valve Move piston N° 1 (the one on the flywheel side) to top dead center. Make sure that intake and exhaust valves A and B are balanced by setting the touch probes of the two dial gauges on the valve caps. 28 Tuning the timing system - Angles The values of the angles can be identified by turning the crank shaft in a clockwise direction (viewed from timing system side).
VIII DISASSEMBLY/REASSEMBLY LGW 627 speed governor the speed governor is a mechanical type with centrifugal weights. It is installed behind aluminium support A fig. 30 and is driven directly by the camshaft.
DISASSEMBLY/REASSEMBLY VIII Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil is unavoidable, you are advised to wash your hands with soap and water as soon as possible. Dispose of old oil in the correct way as it is highly polluting. Donot litter. Demounting the oil pump The oil pump is tested before and after assembly. Do not open it unless you are sure that it is faulty.
VIII DISASSEMBLY/REASSEMBLY LGW 627 rocker cap Many of the more important engine components are on the cylinder head. The rocker cover houses part of the camshaft lubrication duct, that of the rockers and part of the engine bleeding system. External parts of the rocker cover: 1 Screw to fix the rocker cover to the cylinder head 2 Pressure switch (the only point where the engine oil pressure can be gauged) 3 Oil fill plug Tighten the fixing bolts to a 9 Nm torque when remounting the cover.
DISASSEMBLY/REASSEMBLY VIII LGW 523 rocker cover Components : 1 1a 2 3 4 Camshaft and rocker rod lubrication ducts Camshaft and rocker rod lubrication routes Rocker cover without labyrinth for oil vapour Seal for rocker cover without hole for oil vapour access Hole to drain oil from the cylinder head The rocker cover seal ensures that the rocker pivot camshaft lubrication circuit is tight. It is therefore advisable to replace it whenever it is demounted and to remount it with particular care.
VIII DISASSEMBLY/REASSEMBLY Rocker shaft Unscrew the nuts from the supports that fix the rocker shaft to the cylinder head. Tighten them to a 40 Nm torque when they are remounted. The shaft is hollow inside to allow for lubrication and is closed at both ends by two plugs. 43 Rocker shaft, demounting and refitting To take the shaft 1 from the support 2, remove pin 3 by drilling it with a 4 mm bit. On remounting, insert a new pin and recess it in relation to the surface of support A (0 to 1 mm).
DISASSEMBLY/REASSEMBLY VIII Camshaft, demounting Before removing the camshaft, demount the rocker shaft as indicated in fig. 43 Slacken off the screws and remove the cover 1. Make sure that the retention ring 2 is in a perfect condition. Remove the rod from the fuel pump. Remove the camshaft by pulling and turning, paying particular attention since the cam turns directly on the cylinder block without the aid of bushes.
VIII DISASSEMBLY/REASSEMBLY Intake, exhaust cam height LGW 523 A1 = 1st cylinder intake S1 = 1st cylinder exhaust A2 = 2nd cylinder intake S2 = 2nd cylinder exhaust H = 30.78 to 30.718 mm (intake and exhaust cam height) LGW 627 A1 = 1st cylinder intake S1 = 1st cylinder exhaust A2 = 2nd cylinder intake S2 = 2nd cylinder exhaust H = 30.64 to 30.578 mm (intake and exhaust cam height) 52 Do not demount or remount while hot as this could lead to deformations.
DISASSEMBLY/REASSEMBLY VIII Valve springs Measure the free length with a gauge. For LGW 523 - Free length A = 39.8 mm. Replace the spring if the length value is less than 37.3 mm. For LGW 627 - Free length A = 45.6 mm Replace the spring if the length value is less than 43.1 mm. 58 Valves, specifications Exhaust valve A - Stem and mushroom are made of two different materials. 2 Welded section 3 Chromium plated section 4 Section of material: X 45 Cr Si 8 UNI 3992 a = 45°30' to 45°45' D = 29.
VIII DISASSEMBLY/REASSEMBLY Valve seats and housings Dimensions (mm) A = 34.020 to 34.045 B = 34.106 to 34.115 C = 30.020 to 30.041 D = 30.108 to 30.116 a = 44°53' to 45° a1 = 59°53' to 60° Insert the seats in their housings Note: Since they are pre-finished, the seats must no longer be machined after insertion. 62 Valve recessing and width of housing seal. Dimensions (mm) D = 0.5 to 0.8 S = 1.6 to 1.7 D (wear limit) = 1.1 S (wear limit) = 2.0 Grind the valves in their seats with fine emery paste.
DISASSEMBLY/REASSEMBLY VIII Piston Remove the big-end cap. Remove the piston connecting-rod assembly. 67 68 Piston, demounting and inspection Remove the circlips and take out the pin, see fig. 77. Take out the piston rings and clean the slots. Measure diameter Q at dimension A from the base of the skirt (A = 9 mm). Replace the piston and piston rings if wear on the diameter exceeds the minimum given value by more than 0.05 mm. Note: The forecast allowances are 0.50 and 1.00 mm.
VIII DISASSEMBLY/REASSEMBLY Pistons, weight To prevent imbalance, the pistons must be weighed before they are replaced. The difference in weight must not exceed 4 g. 72 Piston rings - Distance between the tips Fit each piston ring into the cylinder and measure the distance between tips A in the operating zone. 1st piston ring A = 0.20 to 0.40 wear limit = 1.0 2nd piston ring A = 0.20 to 0.40 wear limit = 1.0 3rd piston ring A = 0.20 to 0.45 wear limit = 1.0 73 Piston rings, play between slots (mm) A = 0.
DISASSEMBLY/REASSEMBLY VIII Lubricate the following parts with oil before mounting: the piston pin, the piston, the cylinder and the big-end bearing Piston, refitting Couple the piston to the connecting-rod by inserting the pin (after it has been lubricated) and simply pressing with the thumb. Fit in the two circlips that hold the pin in place and make sure that they are well housed in their seats; also see fig. 70.
VIII DISASSEMBLY/REASSEMBLY Once the head has been correctly torqued, it will not need retorquing unless it is disassembled again. Before mounting, it is advisable to lubricate the bolt shanks and under their heads with SPARTAN SAE 460 oil. LGW 523-627 head torquing phases The bolts must be torqued in three phases, in compliance with the numeric order shown in fig. 82: 1st phase = 50 Nm 2nd phase = Turn the torque wrench through 90° in a clockwise direction.
DISASSEMBLY/REASSEMBLY VIII Connecting rod complete with bearings and pin Dimensions (mm) A = 106.98 to 107.02 (for LGW 523) A = 126.48 to 126.52 (for LGW 627) B = 18.015 to 18.025 C = 40.021 to 40.050 (with bearing torqued to 40 Nm) D = 17.996 to 18.000 E = 50.900 to 51.100 (B-D) = 0.015 to 0.039 (B-D) wear limit = 0.060 Note: When the small-end bearing is inserted, make sure that the two lubrication holes coincide.
VIII DISASSEMBLY/REASSEMBLY Cylinders Reset the comparator with a calibrated ring. Check diameter D in points 1, 2 and 3; repeat the same operation by turning the comparator through 90° at the same levels. Check for possible wear in zone X where the piston rings operate and grind the cylinder to the next allowance if it exceeds the max. given limit (e.g. 72 mm) by 0.05 mm. Dimensions (mm) LGW 523, LGW 627 = 71.990 to 72.
DISASSEMBLY/REASSEMBLY VIII Central main bearing caps The central main bearing caps have reference marks that can either be numbers as shown in the figure, or punch marks. The same reference marks are also applied to the cylinder block. Match the caps with the same reference marks and on the same side. In any case, always refer to the two centering marks on the bush. They must be on the same side. Tighten the screws to a 60 Nm torque.
VIII DISASSEMBLY/REASSEMBLY Crank shaft float After having tightened the main bearings, measure float A between the crank shaft support on the flywheel side and the main bearing half-rings. A = 0.130 to 0.313 mm B = 23.05 to 23.10 mm limit 0.5 mm limit 23.50 mm If the play is not within the given value, check value B. Mount oversized half-rings if necessary. See further on. 99 100 Bearing half-rings, oversizes Dimensions Standard 1st Oversize 2nd Oversize 3rd Oversize C 22.787-22.920 22.987-23.120 23.
DISASSEMBLY/REASSEMBLY VIII It is important to wear protective goggles when compressed air is used during repairs Crank shaft, lubrication ducts A = Crank shaft LGW 523 B = Crank shaft LGW 627 Place the shaft in a bath of degreasing and detergent fluid. Remove the plugs and clean ducts 1 and 2 or 3 and 4 with a pointed tool. Blow with compressed air. Fit the plugs back into their housings and check for tightness.
VIII DISASSEMBLY/REASSEMBLY Hydraulic pump drive (for LGW 627) A = Third drive A hydraulic pump (2 PD, Bosch flanging or a 1 PD) type can be mounted on the third drive. The power that can be supplied by the third drive is 7 kW, corresponding to a 37 Nm torque at 3600 rpm. Engine r/min/pump r/min transmission ratio = 1:0.5.
LUBRICATION CIRCUIT IX The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed. Use suitable oil in order to protect the engine. Nothing more than lubrication oil can influence the performances and life of an engine.
IX LUBRICATION CIRCUIT It is important to wear protective goggles when compressed air is used during repairs. Wash the parts with degreasing and detergent liquid. Internal suction strainer and engine oil return tube Wash the internal suction strainer 1 and the engine oil return tube 2; blow them with compressed air. Replace retention rings 3 and 4 . Tighten the bolts to a 10 Nm torque when the sump is remounted. Tighten the oil drain plug to a 40 Nm torque.
LUBRICATION CIRCUIT IX When the oil filter is replaced, keep it separate from other waste. Dispose of the old oil correctly since it is highly polluting. Do not litter. Oil filter cartridge Components: 1 Seal 2 Plate 3 Rubber pad 4 Spring 5 Filtering element 6 By-pass valve 7 Spring Specifications: Maximum working pressure: 7 bar Maximum bursting pressure: 20 bar Filtering degree: 15 m By-pass valve setting: 1.5 to 1.
X COOLING CIRCUIT The cooling circuit contains fluid under pressure. Do not carry out any inspections until the engine has cooled and even then, open the plug of the radiator or expansion chamber with caution. Keep well away from a hot engine if an electric fan is installed since this could start up even when the engine is at a standstill. Coolant fluid is polluting. It must therefore be disposed of correctly. Do not litter.
COOLING CIRCUIT X Radiator and compensation chamber plug, Inspections and tightness Remove the plug from the compensation chamber and make sure that the coolant is at the correct level. Replace the plug with one with a connection for a manual air pump. Compress the air to a pressure of 1 bar for about two minutes. Make sure that there are no leaks from the radiator. The tank plug has a vacuum valve 1 and an overpressure valve 2. Overpressure valve opening pressure 0.7 bar.
XI FUELLING CIRCUIT Do not smoke or use naked flames during the disassembly and reassembly operations as this could lead to explosions or fire outbreaks. Fuel vapours are highly toxic. Only carry out these operations outdoors or in a well ventilated place. Keep your face well away from the cap to avoid inhaling harmful vapours.
FUELLING CIRCUIT XI Carburetor Engine LGW 627 is fuelled by two "DELLORTO" carburetors type FHCD22-18. Comply with the following instructions when adjusting: - The air filter must have a clean cartridge. - Air must not be drawn through vacuum pipes, seals, etc. - Parts that use electric power must not be operating (electric fans, alternator, etc). If the carburetors are remounted, tighten the fixing nuts to an 8 Nm torque and the stud bolts to a 5 Nm torque.
XI FUELLING CIRCUIT Carburetor vacuum balancing test Connect the differential vacum gauges to the two carburetors with the engine idling and make sure that the vacuum in the two intake ducts differs by no more than 0.05 bar (5 kPa). 130a Carburetor vacuum adjustment If the vacuum reading on the vacuum gauges exceeds the previously mentioned 0.05 bar (5 kPa) limit, slacken off check nuts 1 and work on rod 2 until the setting is correct. Lock check nuts 1 after having calibrated.
FUELLING CIRCUIT XI ADJUSTMENTS AND CALIBRATION DESCRIPTION Choke Float Level from float chamber surface Fast running jet High speed air Slow running jet Idling air 1st Progressive outlets 2nd 3rd Idling screw opening turns 1st CONDITION 18 4.5 g. 7 mm 94 300 40 90 70 70 100 2¼ CARBURETOR FHCD22.
XI FUELLING CIRCUIT Carburetor LGW 523 Engine LGW 523 is fuelled by carburetor WEBER 32TLF39. 133 IDLING ADJUSTMENT Preliminary conditions Work with the cold starting device deactivated. Bring the engine to operating temperature by allowing it to run at approx. 2000 r/min until the thermostat opens. Do not allow the engine to idle alone as measurement of the "CO" content is no longer valid when an engine is allowed to idle for several minutes. The idling speed must correspond to the declared values.
FUELLING CIRCUIT CALIBRATED PARTS DESCRIPTION Choke Centering device Main jet Brake air jet Diffuser tube Slow running jet Slow running air jet Pump jet (at 20°) Pump discharge Pump cam Ignition cam Relief capsule bush Pin valve Fuel return hole Non-return hole Idling mixture adjuster hole Idling mixture bush Lead hole under throttle Slot compression holes XI ADJUSTMENTS 1st CONDITION 22 2.8 120 190 F 74 50 160 40 40 14850.218 45200.211 40 150 100 120 170 150 200 4.9x0.
XI FUELLING CIRCUIT Cold starting Enrichment is obtained by shutting off eccentric throttle 2, controlled by a cam. An intermediate cam meanwhile partially opens accelerator throttle 1. Fast idling speed allows the engine to quickly warm up and be immediately used. 137 Normal speed The fuel passes through the reedle valve into the float chamber where float 12, articulated in the center pivot, regulates reedle 13 opening to keep the fuel itself at a constant level.
FUELLING CIRCUIT XI Inspections and adjustments Float chamber level The level in the float chamber must be checked with the cover of the carburetor in a vertical position and with the tongue of the float slightly touching the ball of the reedle valve. In these conditions, the distance between the float and the surface of the cover (with seal) must be 27 ± 0.25 mm (dimension X). Work on the connection of float 1 if the value is different. Pick-up pump delivery Pick-up pump delivery cannot be regulated.
XI FUELLING CIRCUIT 144 Carburetor with variant to keep the engine idling when cold Components: 1 2 3 4 5 6 7 T union Accelerated idling adjuster screw Pressure hole Thermovalve Pneumatic actuator on the carburetor Calibrated hole Not in the drawing - Plant 2193-113 (see fig. 164 on page 73) Operating principle Thermovalve 4, which guarantees regulation of the on-off type in the air circuit, is installed on the water pump support to adjust to the temperature of the aluminium.
IGNITION XII This warning is valid for engines LGW 523 and 627 Take care to fix the harness wires in the correct way to prevent twists from forming. Electromagnetic fields could create abnormal voltage values leading to faulty operation in the ignition system. LGW 523 ignition system Components 1 Sensor with the Hall effect 2 Electronic module serial N° 2 Electronic module serial N° 3 Coil 4 Spark plug wire for cylinder 5 Spark plug wire for cylinder 122.2193.108 (see fig. 162) 122.2193.113 (see fig.
XII IGNITION LGW 523 cut-off In engine LGW 523, the module pilots an inductive load (coil of the cut-off solenoid valve on the carburetor 2 fig. 147) by means of a contact signal (on the idling speed adjuster screw) 1 fig. 147. When the fuel throttle is released, the speed adjuster screw (which is mounted on an insulating support) is grounded. A wire leads from this screw to the module. The module recognizes whether the throttle is being released when the contact is grounded.
IGNITION XII The technical specifications of the modules are similar for engines LGW 523 and LGW 627. Despite this fact, different types can be mounted since the programming maps can vary. Make sure that the right one is installed in case of replacement. The spark lead curve is the same for both engines LGW 523 and LGW 627 Code Technical specifications of the ignition module · Spark produced regardless of a low idling rate · Power source voltage rating : from 5.
XII IGNITION This warning applies to engines LGW 523 and 627 Take care to fix the harness wires in the correct way to prevent coils from forming. Electromagnetic fields could create abnormal voltage values leading to faulty operation in the ignition system. LGW 627 ignition system Components 1 Sensor with Hall effect 2 Electronic module serial N° 122.2193.109 (see fig. 156) 2 Electronic module serial N° 122.2193.114 (see fig.
IGNITION XII The spark plug must always be demounted and remounted when the engine is cold to prevent the thread on the aluminium cylinder head from being damaged. 0.8 mm Fit the spark plugs in place by fully screwing them on to the head by hand. Final torquing must be carried out with the relative 90° angle wrench or to a 30 Nm driving torque. Hex nut 1 to demount and remount the spark plug measures 16 mm. If necessary, clean the electrodes with a bronze bristle brush and blow with compressed air.
XIII ELECTRICAL CIRCUIT Wiring diagram of gasoline (petrol) fuelled engine LGW 627 with external alternator and module serial N° 122.2193.109 155 64 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-509 50778 10.06.99 REVISION 00 DATE 10.06.
ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) fuelled engine LGW 627 with spark lead variation device serial N° 122.2193.109 156 COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
XIII ELECTRICAL CIRCUIT Wiring diagram of gasoline (petrol) fuelled engine LGW 627 with external alternator and module serial N° 122.2193.114 157 66 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-509 50778 10.06.99 REVISION 00 DATE 10.06.
ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) fuelled engine LGW 627 with spark lead variation device serial N° 122.2193.114 158 COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
XIII ELECTRICAL CIRCUIT Wiring diagram of LPG fuelled engine LGW 627 with external alternator and module serial N° 122.2193.114 159 68 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-509 50778 10.06.99 REVISION 00 DATE 10.06.
ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) and LPG fuelled engine LGW 627 with spark lead variation device serial N° 122.2193.114 160 COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
XIII ELECTRICAL CIRCUIT Wiring diagram of gasoline (petrol) fuelled engine LGW 523 without idling back-up device, with internal alternator and module serial N° 122.2193.108 161 70 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-509 50778 10.06.99 REVISION 00 DATE 10.06.
ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) fuelled engine LGW 523 without idling back-up device serial N° 122.2193.108 162 COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
XIII ELECTRICAL CIRCUIT Wiring diagram of gasoline (petrol) fuelled engine LGW 523 with idling back-up device, internal alternator and module serial N° 122.2193.113 163 72 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE 1-5302-509 50778 10.06.99 REVISION 00 DATE 10.06.
ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) fuelled engine LGW 523 with idling back-up device serial N° 122.2193.113 164 COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
XIII ELECTRICAL CIRCUIT Alternator Iskra 14V 33A Voltage rating = 14V Rated current = 33A Max speed = 12000 r/min Max peak speed = 13000 r/min AER 1503 voltage governor Clockwise rotation Note: Tighten nut 1 to a 35 to 45 Nm torque. 165 Characteristic curve of the Iskra 14V 33A alternator The curve was measured at a constant voltage rating of 14V and at an ambient temperature of 25°C. Note: The r/min speed in the table are those of the alternator.
ELECTRICAL CIRCUIT XIII Marelli alternator, type AA 125 R 14V 45A Specifications: Voltage rating Rated current Maximum speed Maximum peak speed (for 15 sec.) Bearing on control side Bearing on collector side Voltage governor Clockwise rotation = 14V = 45A = 14000 r/min = 15000 r/min = 6203-2Z = 6201-2Z/C3 = RTT 119 A Note: Lubricate the bearings with grease suitable for high temperatures. Tighten nut 1 to a 60 Nm torque.
XIII ELECTRICAL CIRCUIT Alternator housed in the flywheel 12V 20A with three output wires 12V 30A with two output wires 1 2 3 4 Flywheel Ring gear Rotor Stator 171 Battery recharging curve for 12V 20A alternator ( three output wires ) The test was conducted after a 20°C heat stabilizing process. The current delivery with reference to the curve may be subjected to variations between +10 % and -5 %.
ELECTRICAL CIRCUIT XIII STARTER MOTOR Bosch type DW 12V 1.1 KW Clockwise rotation A = 17.5 to 19.5 mm (distance from flywheel ring gear plane to starter motor flange plane) Note: Contact the Bosch after-sales service network if repairs are needed. 174 Characteristic curve of starter motor Bosch type DW 12V 1.
XIV STORAGE STORAGE Engines that must be stored for more than 30 days must be prepared in the following way: Temporary protection (1/6 months). - Allow the engine to idle in a no-load condition for 15 minutes. - Fill the sump with protective oil MIL-1-644-P9 and allow the engine to run for 5 to 10 minutes at three-quarters of the top speed. - When the engine is hot, empty out bottom plug (fig. 166) and fill with normal new oil (see recommended oil on page 17). - Remove the fuel pipe and empty the tank.
LPG fuelled ENGINE LGW 627 XV Engine LGW 627 LPG fuelled COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
XV LPG fuelled ENGINE LGW 627 When the relative conversion unit is installed, engine LGW 627 can operate with LPG fuel (liquid petroleum gas). LPG is a mixture of hydrocarbons, amongst which propane and butane are present in major proportions. This fuel is considered a valid alternative to gasoline (petrol) particularly owing to its lower cost and less polluting emissions.
LPG fuelled ENGINE LGW 627 XV 183 Components : A Switch mod. 093 B Connection harness between switch and users C Fuse holder with 7.
XV LPG fuelled ENGINE LGW 627 Operation of the ignition system for gasoline (petrol) or LPG fuelled engines Note that to operate with LPG, the engine must be equipped with module 122.2193.114 and the relative wiring serial N° 2185.942, since this ignition system has been designed to operate when the engine is fuelled with either gasoline (petrol) or LPG.
LPG fuelled ENGINE LGW 627 XV Components of the LPG conversion unit. To fuel the engine with LPG alone, shut off the bleed tubes 1 (fig. 183a) of the carburetors. The bleed tubes must be left open if the engine is also or only to operate with gasoline (petrol). 183a Regulator/atomizer The reducer allows LPG to change from the liquid state to the gaseous state. It is a container divided into compartments by membranes. Gasification of the LPG notably lowers the pressure and temperature.
XV LPG fuelled ENGINE LGW 627 Regulator installation Comply with the following recommendations when installing: · the Regulator must be installed in the engine compartment; · it must be firmly fixed to the bodywork with M10 screws; · it must be positioned parallel to the advancement direction, see fig.
LPG fuelled ENGINE LGW 627 XV Regulator heating circuit connection The regulator should be connected to the cooling circuit of the engine or the heating circuit of the passenger compartment, using the relative pipes (fluid cooling). Fit the T unions in the position indicated in fig. 186, and use the relative pipe clamps for fixing purposes. Comply with the directions indicated by the water inlet and outlet arrows stamped on the regulator/atomizer.
XV LPG fuelled ENGINE LGW 627 Gasoline (petrol) solenoid valve This solenoid valve is a device that allows the flow of gasoline to be shut off when the vehicle is fuelled with gas, and the passage of gasoline (petrol) when the vehicles uses this fuel to operate. It is equipped with a manual device to use if the electrical device breaks down, allowing the valve to be by-passed. Similarly to the LPG solenoid valve, this one consists of a coil and a body with fuel inlet and outlet unions.
LPG fuelled ENGINE LGW 627 XV Electrical system This is an essential component on which the correct operation of the entire system depends.
XV LPG fuelled ENGINE LGW 627 Incorrect adjustments may saturate the air with LPG. Make all the adjustments outdoors or in a well ventilated place, well away from naked flames that could create sparks. REGULATING PROCEDURE WITH REDUCER SE 81 SIC The first operation is to regulate the peak rate: bring the engine to about 2/3 rds of its r/min speed and turn the peak speed adjuster on the reducer/mixer tube to set the CO, HC, CO2 values as shown in the table.
LPG fuelled ENGINE LGW 627 XV HOW TO REGULATE THE SENSITIVITY OF REDUCER SE 81 SIC The reducers will have already been regulated by the manufacturer, but if faults such as an instable idling speed or unsteady acceleration occur, it is advisable to check the sensitivity of the reducer itself. Adjuster screw G is not used to regulate the idling speed but just to adjust the sensitivity of the reducer.
XVI DRIVING TORQUES MAIN DRIVING TORQUES POSITION Spark plug Intake manifold fixing nut (LGW 627) Carburetor fixing nut Rocker arm journal bearing fixing nut Tightening pulley nut Flange for rear tang retention ring Rocker cap fixing Cast iron connecting rod cap Main journal cap Flywheel fixing (self-locking nut) Timing system pulley fixing Fuel pump eccentric Air pump coupling Driving pulley fixing Carburetor stud bolt Intake manifold stud bolt (LGW 627) 3rd P.T.O.
DRIVING TORQUES XVI DRIVING TORQUES FOR STANDARD SCREWS DENOMINATION R ³ 1000 N/mm² R ³ 800 N/mm² Diameter x pitch (mm) R ³ 1200 N/mm² 4x0.70 3.6 0.37 5.1 0.52 6 0.62 5x0.80 7 0.72 9.9 1.01 11.9 1.22 6x1.00 12 1.23 17 1.73 20.4 2.08 7x1.00 19.8 2.02 27.8 2.84 33 3.40 8x1.25 29.6 3.02 41.6 4.25 50 5.10 9x1.25 38 3.88 53.4 5.45 64.2 6.55 10x1.50 52.5 5.36 73.8 7.54 88.7 9.05 13x1.75 89 9.09 125 12.80 150 15.30 14x2.00 135 13.80 190 19.
XVII SPECIFIC TOOLS SPECIFIC TOOLS DENOMINATION SERIAL N° Tool to mount the intake and exhaust valve guide seal 7170-1460-047 Tool to adjust the timing belt tension 7170-1460-049 92 COMPILER TECO/ATI Crank shaft locking tool 7107-1460-051 Shim to insert main bearings into the engine block 7107-1460-053 REG. CODE MODEL N° DATE OF ISSUE 1-5302-509 50778 10.06.99 REVISION 00 DATE 10.06.
NOTES COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE REVISION 1-5302-509 50778 10.06.99 00 DATE 10.06.
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