Aixam City, Crossline, Scouty R, Roadline User Manual

REPAIR MANUAL

CONTENTS

GROUP 0: GENERAL

 General warranty terms ..................................................................................................................................... 2

 Technical characteristics :

- Light quadricycles category L6e ........................................................................................................................ 3,4

- Heavy quadricycles category L7e ..................................................................................................................... 5,6

 Checks to perform before delivering the venicle ............................................................................................... 7

 Work to perform during servicing....................................................................................................................... 8

 Vehicle identification ......................................................................................................................................... 9

GROUP 1: ENGINE

 KUBOTA Z402, Z602 engines

- Cooling system ................................................................................................................................................... 2

- Lubrication system ............................................................................................................................................. 3

- Injection system ................................................................................................................................................. 4 to 7

- Tightening torques Z402 .................................................................................................................................... 8

- Tightening torques Z602 .................................................................................................................................... 9

- Repairs ............................................................................................................................................................... 10 to 12

 LOMBARDINI 523 MPI engine

- Cooling system ................................................................................................................................................... 13

- Lubrication system ............................................................................................................................................. 14

- Injection system ................................................................................................................................................. 15

- Tightening torques ............................................................................................................................................. 16, 17

- Repairs ............................................................................................................................................................... 18

GROUP 3: REVERSER AXLE

 Reverser axle .................................................................................................................................................... 2

 Transmission ..................................................................................................................................................... 3

 Regulator assembly VSP 2000 LP2 version 2 ................................................................................................... 4 to 23

GROUP 4: FRONT AXLE

 Front axle adjustment dimensions

GROUP 5: REAR AXLE

 Rear axle adjustment dimensions

GROUP 6: WHEELS-BRAKES

 Tire pressure ..................................................................................................................................................... 2

 Renewing the brake fluid ................................................................................................................................... 3

 Brakes ............................................................................................................................................................... 4, 5

 Hand brake ........................................................................................................................................................ 6

 Summary on aluminum wheels 2010 ................................................................................................................ 7

GROUP 7: BODY

 Front frame dimensions CITY ........................................................................................................................... 2

 Aluminum cell dimensions CITY ........................................................................................................................ 3 to 5

 Front frame dimensions CROSSLINE ............................................................................................................... 10

 Aluminum cell dimensions CROSSLINE ........................................................................................................... 11 to 13

 Body maintenance............................................................................................................................................. 18

 Gluing ................................................................................................................................................................ 19

GROUP 8: ELECTRICITY-INSTRUMENTS

 Instrument cluster .............................................................................................................................................. 2 to 20

 Fuses ................................................................................................................................................................ 21

 Centralised locking ............................................................................................................................................ 22

 Guarantee on CLARION radio unit .................................................................................................................... 23 to 26

 Changing a lamp ............................................................................................................................................... 27, 28

 Electric diagram ................................................................................................................................................ 29 to 33

 Air conditioning .................................................................................................................................................. 34 to 38

 ABS ...................................................................................................................................................................

GROUP 9: PAINT

 Body colors ....................................................................................................................................................... 2, 3

REPAIR MANUAL

0

General

INDEX

 General terms of warranty ...................................................................................... 2

 Technical characteristics

 Light quadricycles category L6e ....................................................................... 3,4

 Heavy quadricycles category L7e ..................................................................... 5,6

 Checks to perform before delivering the vehicle ..................................................... 7

 Work to perform during servicing ............................................................................ 8

 Vehicle identification .............................................................................................. 9

REPAIR MANUAL

0

General

GENERAL TERMS OF WARRANTY

1. All new vehicles in the AIXAM range are guaranteed for a period of two years from their delivery to the client, against all defects
or manufacturing flaw.

All spare parts or accessories sold by AIXAM are guaranteed against any defect or manufacturing flaw for a period of one year

from the date of delivery to the customer.

2. The following is required to benefit from the AIXAM guarantee:

- The user manual must be filled with the vehicle identification, name and address of the user customer, and the stamp of the
approved dealer.

- The AIXAM approved distributor registers the guarantee on the Internet on the day of sale.

3. The guarantee may be requested from any approved dealer in the AIXAM network. The customer will present his user manual
bearing the stamp of the vehicle seller, the date of delivery to the customer and stamp of the AIXAM approved dealer having
performed servicing and check between 500 and 1 000 km, planned by the manufacturer.

4. Under pain of losing the benefit of the guarantee, the customer will present his vehicle between 500 and 1 000 km to his
approved AIXAM dealer. The latter will perform free of charge (except consumables and small supplies) the labour operations
required for checking, adjusting, tightening planned by the manufacturer at that mileage.

After performing these operations, the AIXAM approved dealer will apply his stamp in the appropriate box, while indicating the

date and exact mileage.

5. The guarantee includes replacement or repair, according to manufacturer instructions, of the part recognised faulty, with labour
required by this replacement or repair free of charge. Repair on site or towing fees are not included.

6. Interventions within the warranty will not extend its period. However, the use of the warranty does extend its period for a time
equal to that necessary for the performance only of the works under warranty, provided the said works require inevitably an
immobilisation of the vehicle during at least 7 consecutive days (Act of 18 January 1992 – Art. 4)

7. The manufacturer is the rightful owner of the parts removed within the warranty.

8. Elements not covered by the warranty:

• Any part and equipment which is not an original AIXAM component.

• Servicing operations, including balancing and adjustment of parallelism of the wheels ; engine and headlight tuning,

changing glow plugs, ignition plugs, lamps, belts, transmission belts, parts required for maintenance of regulators, brake pads
and linings, brake discs and drums, lubricants and fluids.

• Damage, breakdowns and damage resulting from:

-abuse, accidents, theft, fire, vandalism,

-industrial fallout, acid, alkaline, chemical, resin, bird droppings, salt, hail, storms, lighting and others,

-non-observance of servicing programs at the planned periods,

-improper intervention,

-interventions outside the AIXAM network,

-use of non-original parts,

-use of improper fuel or lubricant or containing foreign bodies or fuel other than recommended,

-Overloading, even temporary.

• The entire vehicle if the latter was subject to modifications or transformations not planned by the manufacturer, particularly
when the vehicle no longer matches the original homologation criteria.

• Normal wear of any element including the exhaust, belts and shock absorbers, as well as ageing of the trims, upholstery,
paint and wheel covers.

• Any vehicle with an odometer which was changed or modified in such a way preventing to establish the actual mileage, with

an altered serial number or engine number.

• Expenses resulting from the immobilisation of the vehicle including direct or indirect or commercial loss incurred by the owner
or usual user of the vehicle.

9. Documentations relative to the warranty, servicing, and driving:

All benefactors of the AIXAM warranty receive a user manual delivered with the new vehicle.
The application of the terms of warranty is subject to the presentation of this user manual.

10. In any case, the AIXAM vehicle benefits from the legal warranty against hidden flaws, in compliance with the provisions of

articles 1641 and following of the Civil Code.

REPAIR MANUAL

0

General

GENERAL

CITY

CROSSLINE

Genre

Light quadricycle category L6e

Type and version

SV43AF

SV42AF

Steering wheels

Front

Drive wheels

Front

DIMENSIONS (mm)

CITY

CROSSLINE

Front track width

1345

1345

Rear track width

1345

1345

Wheelbase

1795

2000

Front overhang

524

524

Rear overhang

401

466

Overall length

2720

2990

Overall width

1500

1500

Height

1470

1540

WEIGHT (kilograms)

CITY

CROSSLINE

Gross vehicle weight rating

640

Gross driving weight rating

none

Maximum load:

On front axle

350

On rear axle

400

Empty vehicle curb weight:

Total

380

On front axle

230

On rear axle

150

ENGINE

CITY

CROSSLINE

Brand

KUBOTA

Type

Z402

Cycle

DIESEL

Number of strokes

4

Number and position of the cylinders

2 INLINE

Bore (mm)

64

Stroke (mm)

62,2

Compression ratio

23

Maximum power (kW CE)

4

Maximum power engine speed (rpm)

3200

Maximum torque (N/M CEE)

14

Maximum torque engine speed (rpm)

2400

Maximum rotation engine speed (rpm)

3200

Fuel used

GASOIL

Fuel tank (litres)

16

Ignition

By compression

Engine cooling

Liquid

Sound level at the fixed point:

Sound level value (dba)

79

Maximum corresponding engine speed (rpm)

2400

TECHNICAL CHARACTERISTICS

Light quadricycle category L6e

ENGINE

Heavy quadricycle category L7e

Brand

KUBOTA

LOMBARDINI

Type

Z602

LGW 523MPI

Cycle

DIESEL

GASOLINE

Number of strokes

4

4

Number and position of the cylinders

2 INLINE

2 INLINE

Bore (mm)

72

72

Stroke (mm)

73,6

62

Compression ratio

24

8,7

Maximum power (kW CE)

11,2

15

Maximum power engine speed (rpm)

3600

5000

Maximum torque (N/M CEE)

34

37

Maximum torque engine speed (rpm)

2200

3000

Maximum rotation engine speed (rpm)

3600

5000

Fuel used

GASOIL

LEAD-FREE GASOLINE 95,98

Fuel tank (litres)

16

16

Ignition

BY COMPRESSION

ELECTRONIC

Engine cooling

LIQUID

LIQUID

REPAIR MANUAL

0

General

GENERAL

CROSSLINE

Genre

Heavy quadricycle category L7e

Type and version

ST62AF / ST92AF

Steering wheels

Front

Drive wheels

Front

DIMENSIONS (mm)

Front track width

1345

Rear track width

1345

Wheelbase

2000

Front overhang

524

Rear overhang

466

Overall length

2990

Overall width

1500

Height

1540

WEIGHT (kilograms)

Gross vehicle weight rating

675

Gross driving weight rating

none

Maximum load:

On front axle

350

On rear axle

500

Empty vehicle curb weight:

Total

400

On front axle

240

On rear axle

160

TECHNICAL CHARACTERISTICS

Heavy quadricycle category L7e

REPAIR MANUAL

0

General

CHARACTERISTICS

FRONT

REAR

Type

Discs

Drums

Diameter

210 mm

160 mm

TECHNICAL CHARACTERISTICS

MOVEMENT TRANSMISSION

• Gear type: continuous variable transmission

• Clutch type: centrifugal

• Control mode: automatic

• Transmission type:

Engine → regulator → reverser reducer axle → wheels.

• Maximum speed: 45km/h light quadricycle category L6e

• Maximum speed: 75km/h heavy quadricycle category L7e.

SUSPENSION

• Front: independent wheels, pseudo Mac Pherson type, double effect hydraulic telescopic shock absorbers and helical springs.

• Rear: independent wheels with pulled arms, double effect hydraulic telescopic shock absorbers and helical springs.

STEERING

• Steering type: rack

BRAKING

• Service brake

The front and rear linings are driven by hydraulic pistons controlled by a double circuit master cylinder. This master cylinder, which
includes a brake fluid tank in its upper section, is controlled from inside the vehicle by a pedal within reach of the driver's right foot.
A limiter allows automatic reduction of braking effectiveness on the rear axle.

• Emergency brake

A lever located near the driver's right hand, between both vehicle seats, actuates the rear brakes, by means of a
cross-bar with two cables. This brake is adjusted mechanically by a screw on the level of each rear wheel or the cross­bar. A pawl allows to hold this brake in the applied position.

BODY:

• Body: light engine-powered quadricycle (L6e), heavy engine-powered quadricycle intended for transporting persons (L7e)

• Materials making up the body:

thermoformed ABS

• Number of seats: 2 light quadricycle category L6e, 4 heavy quadricycle category L7e

• Seats: 2 and bench seat Heavy quadricycle category L7e

• Number of doors: 2

• Nature of materials used for windows:

- Windshield: laminated glass

- Side windows: tempered glass

- Rear window: tempered glass

LIGHTING AND SIGNALING

• Headlights:

- indicators: 12V/21W

- position lights: 12V/21W

- low and high beam 12V/50W/60W

• Rear lights:

- rear and stop lights: 12V/21W/5W

- fog lights: 12V/21W

- backup lights: 12V/21W

• Front fog lights:

- fog lights: 12V/35W

• Day lights:

-LED lights: 12V/ 4W

REPAIR MANUAL

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General

CHECKS PERFORMED BEFORE VEHICLE DELIVERY:

•Check of closing and locking of all closing panels (doors, windows, hood, liftback, glove

compartment,….)

•Check of the board tooling.

•Level check:

- engine oil

- reverser axle oil

- washer fluid

- brake fluid

- coolant and antifreeze protection check

•Sealing check:

- brake circuit

- cooling circuit

•Tire pressure check, including the spare wheel.

•Check tightening of wheels, ball joints, engine, regulator, reverser bridge and screws in

general.

•Check operation of electrical and lighting devices.

•Adjustment of idle.

•Check of parallelism.

•Vehicle test.

•Cleaning the vehicle interior and exterior

•Check of the starting battery charge level and tightening of the lugs.

REPAIR MANUAL

0

General

INTERVENTIONS AND CHECKS TO
PERFORMED UPON SERVICING

First servicing at

Servicing at 5000 km or

Additional works at

1000 km or 1 year

1 year and every 5000 km

10000 km and every 10000 km

engine oil draining and renewal with oil filter change

o

o

draining the reverser axle and oil change

o o

oil level check on the reverser axle (top up if
necessary)

o

check of the level of coolant (top up if necessary)

o

o

check sealing of the cooling circuit

o

o

check of the level of brake fluid (top up if necessary)

o

o

check sealing of the brake circuit

o

o

check operation of the brakes including the
handbrake

o

o

cleaning and dust removal of the brakes, change the
linings if required

o

check of the level of battery electrolyte (top up with
demineralised water if required)

o

Adjustment of the reverser lever

0

grease the battery terminals

o

check the condition of the belts and change if
necessary

o

removing dust on entire regulator

o

check of regulator gap and replacement

o

of main bearings if required

check screw tightening (wheels, engine,.......)

o

o

change or clean the air filter

o cleaning

o

change fuel filter

o

tire pressure check, including the spare wheel

o

o

Check sealing of shock absorbers

0

Check the condition of suspension pins (engine,
exhaust)

0

Check the condition of the bellows (joints and
steering rack)

0

Reprogram the maintenance indicator

0 0 0

check the charging circuit

o

check proper operation of the lighting and

o

o

electrical instrumentation

Cleaning the fins of the cooling radiator

0

check and adjust parallelism

o

vehicle test

o

o

WORK TO BE PERFORMED AT SERVICING

CAUTION: Maintenance work to perform regularly (in addition to servicing recommended)

Annually: renew the brake circuit fluid.
Every two years: renew the coolant.

Never use super fuel as antifreeze in diesel fuel.

Use the products recommended in stores

REPAIR MANUAL

0

General

VEHICLE IDENTIFICATION

1-SERIAL NUMBER COLD PUNCH

The serial number is punched on the right-hand cross-member, inner side of the car, under the
right-hand seat slider.

2-MANUFACTURER PLATE

The manufacturer plate is riveted to the right-hand stringer on the inner side of the car, next to the
engraved serial number.

REPAIR MANUAL

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TIGHTENING TORQUES

Mini Maxi

Column tensioner

(upper screw)

M8*20 2

18,4 27,6

Column tensioner

(lower screw)

M8*35 2

18,4 27,6

Flector column M8*20+nylstop 2

18,4 27,6

Steering column nylstop M8 3

18,4 27,6

Steering joint (cardan) M8*35+nylstop 1

18,4 27,6

Steering rack M10*60 2

36 54

Tie rod Nylstop M10*1,25 2

32 48

Steering wheel M12 torx 1

40 60

Handbrake M8*20 2

18,4 27,6

Master Cylinder M8*25+nylstop 2

18,4 27,6

Banjo bolt limiter Thin thread banjo bolt 4

20 30

Brake pedal M 6 x 16 1

8,8 13,2

Safety belt (upper screw) 7/16' 20 UNF 2

25 40

Safety belt (lower screw) 7/16' 20 UNF 2

25 40

Seat belt retractor 7/16' 20 UNF 2

25 40

Belt buckle 7/16' 20 UNF 2

25 40

Seats front sliders M6*30 8

8,8 13,2

Front wheel hub nut Nylstop M16*1,5 2

140 160

Front suspension triangles M10*50+Nylstop 4

38 54

Front suspension ball joints Nylstop M12*1,25 2

40 60

Nylstop M10*1,00 2

16 24

Nylstop M12 2

36 54

Rear wheel hub axle M12*180+Nylstop 2

64 96

M10*65+Nylstop 2

38 54

Rear suspension arm M10*65+nilstop 4

38 54

Front wheel M10*1,25 16

40 60

Rear wheel M10*1,25 16

40 60

Receiver inverter Spiralock nut M12 1

90 110

STEERING

BRAKES

SEATS/BELT

FRONT & REAR AXLE

FUNCTION

DESIGNATION

SCREW

COEF

Torque in Nm

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

INDEX

KUBOTA Z402 and Z602 engines:

 Cooling system .................................................................................................... 2

 Lubrication system ............................................................................................... 3

 Injection system ................................................................................................... 4 to 7

 Tightening torques Z402 ...................................................................................... 8

 Tightening torques Z602 ...................................................................................... 9

 Repair ................................................................................................ .................. 10 to 12

LOMBARDINI 523 MPI engine

 Cooling system .................................................................................................... 13

 Lubrication system ............................................................................................... 14

 Injection system ................................................................................................... 15

 Tightening torques ............................................................................................... 16, 17

 Repair ................................................................................................ .................. 18

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Start of thermostat valve opening

69.5 to 72.5 °C

Full opening of the thermostat valve

85 °C

A: Thermostat closed, short circulation enhancing
engine temperature build-up

B: Thermostat open, long circulation to cool the engine.

Cooling system

Forced circulation cooling system with water pump. Temperature regulation is ensured by a
thermostat fastened on the upper water manifold of the cylinder head.

The thermostat is controlled as defined below:

The water pump is centrifugal and driven by the accessory belt.

1 : Radiator
2 : Water pump
3 : Fan
4 : Thermostat
5 : Cylinder head
6 : Engine block

Quantity of coolant: 2 litres

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Lubrication system

1 : Rocker
2 : Pressure switch
3 : Rocker ramp
4 : Valve
5 : NA on 400
6 : Distribution
7 : Crankshaft
8 : Oil pump
9 : Strainer

10 : Overpressure valve
11 : Oil filter
12 : Push rod
13 : Indexed push rod
14 : Camshaft
15 : Injection pump
16 : Piston

A: Filter OK
B: Clogged filter

Quantity of Z402 oil: 1.80 litres
Quantity of Z602 oil: 2.50 litres

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Injection system

The injection pump delivers the quantity of fuel required to meet the driver's demand.
The injection pump preserves the engine of any overspeeding and ensures idle running stability.
The injection pump controls engine stopping when requested.

It is divided into four separate parts:

- Low pressure

- High pressure

- Regulation

- Control

The low pressure circuit comprises the:

1. Fuel tank

2. Strainer

3. Fuel pre-filter

4. Supply pump

5. Main filter

The high pressure circuit comprises the:

6. Injection pump

7. Injectors

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Adjusting and tuning

The basic adjustments are located on the injection pump or injection pump housing.

1. Engine Stop

2. Min acc. stop

3. Max acc. stop

4. Acceleration lever

5. Idle adjust screw

6. Engine stop lever

7. Max load adjust screw

Idle adjust

Idle adjustment is made from screw 5.
However, idle speed must be reduced by 50 rpm by the min acceleration stop (2) and
compensated with the idle adjust screw (5) to avoid untimely engine stalling.

Load adjust

Max load adjustment is done with screw 7.
However, modifying this adjustment is not authorized. Adjustment of this screw is highly sensitive
and may cause excessive smoke or lack of power. In case of problem linked with this adjustment,
and once all other causes have been eliminated, call after-sales.

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Centrifugal regulator

Regulation principle

1. Accelerator lever

2. Starting spring

3. Regulation lever

4. Regulation spring

5. Intermediate regulation lever

6. –

7. –

8. –

9. –

10. Pump camshaft

11. Idle spring

12. Accelerator control

13. Flow control rod

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Upon starting:
Spring 2 drives lever 3 to the maximum flow position, the control rod is in the maximum flow

position. When the engine starts, the centrifugal force applied to the regulator is stronger that the
cold start spring, hence lever 3 is pushed to the minimum flow position, and the control rod pushes
the idle spring 11.

At idle:
Centrifugal force applied to the regulator is sufficient to maintain lever 3 and the control rod on idle

spring 11. The spring 11 ensures idle running stability.
At full load:
Upon acceleration request, lever 1 applies a tension on spring 2, which drives lever 5. Lever 5

drives lever 3, and moves the flow control rod in max load position. When speed reaches the
maximum, the centrifugal force applied to the regulator becomes higher than that applied by spring
4, the control rod moves to a flow reduction.

Upon engine stop:
The engine stop lever pushes lever 3 in min flow position, the force applied to the lever is

important enough to completely compact the idle spring, hence cutting engine injection.

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Element

Dimension x pitch

N-m

Kgf-m

* Cylinder head cover nuts

M6 x 1.0

3.9 to 5.9

0.4 to 0.6

* Cylinder head screws

M8 x 1.25

37.2 to 42.1

3.8 to 4.3

* Main bearing fastening screw 1

M6 x 1.0

12.7 to 15.7

1.3 to 1.6

* Main bearing fastening screw 1 (flywheel side)

M8 x 1.25

23.5 to 27.4

2.4 to 2.8

* Main bearing fastening screw 2

M7 x 1.0

26.5 to 30.4

2.7 to 3.1

* Flywheel screws

M10 x 1.25

53.9 to 58.8

5.5 to 6

* Piston rod screws

M7 x 0.75

26.5 to 30.4

2.7 to 3.1

* Rocker arm support nuts

M6 x 1.0

9.8 to 11.3

1.00 to 1.15

* Gear shaft screw

M6 x 1.0

9.8 to 11.3

1.00 to 1.15

* Crankshaft end bolt

M12 x 1.5

117.6 to 127.4

12.0 to 13.0

* Bearing box cover screws

M6 x 1.0

9.8 to 11.3

1.00 to 1.15

Glow plugs

M8 x 1.0

7.8 to 14.7

0.8 to 1.5

Injector holder assembly

M20 x 1.5

49.0 to 68.6

5.0 to 7.0

Oil pressure switch tapered screw

PT 1/8

14.7 to 19.6

1.5 to 2.0

Injection duct fastening nuts

M12 x 1.5

24.5 to 34.3

2.5 to 3.5

Overflow pipe assembly fastening nuts

M12 x 1.5

19.6 to 24.5

2.0 to 2.5

Starter nut B terminal fitting nut

M8

8.8 to 11.8

0.9 to 1.2

Grade

Standard screws and

bolts 4

Special screws and

bolts 7

Unit

N-m

Kgf-m

N-m

Kgf-m

Nominal diameter

M6

7.9 to 9.3

0.80 to 0.95

9.8 to 11.3

1.00 to 1.15

M8

17.7 to 20.6

1.8 to 2.1

23.5 to 27.5

2.4 to 2.8

M10

39.2 to 45.1

4.0 to 4.6

48.1 to 55.9

4.9 to 5.7

M12

62.8 to 72.6

6.4 to 7.4

77.5 to 90.2

7.9 to 9.2

Number

engraved

Material grade of the screw or bolt

None or 4

SS41, S20C screw and bolt

7

S43C, S48C special screw and bolt
(refined)

TIGHTENING TORQUES Z402

The screws, bolts and nuts must be tightened at the torque specified using a torque wrench.
Several screws, bolts and nuts, such as those on the cylinder head, must be tightened in a specific sequence and
torque.

1. Tightening torques for screws, bolts and nuts for particular use

 For screws, bolts and nuts marked « * » in the table, smear the threading and seats with motor oil before

tightening.

 The letter « M » of dimension x pitch means that the dimension of the screw, bolt or nut relies on the metric

system.

 The dimension is the nominal outer diameter of the threadings in mm.

 The pitch is the nominal distance in mm between two threads.

2. Tightening torques for screws, bolts and nuts for general use

When tightening torque values are not specified, tighten the screws, bolts, and nuts at the values specified in the
following table.

The material grade is indicated by numbers engraved on the heads of screws and bolts. Always check the numbers
indicated below before tightening.

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Elements

Dimension x

pitch

N-m

Kgf-m

Pounds-feet

* Rocker cover bolts

M6 x 1

6.86 to 11.3

0.7 to 1.15

5.1 to 8.3

Injection duct fastening nut

M12 x 1.5

24.5 to 34.3

2.5 to 3.5

18.1 to 25.3

Overflow duct fastening nut

M12 x 1.5

19.6 to 24.5

2.0 to 2.5

14.5 to 18.1

Injector unit

M20 x 15

49.0 to 68.6

5.0 to 7.0

36.2 to 50.6

Glow plug

M8 x 1

7.8 to 14.7

0.8 to 1.5

5.8 to 10.8

* Rocker ramp nut

M6 x 1

9.8 to 11.3

1.00 to 1.15

7.2 to 8.3

* Cylinder head bolt

M8 x 1.25

37.3 to 42.2

3.8 to 4.3

27.5 to 31.1

* Fan drive pulley screw

M12 x 1.5

117.7 to

127.5

12.0 to 13.0

86.8 to 94.0

* Intermediate gear shaft fastening screws

M6 x 1

9.8 to 11.3

1.00 to 1.15

7.2 to 8.3

Injection pump fastening screws

M8 x 1.25

17.7 to 21.6

1.80 to 2.20

13.0 to 15.9

* Connecting rod head bolt

M7 x 0.75

26.5 to 30.4

2.7 to 3.1

19.5 to 22.4

* Flywheel bolt

M10 x 1.25

53.9 to 58.8

5.5 to 6.0

39.8 to 43.4

Main bearing cap cover fastening bolt

M6 x 1

9.8 to 11.3

1.00 to 1.15

7.2 to 8.3

* Main crankshaft bearing bolt 2

M7 x 1

26.5 to 30.4

2.7 to 3.1

19.5 to 22.4

* Main crankshaft bearing bolt 1

M6 x 1

12.7 to 15.7

1.3 to 1.6

9.4 to 11.6

Oil pressure switch

PT 1/8

14.7 to 19.6

1.5 to 2.0

10.8 to 14.5

Injector nose support

34.3 to 39.2

3.5 to 4.0

25.3 to 28.9

Starter B terminal fastening nut (electromagnetic drive
type)

M8

7.8 to 9.8

0.8 to 1.0

5.8 to 7.2

Starter B terminal fastening nut (planetary gear
reduction type)

M8

5.9 to 11.8

0.6 to 1.2

4.3 to 8.7

Generator pulley nut

M10 x 1.25

39.2 to 44.1

4.0 to 4.5

28.9 to 32.5

Alternator pulley nut

58.3 to 78.9

5.95 to 8.05

43.0 to 58.2

Drain plug with copper gasket

M12 x 1.25

32.4 to 37.3

3.3 to 3.8

23.9 to 27.5

Drain plug with copper gasket

M22 x 1.5

63.7 to 73.5

6.5 to 7.5

47.0 to 54.2

Drain plug with rubber coating gasket

M22 x 1.5

44.1 to 53.9

4.5 to 5.5

32.5 to 39.8

TIGHTENING TORQUES Z602

Tightening torques for screws, bolts and nuts for particular use

 For screws, bolts and nuts marked « * » in the table, smear the threading and seats with motor oil before

tightening.

 The letter « M » of dimension x pitch means that the dimension of the screw, bolt or nut relies on the metric

system.

 The dimension is the nominal outer diameter of the threadings in mm.

 The pitch is the nominal distance in mm between two threads.

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Anomaly

Possible cause

Solution

The engine does

not start

No fuel

Fill up

Air in the supply circuit

Purge the air

Water in the supply circuit

Change the fuel and repair or change the
supply system

Clogged supply duct

Clean

Clogged fuel filter

Clean or change

Fuel or oil viscosity too high

Use the fuel or motor oil specified
Low hexadecane index fuel

Use the fuel specified

Fuel leak due to bad tightening of a
fastening nut on the injection duct

Tighten the nut
Bad injection timing

Adjust

Camshaft wear

Change

Clogged injector

Clean

Bad operation of the injection pump

Repair or change

Seized crankshaft, camshaft, piston,
cylinder jacket or main bearing

Repair or change

No compression in the cylinder

Change the cylinder head gasket, tighten
the cylinder head screw, change the glow
plug and injector holder

Bad timing

Readjust or change the timing gear
Worn piston rings and jacket

Change

Excess play in timing

Adjust

The starter is

inoperative

Battery discharged

Charge

Faulty starter operation

Repair or change

Faulty key switch

Repair or change
Wiring disconnected

Connect

REPAIR

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Anomaly

Possible cause

Solution

The engine does

not run regularly

Clogged or dirty fuel filter

Clean or change

Clogged air filter

Clean or change

Fuel leak due to bad tightening of a
fastening nut on the injector duct

Retighten the nut

Bad operation of the injection pump

Repair or change
Bad injector opening pressure

Adjust

Stuck or clogged injector

Repair or change

Faulty regulator operation

Repair

Exhaust gases

black, or dark grey

Excess motor oil

Reduce to level specified

Wear or sticking of a piston ring and a
jacket

Repair or change
Bad injection timing

Adjust

Bad compression

Adjust neutral spaces

Overload

Reduce the load

Bad quality fuel

Use the fuel specified

Clogged fuel filter

Clean or change

Clogged air filter

Clean or change

Faulty injector

Repair or change the injector

Insufficient power

Bad injection timing

Adjust

The engine moving parts seem to be seized

Repair or change

Irregular fuel injection

Repair or change the injection pump
Faulty injector

Repair or change the injector

Lack of compression

Change the cylinder head gasket, tighten
the cylinder head screw, the glow plug and
injector holder

Excessive oil
consumption

The cutting gap is set in the same direction
for all piston rings

Modify the location of the cutting gap
Worn or stuck oil control ring

Change

Worn piston ring groove

Change the piston

Worn valve stem and guide

Change

Worn crankshaft main bearings or trunnion
bearings

Change

Oil leaked caused by a faulty lining or
sealing

Change

REPAIR (cont’d)

REPAIR MANUAL

1

KUBOTA Z402 and Z602 engines

Anomaly

Possible cause

Solution

Fuel mixed with

lubrication oil

Worn injection pump plunger

Change the pump element or pump
Faulty injector

Repair or change the injector

Injection pump

Change

Water mixed with

lubrication oil

Faulty cylinder head gasket

Change

Flaky casing or cylinder head

Change

Low oil pressure

Low motor oil

Top up

Clogged strainer

Clean

Discharge valve stuck by dirt

Clean

Fatigue or broken discharge valve spring

Change

Too much running gap of a crankshaft
bearing

Change

Too much running gap of a connecting
rod head bearing

Change

Too much running gap of a push rod
bushing

Change
Clogged oil passage

Clean

Inappropriate type of oil

Use the type of oil specified

Faulty oil pump

Repair or change

High oil pressure

Inappropriate type of oil

Use the type of oil specified

Faulty discharge valve

Change

Overheating engine

Low motor oil

Top up

Fan belt broken or loose

Change or adjust
Low coolant

Top up

Radiator honeycomb or fins clogged

Clean
Corroded radiator interior

Clean or change

Corroded coolant circuit

Clean or change
Faulty radiator plug

Change

Run with overload

Reduce the load

Faulty cylinder head gasket

Change

Bad injection timing

Adjust

Inappropriate fuel type

Use the fuel specified

Battery discharges

too fast

Low electrolyte

Fill distilled water and charge the battery

Slipping fan belt

Adjust belt tension or change it
Wiring disconnected

Reconnect

Rectifier disconnected

Change

Faulty fan generator

Change

Faulty battery

Change

REPAIR (cont’d)

REPAIR MANUAL

1

LOMBARDINI 523 MPI engine

COOLING SYSTEM

3. Thermostatic valve

4. Cylinder block

5. Coolant temperature indicator thermostat

6. Circulation pump

7. Ventilation helix

8. Radiator

Quantity of coolant: 2 litres

REPAIR MANUAL

1

LOMBARDINI 523 MPI engine

LUBRICATION SYSTEM

1. Pressure switch

2. Rocker stud

3. Connecting rod head stud

4. Oil filter cartridge

5. Main bearing stud

6. Oil change plug

7. Oil gauge

8. Vent

9. Oil fill plug

10. Camshaft

11. Oil pressure adjust valve

12. Oil pump

13. Crankshaft

14. Oil suction filter

15. Hydraulic push rod

Oil quantity (with filter) = 1.3 litres
Oil quantity (without filter) = 1.2 litres

REPAIR MANUAL

1

LOMBARDINI 523 MPI engine

INJECTION SYSTEM

1. Filling pipe

2. Tank

3. Fuel pump / gauge plant

4. Filter

5. Supply duct

6. Injector supply pipe

7. Injector

8. Pressure regulator

9. Injector holding spring

10. Pressure regulator return pipe

11. Supply pipe fastening screw

REPAIR MANUAL

1

LOMBARDINI 523 MPI engine

TABLE OF TIGHTENING TORQUES OF STANDARD SCREWS (wide pitch)

Resistance class (R)

Grade /

Dimensions

Diameter

R>400N/mm²

R>500N/mm²

R>600N/mm²

R>800N/mm²

R>1000N/mm²

R>1200N/mm²

Nm

Nm

Nm

Nm

Nm

Nm

Nm

Nm

M3

0,5

0,7

0,6

0,9 1 1,4

1,9

2,3

M4

1,1

1,5

1,4

1,8

2,2

2,9

4,1

4,9

M5

2,3 3 2,8

3,8

4,5 6 8,5

10

M6

3,8 5 4,7

6,3

7,5

10

14

17

M8

9,4

13

12

16

19

25

35

41

M10

18

25

23

31

37

49

69

83

M12

32

43

40

54

65

86

120

145

M14

51

68

63

84

101

135

190

230

M16

79

105

98

131

158

210

295

355

M18

109

145

135

181

218

290

405

485

M20

154

205

193

256

308

410

580

690

M22

206

275

260

344

413

550

780

930

M24

266

355

333

444

533

710

1000

1200

M27

394

525

500

656

788

1050

1500

1800

M30

544

725

680

906

1088

1450

2000

2400

TABLE OF TIGHTENING TORQUES OF STANDARD SCREWS (thin pitch)

Diameter

R>400N/mm²

R>500N/mm²

R>600N/mm²

R>800N/mm²

R>1000N/mm²

R>1200N/mm²

Nm

Nm

Nm

Nm

Nm

Nm

Nm

Nm

M 8x1

10

14

23

17

20

27

38

45

M 10x1

21

28

26

35

42

56

79

95

M 10x1.25

20

26

24

33

39

52

73

88

M 12x1.25

36

48

45

59

71

95

135

160

M 12x1.5

38

45

42

56

68

90

125

150

M 14x1.5

56

75

70

94

113

150

210

250

M 16x1.5

84

113

105

141

169

225

315

380

M 18x1.5

122

163

153

203

244

325

460

550

M 18x2

117

157

147

196

235

313

440

530

M 20x1,5

173

230

213

288

345

460

640

770

M 20x2

164

218

204

273

327

436

615

740

M 22x1.5

229

305

287

381

458

610

860

1050

M 24x2

293

390

367

488

585

780

1100

1300

M 27x2

431

575

533

719

863

1150

1600

1950

M 30x2

600

800

750

1000

1200

1600

2250

2700

TIGHTENING TORQUES

The following tables indicate the tightening torques for standard screws and main components.
The tightening torques are also indicated with the tightening methods and sequences, in the
indications of fitting of components and/or the plant.

REPAIR MANUAL

1

LOMBARDINI 523 MPI engine

DESCRIPTION

DIAMETER x PITCH
(mm)

TIGHTENING TORQUE (Nm)

Connecting rod

8x1

40

Rocker cover

6x1

9

Casing (crankshaft fastening screws)

M 10

50

Casing (one-piece fastening screws)

M 6

10

Timing belt roller nut

M 10

40

Rocker stud holder nut

10x1.5

40

Oil sealing ring flange screw (flywheel side)

M 6

12

Crankshaft pulley screw (timing side)

16x1.5 sin

180(1)*

Camshaft pulley screw

10x1.25

50

Timing shaft bearing panel

M 6x1

10

Camshaft holder flange

M 6x1

10

Small closing flange

M 6x1

10

Suction manifold fastening screw

M 6x1

10

Revolution sensor holder fastening screw

M 6x1

10

Revolution sensor fastening screw

M 8x1.25

10

Oil pressure switch 25

Oil plug

12x1.5

40

Engine cylinder head screw

12x1.5

(2)*

Flywheel screw 80

Coolant thermostat

10x1.5

30

TIGHTENING TORQUES

Table of tightening torques for the main components

(1)* Lubricate the lower part of the screw and pulley centre with some « Molysilp »
(2)* For more precise information see « Fitting the cylinder head »

REPAIR MANUAL

1

LOMBARDINI 523 MPI engine

The engine does not start

Difficult starting with cold engine

Difficult starting with warm engine

Overheating motor

Unstable idle running

Idle running too high

Idle running too low

The engine stops at idle

The engine stops sometimes

Jolting upon reacceleration

Jolting once idle running stabilized

Jolting acceleration

Low performance

High consumption

Noise (beating or rattling)

Crackling

Blue smoke

White smoke

Damaged catalyst

Air supply

Air filter

Leak on the manifold

Butterfly body

Fuel supply

The pressure regulator stays open

The pressure regulator stays closed

Clogged pipes

No pump flow

Running injector

Poor fuel quality

Ignition

Coil (coil short-circuit)

Faulty spark plug cable

Worn spark plugs

Spark plugs too cold

Spark plugs too warm

Exhaust

Leaks on the manifold

Oxygen probe

Engine and mechanical

Leaky valve

Valve stuck

Bad valve sealing guide

Jacket / piston wear

Embedded combustion chamber

Insufficient cooling

Damaged cylinder head gasket

Damaged revolution sensor phonic wheel

Faulty hydraulic push rods

Oil level too high

Electrical equipment

Low contact on fuel pump connector

Burnt fuse

Faulty relay

Faulty engine wiring

Faulty battery elements

Battery terminals sulphated

REPAIR

Table of probable anomalies according to symptoms

REPAIR MANUAL

3

Reverser bridge

INDEX

 Reverser axle ....................................................................................................... 2

 Transmission ....................................................................................................... 3

 Regulator set VSP 2000 LP2 version 2................................................................ 4 to 23