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
	TECHNICAL CHARACTERISTICS
	Light quadricycle category L6e

	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

REPAIR MANUAL

0

General

TECHNICAL CHARACTERISTICS

Heavy quadricycle category L7e

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

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

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

CHARACTERISTICS	FRONT	REAR
Type	Discs	Drums
Diameter	210 mm	160 mm

• 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	0
	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

General

0

WORK TO BE PERFORMED AT SERVICING

INTERVENTIONS AND CHECKS TO

PERFORMED UPON SERVICING

engine oil draining and renewal with oil filter change

draining the reverser axle and oil change

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

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

check sealing of the cooling circuit

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

check sealing of the brake circuit

check operation of the brakes including the handbrake

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

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

Adjustment of the reverser lever

grease the battery terminals

check the condition of the belts and change if necessary

removing dust on entire regulator

check of regulator gap and replacement of main bearings if required

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

change or clean the air filter

change fuel filter

tire pressure check, including the spare wheel

Check sealing of shock absorbers

Check the condition of suspension pins (engine, exhaust)

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

Reprogram the maintenance indicator

check the charging circuit

check proper operation of the lighting and electrical instrumentation

Cleaning the fins of the cooling radiator

check and adjust parallelism

vehicle test

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
o		o
o				o
		o
o		o
o		o
o		o
o		o
o		o
				o
				o
	0
				o
		o
		o
		o
o		o
		o cleaning		o
		o
o		o
	0
	0
	0
0	0		0
		o
o		o
			0
o
o		o

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	0
	TIGHTENING TORQUES

	FUNCTION	DESIGNATION	SCREW	COEF	Torque in Nm
					Mini	Maxi
		Column tensioner	M8*20	2	18,4	27,6
		(upper screw)
		Column tensioner	M8*35	2	18,4	27,6
	STEERING	(lower screw)
		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
	BRAKES	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
	SEATS/BELT	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
	AXLE	Front suspension triangles	M10*50+Nylstop	4	38	54
		Front suspension ball joints	Nylstop M12*1,25	2	40	60
		t shock absorbers (upper sc	Nylstop M10*1,00	2	16	24
	& REAR
		t shock absorbers (lower sc	Nylstop M12	2	36	54
		Rear wheel hub axle	M12*180+Nylstop	2	64	96
	FRONT	r shock absorber (upper scr	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
	TRANSMISSION	Receiver inverter	Spiralock nut M12	1	90	110

	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

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:

Start of thermostat valve opening	69.5 to 72.5 °C
Full opening of the thermostat valve	85 °C

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

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

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

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

Regulation principle

1.Accelerator lever

2.Starting spring

3.Regulation lever

4.Regulation spring

5.Intermediate regulation lever

6.–

7.–

Centrifugal regulator

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

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.

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

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.

		Grade	Standard screws and		Special screws and
			bolts 4		bolts 7
		Unit	N-m	Kgf-m	N-m	Kgf-m
		M6	7.9 to 9.3	0.80 to 0.95	9.8 to 11.3	1.00 to 1.15
	Nominal diameter	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

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

Number
engraved	Material grade of the screw or bolt
None or 4	SS41, S20C screw and bolt
	S43C, S48C special screw and bolt
7	(refined)

	REPAIR MANUAL
		1
	KUBOTA Z402 and Z602 engines

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.

	Dimension x
Elements	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
			117.7 to
* Fan drive pulley screw	M12 x 1.5		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	M8		7.8 to 9.8	0.8 to 1.0	5.8 to 7.2
type)
Starter B terminal fastening nut (planetary gear	M8		5.9 to 11.8	0.6 to 1.2	4.3 to 8.7
reduction type)
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

	REPAIR MANUAL
		1
	KUBOTA Z402 and Z602 engines
	REPAIR

	Anomaly	Possible cause	Solution
		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	Tighten the nut
		fastening nut on the injection duct
		Bad injection timing	Adjust
	The engine does
		Camshaft wear	Change
	not start
		Clogged injector	Clean
		Bad operation of the injection pump	Repair or change
		Seized crankshaft, camshaft, piston,	Repair or change
		cylinder jacket or main bearing
			Change the cylinder head gasket, tighten
		No compression in the cylinder	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
		Battery discharged	Charge
		Faulty starter operation	Repair or change
	The starter is
	inoperative	Faulty key switch	Repair or change
		Wiring disconnected	Connect

	REPAIR MANUAL
		1
	KUBOTA Z402 and Z602 engines
	REPAIR (cont’d)

	Anomaly	Possible cause	Solution
		Clogged or dirty fuel filter	Clean or change
		Clogged air filter	Clean or change
		Fuel leak due to bad tightening of a	Retighten the nut
		fastening nut on the injector duct
	The engine does
	not run regularly	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
		Excess motor oil	Reduce to level specified
		Wear or sticking of a piston ring and a	Repair or change
		jacket
		Bad injection timing	Adjust
	Exhaust gases	Bad compression	Adjust neutral spaces
	black, or dark grey	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
		Bad injection timing	Adjust
		The engine moving parts seem to be seized	Repair or change
	Insufficient power	Irregular fuel injection	Repair or change the injection pump
		Faulty injector	Repair or change the injector
			Change the cylinder head gasket, tighten
		Lack of compression	the cylinder head screw, the glow plug and
			injector holder
		The cutting gap is set in the same direction	Modify the location of the cutting gap
		for all piston rings
		Worn or stuck oil control ring	Change
		Worn piston ring groove	Change the piston
	Excessive oil	Worn valve stem and guide	Change
	consumption
		Worn crankshaft main bearings or trunnion	Change
		bearings
		Oil leaked caused by a faulty lining or	Change
		sealing

	REPAIR MANUAL
		1
	KUBOTA Z402 and Z602 engines
	REPAIR (cont’d)

	Anomaly	Possible cause	Solution
	Fuel mixed with	Worn injection pump plunger	Change the pump element or pump
	lubrication oil	Faulty injector	Repair or change the injector
		Injection pump	Change
	Water mixed with	Faulty cylinder head gasket	Change
	lubrication oil	Flaky casing or cylinder head	Change
		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	Change
		bearing
	Low oil pressure
		Too much running gap of a connecting	Change
		rod head bearing
		Too much running gap of a push rod	Change
		bushing
		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
		Low motor oil	Top up
		Fan belt broken or loose	Change or adjust
		Low coolant	Top up
		Radiator honeycomb or fins clogged	Clean
	Overheating engine	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
		Low electrolyte	Fill distilled water and charge the battery
	Battery discharges	Slipping fan belt	Adjust belt tension or change it
	too fast	Wiring disconnected	Reconnect
		Rectifier disconnected	Change
		Faulty fan generator	Change
		Faulty battery	Change

		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

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.

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

	REPAIR MANUAL
		1
	LOMBARDINI 523 MPI engine
	TIGHTENING TORQUES

Table of tightening torques for the main components

	DIAMETER x PITCH
DESCRIPTION	(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

(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

REPAIR

Table of probable anomalies according to symptoms

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 MANUAL	3
	Reverser bridge

	INDEX
	Reverser axle.......................................................................................................	2
	Transmission .......................................................................................................	3
 Regulator set VSP 2000 LP2 version 2................................................................		4 to 23