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11 LD 625-3 11 LD 626-3

1. Pushrod tube spring fitting Components 1 Spring 2 Tool Part No 1460 009 3 Rocker arm lubrication tube 4 Gasket 5 Pushrod tube 6 Gasket To mount the spring 1 on the tappet rod protection pipe 5 insert it into the tool 2 with the help of a vice Make sure that the rocker arm lubrication hose 3 and the seals 4 and 6 are fully in place Cylinder Measure diameter size between two diametrically opposed points at three different heights Q Cylinder 95 00 95 03 mm In case wear exceeds 0 10 mm bore the cylinder and fit oversize piston and rings In case of less wear replace piston rings only Checks and cyiinder roughness The cylinder should show no blowholes or porosities Seal both ends of cylinder and pressurize with compressed air at 4 bar for 30 sec Fins must be intact Cross hatch pattern must range between 115 140 they must be uniform and clear in both directions Average roughness should range between 0 5 and 1 um Piston Remove the Sieger stop rings and extract the pin After removing the snap rings from the piston clean the grooves if necessary Measure the diameter at 2 mm from the base using an external micrometer Q Piston 94 92 94 95 mm Replace the piston and the snap rings if the diameter of the wear is greater than 0 05 mm of the minimu
2. The high pressure pipe union must be tightened to the injector union to 20 25 Nm using a torque wrench Injector protrusion It is only possible to check injector protrusion with the cylinder head disassembled The end of the nozzle must be 3 3 5 mm with respect to the head surface A Protrusion is adjusted by adding or removing copper seals B which are supplied at a thickness of 0 5 and 1 mm Cylinder Head Caution Warning Do not demount or remount while hot as this could lead to deformations If the head surface is distorted grind it by removing up to 0 3 mm thickness When reassembling before tightening make sure that the rocker arm lubrication hose is firmly lodged into holes The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up Always replace the copper seal between the cylinder head and the cylinder that determines clearance volume see page 34 for the choice of thickness See page 32 for how to mount the spring on the tappet rod protection pipe O The cylinder head fastening nuts must be tightened gradually to 55 Nm and in the sequence 1 2 3 4 see fig 35 Valves Components Intake valve a Exhaust valve Lower spring collar Valve stem sealing ring Spring Upper spring collar Three groove half collets O O1 BR ND Te remove half collets firmly press down the special tool 1460 113 as shown in the figure 36
3. cael 2222224 222222272 gt Pak ae A 7777 FCR ri 10 11 JE e Te D oat N a 7 TS m FR OO OW NH Blower assembly components with 14 A alternator 1 Housing 2 14 A alternator 3 Key 4 Ball bearing 5 Washer 6 Nut 7 Shaft 8 Bolt 9 Fan 10 14 A alternator bell 11 Spacer Blower assembly components with 21 A alternator 1 Housing 2 21 A alternator 3 Key 4 Washer 5 Nut 6 Shaft 7 Bearing 8 Bolt 9 Fan 10 21 A alternator bell 11 Spacer Blower control pulley Disassembly The blower control pulley is installed on and is driven by the crankshaft To disassemble the pulley unscrew the left handed bolt clockwise after blocking the crankshaft O When reassembling tighten the bolt using a torque wrench to a torque of 300 Nm 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 Ls 7 ST uf y Crankshaft pulley Remove the pulley using extractor serial no 1460 200 Components 22 1 Left handed bolt 2 Washer 3 Blower control pulley Note It is only possible to check crankshaft axial clearance after tightening the pulley
4. 23 ca EM ADe noaa IERI URINE 23 PISTON 2 cite 34 Piston Reflttirig ote EA vk Lig bete na de eMe ei eH 36 tie detur 36 ops 35 Pushrod tube Spring 34 RECOMMENDATIONS FOR DISASSEMBLING AND 5 2 0 2 4 00 0 000 nnne nenne 22 RECOMMENDATIONS FOR OVERHAULS AND TUNING ire 22 Hocker armassembly 55 de equ eR NIE EGER EU 29 Spring for extra fuel supply at starting sise 48 P 28 TENSION CHECK iii tette Late dete i e o 25 COVER ss c die i qe n dte MOORE GI E 27 MAING GOAN sea ERE 38 Use of 3rd and 4th PTO ria an et eee ie a a ei a 46 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI KOHLER COMPANY INTRODUCTION Valve rocker arm Clearance ts acute tl Annee ec de ee lth e dad eens A daft d redes 28 Valve guide Insertion ete eph pees ide ate GPa Ai al ae in dee a eae i
5. 63 12 5 Ane YN Cd ATILO OEE P A AR M an aOR ee 62 14 V 33 A Bosch G1 alternator battery charger curve siennes 66 Alternator battery charger curve 12 V 21 63 Alternator battery charger curve 12 5 V 14 4 000 63 Alternator type Bosch Gi T4 V 39 ioo ed cen teet menton ren re ed e e Ded unc Pe Lee Re ER sb deca 66 Alternator type Bosch Gil 14 V 33 A layout iii 66 Characteristic curves for starting motor type Bosch JF R 12 Venere 67 Ghecking or cable Continuity 2 ee nat o Reid Pe ea recita MIC cette 64 Electric starting layout without battery charging 62 Electrical starting layout with battery charging 62 How to check voltage regulator for proper operation 65 Magnetization checking toolis te dde ttc eorura ciim eee de chastened chet ess 64 Standard el ctric equipment Se I RO eine wins nter e Sn 62 Starting motor lay QUE Deci ec Rede creta cere 67 Starting motor type Bosch JF 12 V class 2 5 7 67 Voltage regulator 2 ee noi ua nd irte ober isis neces tie ee eee LH tee M eet 64 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 5 INTRODUCTION A CEOMPAEDINI
6. aati Miche ect here hee Oi at intitle 44 Center main bearing support locating bolts sise 39 Checking intake exhaust cam eene nnne 43 Checking main journals and Crank pins sisiiseeseeneeeneneeeeeereennenre 40 Ghecks and cyiinder ro gliness s a a ene on or bot eor diet RE cus 34 Clearance between main journals crank pins and connecting rod 41 Compression release are e E ne C Fe Die ee ente POTE DU ve Ra ne 29 Corinecting rod petri eU dic on ORE ORI IO eH ms 36 Connecting rod alignment x ER 37 Connecting rod vie ene ieee hea Give al eee 37 Connecting rod small end bearing and pin nennen nennen neret sene nennen nennen nes 37 Connecting rod ee DU PRAG HR Db datione pci 37 GRANKSHART A cope ecc ae atest cce t Ln otre need ro diese p ce 39 Crankshaft center main bearing supports iii 39 Grankshaft end plays et Leder ate tne HR DER A e n cu os Pet At 42 Grankshaft journal radilis s 32 3 itt eo m Ea ed o tee ein tien mieten S 40 Grankshatt lubrication secedere duit ente pde coe d fa teca es 40
7. a h L m un gy aa l 6 Cy ae el 88 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 Q Disassembly Reassembly Il COMPONENTS TABLE 1 Stud bolt M8x20 11 Screw TCEI M 8x18 2 Silicone O ring 12 Fuel supply pump seal 3 Snap pin 2x10 13 Sensor pump connection rod 4 Conical screw STEI M 10x1 5 14 AC pump and angular position sensor cover 5 Self locking flanged hex nut 15 Sensor control lever 6 Copper washer 16 Connecting pin between rod and sensor 7 Crinkled spring washer 17 Discharge stop plate 8 Screw TCE UNI 5931 4x35 18 Angular position sensor 9 Screw STEI M 8x20 19 Flathead screw 10 Fuel supply pump 11 LD Workshop Manual cod 1 5302 296 5 04 89 Il Disassembly Reassembly amp am MS EH Phase sensor assembly diagram A 4 q A t OS T3 2 X 9 Adjust with 0 2 mm shims COMPONENTS TABLE 1 Silicone O ring 2 Washer 6x12xSp1 3 Screw UNI 5931 M 6x10 4 Screw TCEI UNI 5931 M 6x25 5 Speed and phase sensors 6 Phase sensor air gap adjustment shim 7 Phase sensor support 90 11 LD Workshop Manual cod 1 5302 296 5 ed 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly To assemble the phase sensor conn
8. 80 83 Crankshaft lubrication ducts AN Important During repair operations when using compressed air wear eye protection Remove the caps clean ducts A B and C using a drill bit with the same diameter and blow with compressed air After cleaning replace the new caps in their seats and make sure they are sealed Crankshaft journal radius The radius connecting journal to shoulders is 2 8 3 2 mm Note When grinding main journals or crank pins restore the R value to original specification Checking main journals and crank pins Use an outside micrometer gauge Main journal and crank pin diameter Dimensions mm 80 781 80 800 45 500 45 516 55 350 55 370 Tp 40 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 T SA 85 Diameter of main bearings _ Use an inside micrometer to measure the inside Main bearing and connecting rod big end bearing inside diameter Dimensions mm 80 870 80 890 45 548 45 578 55 430 55 460 55 000 55 020 The above dimensions refer to driven in or tightened bearings Note Both main bearings and connecting rod big end bearings
9. Blower belt alternator Reassembly O The half pulley fastening nuts must be tightened using the torque wrench to a final torque of 10 Nm Again during this phase the nut must be in position A when tightened as in fig 7 page 22 Tension check A 4 Kg load located halfway between the pulleys should cause the belt to bend 5 15 mm The correct belt tension can also be checked with special tools that are available on sale Air shroud and baffles Disassembly The air shroud 1 and the baffles 2 3 4 5 are shaped in such a way as to direct the flow of air onto the cylinders in order to cool them As the shroud is completely covered in noise absorbent material it also has the function of reducing the amount of noise generated by the blower fan and vibrations Blower assembly pL A Danger Attention Before demounting the cooling fan disconnect the positive battery cable to prevent accidental short circuits which could consequently energize the starter motor The plate and tension regulator are fixed to the outside of the blower fan stator A 14 A or 21 A alternator is housed inside the stator gt page 60 61 for the alternator technical data gt 13 for the cooling air volume 11 LD Workshop Manual cod 1 5302 296 5 04 25 4 Disassembly Reassembly C LOMBARDINI A KOHLER COMPANY
10. 128 19 Threaded plug 20 Adjustment rod locking device 21 Area in which the pump delivery class is stamped In this engine the injection pumps are preset by the manufacturer who supplies them stamped with alphabetical classes A Ax B Bx C Cx or D for standard and 97 68 EC engines while for EPA2 engines the classes are numerical 5 6 7 8 9 10 11 12 13 and 14 The adjustment rod is locked via the bayonet device Injection pump only for EPA engines 1 Delivery union 2 PRV valve 3 O Ring 4 Pump housing 5 Pumping piston 6 Pumpung plunger 7 Elastic pin 8 Rack rod 9 Superior retainer 10 Spring tappet 11 Tappet body 12 Inferior retainer 13 Roller 14 Journal guide tappet 15 Elastic pin 16 Adjustment hose 17 Plunger stop pin 18 Cap Injection pump only for standard and 97 68 Ce engines 1 Delivery union 2 Rubber ring 3 Delivery valve 4 Pump housing 5 Piston 6 Plunger 7 Rack rod 8 Spring 9 Tappet body 10 Roller 11 Journal 12 Pin 13 Spring retainer 14 Eccentric 15 Copper gasket 16 Spring 17 Filler 11 LD Workshop Manual cod 1 5302 296 5 04 53 Fuel system A LOMBARDINI A KOHLER COMPANY D 129 222222222222 ALT LZZZZZCLLZZZ Plunger Dimensions mm 1 000 1 100 mm 7 445 7 455 mm 7 500 mm 3 000 3 025 mm 7 225 7 275 mm 130 How to check plunger and barrel fo
11. 29 Replace the timing cover placing a new seal and lining up with the PN 1 two centring pins O Tighten the screws to a 25 Nm torque Refit the oil feed bushing to the variator placing the oil seal support ring in between Replace the seal O Tighten the three screws M6 to an 8 Nm torque Replace the speed sensor taking care not to damage the O ring 11 LD Workshop Manual cod 1 5302 296 5 rev 04 85 Disassembly Reassembly C LOMBARDINI A KOHLER COMPANY O Attach the sensor using screw M6 to a torque of 8 Nm Replace and check the belt tension see page 22 23 Replace the variator circuit oil pipes If in doubt consult the diagram on page 78 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 MEARE Disassembly Reassembly Il 4 Insert the solenoid valve connectors following the references IN and OUT shown on the cables and on the solenoid valve block O Replace the built guard and tighten to 15 Nm D 47 11 LD Workshop Manual cod 1 5302 296 5 04 87 LO ARDINI Il Disassembly Reassembly amp w B KOHLER COMPANY Angular position sensor and AC pump assembly diagram 7K
12. KOHLER COMPANY 8 SETTINGS 68 Injection pump delivery setting c cc ccchsctnetesceeeasecetancecateccepsisteeagedsapavsepevban estanchansedanseaneauscksasescageesasedsigderustesenteaeataierdapessees 68 e tute LET M 68 68 9 STORAGE 100 101 External engine protection cis ac ER 100 Internal engine protection te divin ated a ho ele ee 100 Injection Systems protection 2 iecore ere Lie Pre ee eee ae Le eas ae 100 PROCEDURES TO BE CARRIED OUT BEFORE START THE 101 10 MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS 102 104 MAIN TORQUE SPECIFICATIONS 5 en He bee em terti tic ete eto Ee edet a mie ec Rn aud 102 103 Table of tightening torques for standard screws coarse thread seem 104 Table of tightening torques for standard screws fine thread 104 USE OF SEALANTS maine anu etn etit dati ET 108 11 SPECIAL TOOLS 105 with advance variator l ADVANCE VARIATOR OPERATING PRINCIPLE 72 73 DISASSEMBLY 7 REASSEMBLY 5 eek aii ane ss 74 98 6 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 LOMBARDINI GENERAL REMARKS AND SAFETY INFORMATION 1 A KOHLER C
13. Displacement 1870 1870 Compression ratio 17 1 17 1 20 19 R P M 3000 3000 80 1269 ISO 1585 kW CV 28 38 30 8 42 Power kW HP NB ISO 3046 IFN kW CV 26 35 4 28 6 39 NA ISO 3046 ICXN kW CV 24 82 7 26 3 35 8 torque Nm kgm 104 10 6 2000 114 5 11 7 2000 Max torque at 3rd p t o at 3200 r p m kW CV 13 17 7 13 17 7 Max torque at 4th p t o at 3200 r p m kW CV 7 98 10 8 7 98 10 8 Specific fuel consumption g CV h g kW h 190 258 5 184 250 Tank capacity 15 15 Oil consumption kg h 0 017 0 017 Oil sump capacity 5 5 Dry weight kg 170 170 Combustion air volume at 3000 r p m 2400 2400 Cooling air volume at 3000 r p m 38000 38000 Max permissible driving shaft axial load in both directions kg 300 300 momentary Qa 35 35 Max inclination lasting up to 1 h Qa 25 25 permanent CELL CELL Firing Order A Only for 97 68 CE and EPA approved engines Referred to power A At NA power Depending on the application 1 3 2 1 3 2 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 13 2 Technical information C LOMBARDINI A KOHLER COMPANY PERFORMANCE DIAGRAMS 11 LD 62
14. This indicates situations of grave danger which if ignored Danger Attention AN Important may seriously threaten the health and safety of individuals This indicates particularly important technical information that should not be ignored SAFETY REGULATIONS LOMBARDINI Engines are built to supply their performances in a safe and long lasting way To obtain these results it is essential for users to comply with the servicing instructions given in the relative manual along with the safety recommendations listed below The engine has been made according to a machine manufacturer s specifications and all actions required to meet the essential safety and health safeguarding requisites have been taken as prescribed by the current laws in merit All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined by LOMBARDINI which thus declines all liability for any accidents deriving from such operations The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine operation in particular along with the relative routine maintenance work The user must read these instructions carefully and become familiar with the operations described Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of the machine The engine may only be used or assem
15. 5 Washer 11 Gasket 6 Nut 12 Cover A max torque of 243 Nm can be obtained from this p t o Use of 3rd and 4th p t o 1 Hydraulic pump group 2 mounted at 3rd p t o 2 Hydraulic pump group 1 mounted at 4th p t o Total power obtainable from 3rd and 4th plo is 13 kW 17 7 HP Ratio for both p t o compared to the engine r p m is 1 1 for 4 PTO is 1 1 067 for 3 PTO 46 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 16 15 14 3 12 11 10 108 109 Mechanical speed governor The governor with centrifugal weights is housed inside the crankcase and is controlled by a camshaft gear To remove speed governor 1 remove camshaft bell 2 and speed governor control gear 3 Mechanical speed governor components standard 1 Drive rod 9 Key 2 Stop ring 10 Thrust washer 3 Bearing 11 Bearings 4 Washer 12 Shaft support 5 Pin 13 Gear 6 Weights 14 Spring washer 7 Weight support 15 Flat washer 8 Shaft 16 Nut Mechanical speed governor operation standard Weights 1 are moved to the periphery by the centrifugal force and thus axially shift the washer 2 and the drive rod 3 which by means of a linkage move injection pump control lever 4 The governor springs 5 placed under tension by the accelerator control l
16. Check camshaft end play after removing cylinder head injection pump and fuel feed pump from the engine O Check that the three cover 1 screws are tightened at 25 Nm Place the dial gauge on the camshaft gear outer part push and pull same gear as required Camshaft end play should be 0 15 0 30 mm 11 LD Workshop Manual cod 1 5302 296 5 rev 04 43 Disassembly Reassembly A LOMBARDINI A KOHLER COMPANY Camshaft timing Fit camshaft gear by making timing mark 2 coincide with timing marks 1 O Tighten camshaft bolt at 250 Nm Valve timing without considering timing marks Locate piston 1 on flywheel side at the top dead center Position two small cylinders A of the same height onto the tappets Rotate camshaft stopping when cylinder 1 tappets are in overlap position intake open exhaust closed By means of ruler B check that tappets are at the same height Valve timing check Check using an index plate suitable for reading angles integral with the crankshaft Readings are taken in degrees Set valve clearance at 0 65 0 70 mm after checking restore the value al 0 15 0 20 mm Set dial gauge on intake valve to a zero value by rotating the driving shaft according to its direction of rotation you can measure intake valve opening advance referred to top dead centre PMS
17. Unscrew screws M10 on the variator to the camshaft Remove screw M10 422 Remove the variator The figure shows the camshaft pin for correct variator timing A Cylindrical pin 5x16 B Pin housing 82 11 LD Workshop Manual cod 1 5302 296 5 04 A Pd AE Disassembly Reassembly Il View of the camshaft ends with pin inserted Remove the shoulder housing of the idle gear that drives the speed governor 11 LD Workshop Manual cod 1 5302 296 5 04 83 Il Disassembly Reassembly A MSAT A KOHLER COMPANY O After refitting the housing tighten the screws to 20 Nm using a torque wrench Remove the distribution control gear from the crankshaft Assemble the variator onto the end of the camshaft taking care to properly insert the timing pin into place and ensuring that the variator comes into contact with the surface of the speed governor idle gear O Tighten screw M10 to 65 Nm using a torque wrench Assemble the timing control gear onto the crankshaft so that reference mark A is lined up with the two reference marks B on the idle gear installed on the camshaft 84 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly Il
18. 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 31 Disassembly Reassembly A LOMBARDINI KOHLER COMPANY Valve stem sealing rings Reassembly Lubricate the inside of the sealing ring with Molikote BR2 Plus and insert them all the way onto the guides using tool 1460 108 To prevent deformation of the sealing ring 1 as it is inserted onto the valve guide 2 insert it onto tool 3 Lubricate valve stem with the same type of grease insert the valves into the guides rotating them particularly as they enter the sealing ring Valve springs Measure free length with a gauge Using a spring tester check that the spring length under two different loads corresponds to the values below Free length A 52 mm Length B compressed by a 21 Kg weight 34 8 mm Length C compressed by a 32 Kg weight 25 8 mm Valve material Intake valves A Material X 45 Cr Si 9 3 UNI EN 10090 1 Chromium plated portion a 45 15 45 25 Exhaust valve B Shaft and head are made of 2 different materials 2 Welded portion 3 Chromium plated portion 4 Portion made of X 45 Cr Si 9 3 UNI EN 10090 5 Portion made of X 53 Cr Mn Ni N 21 9 UNI EN 10090 a 45 15 45 25 Valve guides and cylinder head housings Intake and exhaust valve guides are both made of phosphoric cast
19. Filtering 5000 2 Degree of filtrafion 2 3 um Max working pressure 4 bar 123 gt See page 17 for periodical maintenance details Fuel feeding pump The fuel feeding pump is of the diaphgragm type operated by a camshaft eccentric through a drive rod It features an external lever for manual operation Components 1 Drive rod shelf 1 470 2 070 mm 2 Gasket 3 Camshaft eccentric Characteristics when the control eccentric rotates at 1500 r p m minimum delivery is 64 l h while self regulation pressure is 4 5 m water column Injection pump The Bosch injection system consists of three pumps each feeding one cylinder The pumps mounted on the crankcase corresponding to their proper cylinder are directly operated by the camshaft 52 11 LD Workshop Manual cod 1 5302 296 5 04 A LOMBARDINI A KOHLER COMPANY Fuel system 6 126 1 KG E SS AOS REY MAGS 127 e e VERA S 2 AY LA 22 SAN A J 4 AUT d M ma 43 S BE ONT zc or 42 ED 9 SS Wen D NDS Wek al
20. Reassembly Il Resetting the dial indicator Components 1 Dial indicator 2 Support for dial indicator 3 Camshaft sensor support surface control gauge measurement 30 24 30 26 mm 4 Resetting master measure 30 24 30 26 mm for gauge 5 Resetting reference base If replacing the sensor camshaft or engine block via the tool see figure 56 Make sure that the support surface of the sensor on the camshaft support measures 30 24 30 26 mm Assemble the dial indicator 1 in the support 2 Insert the support 2 complete with dial indicator 1 into the gauge 3 Set the master 4 and reset the dial indicator while resting on the base 5 as in 6 Measuring the depth between the sensor support and the camshaft Insert the gauge complete with dial indicator onto the sensor support and attach using the three screws Make sure the measurements taken are within the specific tolerance limits 30 24 30 26 mm O The three screws for the phase sensor support screws must be tightened to 8 Nm using a torque wrench Air gap adjustment The air gap is adjusted using shims measuring 0 2 mm in thickness which are placed between the sensor surface and its support The air gap must be between 0 3 and 0 5 mm see phase sensor assembly diagram page 94 When adjusting the air gap with shims it is important to consider any difference between the measurements taken leng
21. injure the operator Wear protective goggles when removing the flywheel ring Remove the bolts which attach the flywheel to the crankshaft To replace starter ring gear heat it up to 300 C for 15 20 minutes Drive it onto the flywheei caretully checking that it perfectly fits into its seat Let it cool down slowly O When reassembling gradually tighten the fastening screws to 140 Nm on the crankshaft using a torque wrench Valve rocker arm clearance Caution Warning Make settings when the engine is cold Remove the rocker arm covers and make sure the seals are intact otherwise replace them Bring the cylinder piston that is to be adjusted to the compression top dead centre Loosen the fastening nut C insert the thickness gauge D between the rocker arm and the top of the valve stem then using a cross head screwdriver turn the adjusting screw B to set clearance Tighten the fastening screw C and check valve clearance A again to ensure that it is between 0 15 and 0 2 mm for intake and 0 3 0 35 mm for exhaust O When refitting tighten cover screws to 20 Nm If necessary place 0 30 0 40 mm shim at B 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 Compression release optional Bring piston to top dead center on the compression stroke Unscrew rock
22. 8 intake valve closing delay referred to bottom 1 dead centre Follow the same procedure for exhaust valves checking y exhaust valve opening advance 6 exhaust valve closing delay 44 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 e ME ARRIN Disassembly Reassembly 4 Legend S piston at top dead center l piston at bottom dead center a intake valve open intake valve closed y exhaust valve open 6 exhaust valve closed Value expressed in degrees of the timing angles valves clearance 0 65 0 70 mm open 2 before P M S close 34 after open 34 before close 2 after P M S 101 11 LD Workshop Manual cod 1 5302 296 5 04 45 Disassembly Reassembly A LOMBARDINI A KOHLER COMPANY Hydraulic pump p t o group 1 A hydraulic pump of group 1 or 2 can be installed on the gear side A 3rd p t o A group 1 hydraulic pump can be installed at the 4th p t o B Hydraulic pump 3rd p t o group 2 Components 1 Gear 2 Gear support 3 Bearing 4 Drive 5 Flange 6 Washer 7 Seal ring 8 Circlip A max torque of 39 6 Nm can be obtained from this p t o Hydraulic pump 4th p t o group 1 Components 1 Drive 7 Seal ring 2 Control shaft 8 Seal ring 3 Pin 9 Centering ring 4 Gear 10 Bracket
23. Blower control pulley diameter There are three pulleys with different diameters A which take account of engine settings from 2401 to 3000 r p m from 2001 to 2400 r p m from 1500 to 1800 r p m Check S surface in contact with oil seal ring and if necessary rub with a fine grain emery cloth Timing cover Loosen the screws and remove the cover O When refitting tighten screws at 25 Nm Check oil seal ring 1 and replace if warped hardened or worn out Replace gasket 2 11 LD Workshop Manual cod 1 5302 296 5 04 27 4 Disassembly Reassembly LOMBARDINI A KOHLER COMPANY Tank A Danger Attention Do not smoke or use naked flames during the demounting operations as these could cause explosions or fire outbreaks Fuel fumes are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the filler cap or you could inhale harmful fumes Dispose of fuel in the correct way as it is highly polluting Do not litter Remove fuel filter and loosen clamp screws Completely empty the tank and check that no impurities are found inside Check that cap breather is not clogged Flywheel Danger Attention During the demounting phases pay particular attention to prevent the flywheel from dropping as this could seriously
24. COMPANY Oil pump Check that gear teeth are intact and that clearance between gear edge and pump body is 0 041 0 053 mm with limit value 0 10 mm Furthermore check that control shaft is tree to rotate with end float of 0 040 0 090 mm with limit value of 0 170 mm Oil pump delivery at 3000 r p m is 18 liters min Oil pressure relief valve Components 1 Plug 5 Rubber gasket 2 Copper gasket 6 Ring 3 Bushing 7 Hole for pressure switch connection 4 Piston 8 Spring Note Blow by at an oil temperature of 40 50 C and pressure of 3 bar should be less than 1 l min When refitting screw bushing 3 so that it touches gasket 5 Do not tighten excessively since gasket 5 might break causing an oil pressure drop in the system Oil filter cartridge Components 1 Retainer 6 Upper cover 2 Plate 7 Blade 3 Valve 8 Filtering element 4 Gasket 9 Assembly 5 Gasket 10 Belleville washer 11 Tank Characteristics Max working pressure 13 bar Filtering cete 955 cm Type of filtration 20 um By pass valve opening pressure 1 4 1 8 bar Oil pressure check Once the engine is fitted fill with oil and fuel connect a 10 bar pressure gauge to the oil filter fitting Start the engine and check pressure as a function of the oil temperature
25. Grankshaft cott hon ak ii n d Gh pier ee e e PUE pem Crankshaft removal Cylinder Gylinder Elead xot Sere bog e orte n itae iio t citet nba cobi oh eode Mo scere c Diameter of main bearings nn De FREE onte enne nete ER 41 Dimensions and clearance between guides and 33 Dimensions of camshaft journals and 43 Disassembling size P Injectob scd ere pe cnet e eei i n e P ER EVE aed Sep dut datant 29 31 Exhaust manifold eich nir ie ce ERE hein adi eames dee vs 23 Flywheel d e 28 Halt pulley Reassembly e ed eene HERO CERE ota e eI 24 How to measure camshaft bearing and journal inside 42 0 2 e rt ete epe rte ten Ru ne ER ue cepe 46 Flydraulic p rmp 4th pto group 1 3 onte rere eie veut eer eet ete ei Ce e e ced e nt 46 Hydraulic pump pto HOUD e e AU pie I RE 46 Injector PROUUSION EL 31 Intake manifold 4 5 sak itn A Se ah ev ee a ave a E at eee ea Gena 24 Intake exhaust cam helght 5 ri o eh es teenie a eee eed ce pera ved aet ege eg 43 Main bearing and connecting rod big end bearing inside diamet
26. KOHLER COMPANY 6 3 GER AZZURRO AZUR 2 S 1554 2 E 3 148 15mm 15mm 2 5 mm2 RR gc EN ERA il o LO OOO 35mm s 35mm Standard electric equipment Electric starting layout without battery charging light Components 1 Alternator 2 Starting motor 3 Voltage regulator 4 Battery 5 Pressure switch 6 Oil pressure warning light 7 Key switch 150 LIFE 22724 24 esi Electrical starting layout with battery charging light Components 1 Alternator 2 Starting motor 3 Voltage regulator 4 Battery 5 Pressure switch 6 Oil pressure warning light 7 Key switch 8 Battery charging light Note Battery which is not supplied by Lombardini should feature a 12V voltage When choosing battery capacity please consider environmental conditions 66 Ah are recommended down to 10 C 88 Ah are recommended below 15 C in any case do not use battery with greater capacity than 110 Ah 12 5 V 14 A Alternator Features a fixed armature winding housed in the bell inside the blower stator The rotating permanent magnet inductor is located in the fan spindle See page 24 Rei Dimensions nm 111 701 111 788 31 000 33 500 76228 76300 77 400 77 474 Note Clearance between armature winding and
27. LOMBARDINI A KOHLER COMPANY a SS NIY AN Er AN ER Intake manifold Before reassembling the manifold check the levelness of the flanges Always replace the seals between the manifold and the intake pipes O Tighten the nuts gradually to 25 Nm Note In case of low temperature starting we can supply a manifold with provision for a glow plug for air preheating Blower belt alternator Components 1 Guard 2 Pulley 3 Spacers 4 V belt Unscrew the fastening screws of the belt guard and remove it then take out the nuts on the three stud bolts on the half pulley Remove the V belt and check for wear gt See page 17 for periodic maintenance details Belt tension adjustment A Danger Attention Check the belt tension only when the engine is not running The belt tension is adjusted by adding to reduce tension or removing to increase tension spacers between the half pulleys Spacers are available in thicknesses of 0 5 1 and 2 mm Half pulley Reassembly AN Important The three stop nuts of the half pulley should never be tightened simultaneously Turn the pulley so that whenever you tighten a nut this is in the position indicated A in the figure 7 Tightening should be carried out gradually 24 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A COME ARPIN Disassembly Reassembly 4
28. be suitabie for reading the required value 14 or 21 A and for withstanding the starting motor peak absorption 400 450 A Start a couple of times until battery voltage drops below 13 V When battery voltage reaches 14 5 V the ammeter current suddeniy drops down to almost zero Replace regulator if recharge current is zero with voltage below 14 V JAUNE YELLOW GELB AMARILLO A Important When the engine is running do not disconnect battery cables or remove the key from the control panel Keep regulator away from heat sources since temperatures above 75 C mmght damage it No electric welding on eng ne or application 158 11 LD Workshop Manual cod 1 5302 296 5 04 65 7 Electric system e UE bro ih Alternator type Bosch G1 14 V 33 A The alternator is ot the claw pole rotor type with built in voltage reguiator The rotating motion is conveyed by the engine through a V belt and sheave Features 12V rated voltage Max current 33A at 7000 alternator r p m RH direction of rotation 159 Alternator type Bosch Gil 14 V 33 A layout Components 1 Alternator 2 Starting motor 3 Battery 4 Key switch 5 Pressure switch 6 Oil pressure warning light 7 Battery charging light 160 14 V 33 A Bosch G1 alternator battery charger curve The curve was obtained at room temperature of 25 C Bat
29. bearing Connect piston to connecting rod in a way that the combustion chamber center b is under nozzle tip a Lubricate piston pin and introduce it into the piston by exerting pressure with your thumb Check that both circlips are well inside their seats Piston clearance A Clearance volume is 0 65 0 7 mm for size S injectors and 0 55 0 6 mm for size P injectors B Copper seal with various thicknesses The piston crown in the TDC top dead centre position may vary 2 and extend or be short of the upper surface of the cylinder Use dial indicator to measure the positive or negative difference between the two surfaces piston crown and upper cylinder surface and use a Suitable thickness copper gasket B for the cylinder head Ls to adjust the clearance volume A between the cylinder head and the D piston crown and which must be between 0 65 and 0 7 mm for size SNA S injectors and 0 55 0 6 mm for size P injectors 63 64 The table below shows how to choose the most suitable cylinder head copper seal according to the position of the piston in relation to the upper surface of the cylinder Seal thickness 045 050 0 55 060 0 65 070 075 080 085 090 095 1 00 0 25 0 15 0 05 0 05 0 15 0 25 0 35 0 20 0 10 0 0 10 0 20 0 30 Position Connecting rod Caution Warning When remounting the big end bearings rememb
30. iron Components 1 Exhaust valve guide 2 Intake valve guide Dimensions mm 42 00 48 00 14 000 14 018 14 045 14 056 Valve guides with outside diameter increased by 0 5 mm are also available in such cases valve guide bore C should also be increased by 0 5 mm 32 11 LD Workshop Manual cod 1 5302 296 5 rev 04 e ME Disassembly Reassembly 4 Valve guide insertion Heat cylinder head up to 160 180 C Thread guides considering the A e B distances from the head plane Dimensions mm 22 30 80 31 20 24 80 25 20 222222222 B Note If the guides are supplied with the housing for the lock ring C insert the ring then drive the guides until the lock ring is stopped without worrying about A and B Dimensions and clearance between guides and valves Dimensions Clearance Limit value mm mm mm 8 025 8 040 0 025 0 055 7 985 8 000 Valve seats and housings Dimensions mm EXHAUST INTAKE VALVE VALVE 46 Valve seat lapping After cutting lap valve seats with fine emery paste in oil suspension The sealing surface S should not exceed 2 mm Valve recess after grinding oms r 11 LD Workshop Manual cod 1 5302 296 5 rev 04 33 Disassembly Reassembly A LOMBARDINI KOHLER COMPANY
31. is useful for comparing different brands and choosing the kind with the right characteristics Usually a specification showing a following letter or number is preferable to one with a preceding letter or number An SF oil for instance is more performing than a SE oil but less performing than a SG one ACEA Regualtions ACEA Sequences PETROL HEAVY DUTY DIESEL ENGINES 1 Low viscosity for frictions reduction EPZOBSOLETE A2 Standard performances 2 Standard Heavy conditions Euro 1 Euro 2 engines LIGHT DUTY DIESEL ENGINES E4 Heavy conditions Euro 1 Euro 2 Euro engines 5 High performances in heavy conditions Euro 1 Euro 2 Bi Low viscosity for frictions reduction Euro 3 engines B2 Standard performances indirect injection B4 High quality direct injection 18 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 e LOMBARDINI Maintenance Prescribed lubricant Refilling 3 A KOHLER COMPANY API MIL Sequences DIESEL PETROL VO ENE MERI EEN SEINE L 2104 D E CURRENT OBSOLETE PRESCRIBEDLUBRICANT AGIP API CF 4 SUPERDIESEL specifications ACEA B2 s E2 MULTIGRADE MIL L 2104 D E 15W40 In the countries where AGIP products are not available use oil API SJ CF for Diesel engines or oil corresponding to the military specification MIL L 2104 D E For a temperature of
32. nter tete timen cifeo ODDO 8 9 SAFETY AND WARNING DEGALS e Cen ue dee iret ee prese Et eee fe cit ds 8 GENERAL SAFETY DURING OPERATING PHASES iii 9 SAFETY AND ENVIRONMENTAL 7 8 9 2 TECHNICAL INFORMATION 10 16 POSSIBLE CAUSES AND TROUBLE 7 10 11 MANUFACTURER AND MOTOR IDENTIFICATION 11 2 22220 00 12 TEGHINICGALSPEGIEIGATIONS sss icu roto teer tete 13 PERFORMANCE a a ae ga Nove oie 14 15 OVERALL DIMENSIONS EE UY ele 16 3 MAINTENANCE RECOMMENDED OIL TYPE REFILLING scsi 17 20 ROUTINE ENGINE MAINTENANCE d e Re ear sedo roe levee 17 iei cte ORE Re SERERE ROI ONDE Sabina 18 19 SAE 1 5511 ones oc rnt tote hebes nito Lie tuii 18 ACEA Regualtions ACEA Sequences 10 enne eene nenne 18 International Specifications 3522 5 aah de ect ed tee t EE Ee dent a Be eT 18 MIE S quences UR e
33. of injection pump check that the new one has a same reference mark as the old one The reference marks of injection pumps must be the same Replace as follows O Fit pump into the crankcase and tighten screws at 25 Nm Remove lock 1 and check that rack rod is free to move If pump removal is required fit lock 1 to its original position the rack rod centre should coincide with the pump axis see fig 126 When replacing the crankcase or the camshaft preserve the same distance A between D injection pump support and C injection cam radius add shims G on D to obtain the right A value if required Seals G are supplied with different thicknesses 0 05 0 1 0 3 and 0 5 mm Size S injector Components 1 Intake fitting 2 Nozzle holder 3 Shim 4 Spring 5 Pressure rod 6 Intermediate flange 7 Nozzle 8 Needle valve 9 Fixing flange 10 Taper pin 11 Gasket 12 System duct 13 Sump 14 Cup 56 11 LD Workshop Manual cod 1 5302 296 5 rev 04 A LOMBARDINI A KOHLER COMPANY Fuel system 6 131 OOO 11 a i PPE Se ae ie A RR p 132 133 Size S nozzle Features Hole number and diameter 4x0 28 mm Jet 160 Needle valve elevation 0 20 0 22 mm Hole length 0 7 mm Sump diamete
34. rev 04 103 14 MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS LOMBARDINI Table of tightening torques for standard screws coarse thread Resistance class R Quality Dimensions R gt 500N mm R gt 800N mm R 1200N mn Nm Nm Nm Nm 0 6 0 9 1 4 2 3 1 4 1 8 2 9 4 9 2 8 3 8 6 10 4 7 6 3 10 17 12 16 25 41 23 31 49 83 40 54 86 63 84 98 Diameter Quality Dimensions R gt 500N mm R gt 800N mm R gt 1200N mnr Nm Nm Nm Nm M 8 1 13 17 27 45 M 10x1 26 35 56 95 M 10x1 25 24 33 52 88 M 12x1 25 45 59 95 M 12 1 5 42 56 90 M 14 1 5 70 94 M 16 1 5 M 18 1 5 M 18x2 M 20 1 5 M 20x2 M 22 1 5 M 24x2 M 27x2 M 30x2 Diameter 104 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY SPECIAL TOOLS 15 SPECIAL TOOLS DESCRIPTION Part No 1 Valve control lowering tool static injection advance 2 Dial indicator support 3 Dial indicator Overall 1460 266 1460 275 1460 270 1460 274 High pressure pump for static advance control 1460 273 Injection pump static injection advance tester 1460 024 Tool for fitting valve stem seal ring 1460 108 Blower control pulley extractor 1460 200 Tool for assembling removin
35. 10 C an oil with 5W40 viscosity is recommended For a temperature of 15 C an oil with a OW30 viscosity is recommended 11 LD 625 3 626 3 ENGINES OIL CAPACITY OIL VOLUME AT MAX LEVEL OIL FILTER INCLUDED Litres OIL VOLUME AT MAX LEVEL WITHOUT OIL FILTER Litres Attention engine be damaged if operated with insufficient lube It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion Use proper lube oil preserve your engine Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly Always use oil with the right viscosity for the ambient temperature in which your engine is being operated Danger Attention The used engine oil can cause skin cancer if kept frequently in contact for prolonged periods If contact with oil cannot be avoided wash carefully your hands with water and soap as soon as possible Do not disperse the oil in the ambient as it has a high pollution power 11 LD Workshop Manual cod 1 5302 296 5 04 19 in LOMBARDINI 3 Maintenance Prescribed lubricant Refilling amp KOH
36. 302 296 5 rev 04 67 SETTINGS A LOMBARDINI A KOHLER COMPANY D sees 165 168 Seitings 1 Idling speed setting in no load conditions standard After filling with oil and fuel start the engine and let it warm up for 10 minutes Adjust idling speed at 800 900 r p m by turning setscrew 1 then tighten lock nut 2 Full speed setting in no load conditions standard After setting idle speed turn screw 2 and set full speed in no load conditions at 3200 r p m then tighten lock nut Note When the engine reaches the pre set power full speed stabilizes at 3000 r p m Injection pump delivery setting This setting should be performed at the torque dynamometer If not setting is only approximate The following steps are required Loosen delivery limiting device C by 5 turns Bring engine to full speed in no load conditions i e 3200 r p m Tighten limiting device until the engine shows a drop r p m Unscrew limiting device C by 1 7 turn Tighten lock nut Note If the engine under full load generates too much smoke tighten C if no smoke is observed at the exhaust and the engine cannot reach its full power unscrew C Stop setting Remove fuel feeding pump and cover 1 Loosen both bolts fixing plate A 2 Push injection pump B control rod to the right and
37. 5 156 Magnetization checking tool Part No 7000 9727 001 Components 1 Casing 2 Slider 3 Casing reference line 4 Slider reference line Rest the tool end horizontally onto the magnetic poles Hold sfider so that its reference line coincides with the casing reference line Release slider if no attraction occurs the rotor is demagnetized therefore replace alternator Checking for cable continuity Check that stator windings have no unsoldered connections burnt areas or grounded wires Using an ohmmeter check for continuity between the red cable and the two yellow ones Furthermore check that they are insulated from the ground Voltage regulator Supplied by SAPRISA Voltage 12 V max current 26A To avoid wrong connections 3 different sizes are supplied Ref Connection size mm Width Thickness 6 25 0 8 9 50 1 12 9 50 1 12 LE 4 75 0 5 o 0 6 25 0 8 157 64 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 LOM e P RN Electric system 7 How to check voltage regulator for proper operation Check that connections correspond to the layout Disconnect the terminal from the battery positive poie MARRON Connect a d c voltmeter between the two battery poles MARON Fit an ammeter between the positive pole and the corresponding cable 1 terminal The ammeter should
38. 5 and 0 50 mm unders ze configurations as spare parts O When refitting tighten screws at 25 Nm 38 11 LD Workshop Manual cod 1 5302 296 5 rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 Main bearing support flywheel side Loosen nuts and extract main bearing support using two M 8x1 25 screws with fully threaded length of 40 mm Check oil seal ring and replace if warped hardened or worn out O When refitting tighten nuts at 25 Nm See Page 40 for dimensions CRANKSHAFT Center main bearing support locating bolts Before removing the crankshaft straighten the safety stop 1 and unscrew the bolts 2 of the central main bearings Crankshaft removal X To pull out the crankshaft tap lightly on the gear side end using a copperheaded hammer When refitting align center main bearing supports so that the locating bolt holes coincide with the crankcase holes Crankshaft center main bearing supports Main bearing supports 2 and 3 have a different diameter size see page 40 for dimensions When refitting both centering notches A and B must be located on the same side O Tighten screws at 30 Nm 11 LD Workshop Manual cod 1 5302 296 5 04 39 Disassembly Reassembly A LOMBARDINI KOHLER COMPANY
39. 6 3 NR 3000 r p m Nm 105 107 es es par 7 e Les g kWh g CVh 220 290 270 200 250 490 230 no 11 rpm 11 LD 626 3 3000 r p m pip je 12 10 9 8 g CVh 220 200 100 160 11 LD 626 3 B2 NR 2800 r p m Nm 9 as 75 LIS 6 Les ss 29 25 23 21 19 g kWh g CVh 300 7 15 260 13 220 160 11 LD 625 3 9 3000 r p m kw Nm kgm 100 102 EE EB 80 82 EH 815 a 37 27 HHH un 33 LT HH 2 29 B 19 H 23 17 21 15 19 13 14 11 LD Workshop Manual_cod 1 5302 296_5 ed_ 04 e VIBARDINI Technical information 2 11 LD 625 3 626 3 EPA 2400 r p m 2600 r p m kW 24 30 2 28 20 28 18 2 16 20 14 18 48 12 4 10 N 80 1269 EEC ISO 1585 AUTOMOTIVE RATING Intermittent operation with variable speed and variable load NB ISO 3046 1 IFN RATING WITH NO OWERLOAD CAPABILITY continuos ligth duty operation with constant speed and variable load NA ISO 3046 1 ICXN CONTINUOS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and constant load MN Torque at N power MB NB curve MA NA curve C Specific fuel consumption at NB power The above power valu
40. Clean carefully cylinder cooling system fins and the blowing fan eo eS Loosen the drive belt of the blowing fan Ae Protect the external non painted surfaces with AGIP RUSTIA 100 i 2 wb nU 9 F lt u X Seal with adhesive tape the intake and exhaust systems RS o Coat the engine with a nylon or plastic sheet 5 Keep in a dry place If possible not in direct contact with the ground and away from high voltage electric lines il NW ni TA IN M if m i MM 171 5 100 11 LD Workshop Manual cod 1 5302 296_5 ed_ 04 A LOMBARDINI A KOHLER COMPANY Storage 13 PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE 172 Pd SS 2 7 ae V7 174 Ls ars Remove all protections and coverings Remove the rust preventer from the external part of the engine by means of adequate products solvent or degreaser Tension the blower timing belt Disassemble the injectors and introduce by means of a bowl motor oil on the piston crown no more than 2 cc for every cylinder Remove valve covers and spray motor oil on the valves then turn the crankshaft manually for a few revolutions Start the engine and heat it for about 10 minutes Remove the drain plug and let the protective oil f
41. Do not allow the oil to come into contact with the skin e Pay attention to the temperature of the oil filter when the filter itself is replaced Only check top up and change the coolant fluid when the engine is off and cold Take care to prevent fluids containing nitrites from being mixed with others that do not contain these substances since Nitrosamine dangerous for the health can form The coolant fluid is polluting and must therefore be disposed of in the correct way to safeguard the environment e During operations that involve access to moving parts of the engine and or removal of rotating guards disconnect and insulate the positive wire of the battery to prevent accidental short circuits and to stop the starter motor from being energized Only check belt tension when the engine is off Only use the eyebolts installed by LOMBARDINI to move the engine These lifting points are not suitable for the entire machine in this case the eyebolts installed by the manufacturer should be used GENERAL SAFETY DURING OPERATING PHASES The procedures contained in this manual have been tested and selected by the manufacturer s technical experts and hence are to be recognised as authorised operating methods A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations All tools must be in good working condition so that engine components are not damaged and t
42. LER COMPANY FUEL SPECIFICATIONS A Danger Attention To avoid explosions or fire outbreaks do not smoke or use naked flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the plug to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting To achieve optimum performance of the engine use good quality fuel with certain characteristics Cetane number minimum 51 indicates the ignition quality A fuel with a low cetane number may cause problems when starting from cold and have a negative effect on combustion Viscosity 2 0 4 5 centistokes at 40 C this is the resistance to flow and performance may decline if not within the limits Density 0 835 0 855 Kg litre a low density reduces the power of the engine and density that is too high increases performance and opacity of the exhaust Distillation 85 at 350 this is an indication of the mixture of different hydrocarbons in the fuel A high ratio of light hydrocarbons may have a negative effect on combustion Sulphur maximum 0 05 of the weight high sulphur content may cause engine wear In those countries where diesel has a high sulphur content it is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer
43. OMPANY WARRANTY CERTIFICATE The products manufactured by LOMBARDINI Srl are warranted to be free from conformity defects for a period of 24 months from the date of delivery to the first end user For engines fitted to stationary equipment working at constant load and at constant and or slightly variable speed within the setting limits the warranty covers a period up to a limit of 2000 working hours if the above mentioned period 24 months is not expired If no hour meter is fitted 12 working hours per calendar day will be considered For what concerns the parts subject to wear and deterioration injection feeding system electrical system cooling system sealing parts non metallic pipes belts warranty covers a maximum limit of 2000 working hours if the above mentioned period 24 months is not expired For correct maintenance and replacement of these parts it is necessary to follow the instructions reported in the documentation supplied with each engine Toensure the engine warranty is valid the engine installation considering the product technical features must be carried out by qualified personnel only Thelist ofthe LOMBARDINI authorized dealers is reported in the Service booklet supplied with each engine Special applications involving considerable modifications to the cooling lubricating system for ex dry oil sump filtering system turbo charged models will require special written warranty agreement
44. Refilling Q LOMBARDINI LUBRICANT SAE Classification In the SAE classification oils differ on the basis of their viscosity and no other qualitative characteristic is taken into account The first number refers to the viscosity when the engine is cold symbol W winter while the second considers viscosity with the engine at r gime The criteria for choosing must consider during winter the lowest outside temperature to which the engine will be subject and the highest functioning temperature during summer Single degree oils are normally used when the running temperature varies scarcely Multi degree oil is less sensitive to temperature changes Mineral base SAE Grade Semi synthetic base Synthetic base International specifications They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind American Petroleum Institute MIL Engine oil U S military specifications released for logistic reasons ACEA European Automobile Manufacturers Association Tables shown are of useful reference when buying a kind of oil Codes are usually printed out on the oil container and the understanding of their meaning
45. UNI 5931 M 6x14 Lid seal rev counter Oil seal support ring Variator oil bush Special tab for variator Advance variator device Timing cover side cover for variator Speed and phase sensors Cylindrical pin 5x16 Speed sensor support 78 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 MEARE Disassembly Reassembly Il To remove the speed sensor cable connector press the spring as shown in figures 16 and 17 and draw upwards Loosen the two screws M8 to disassemble the solenoid valve support bracket Loosen screw M6 to remove the speed sensor from its support 11 LD Workshop Manual cod 1 5302 296 5 rev 04 79 Il Disassembly Reassembly e CE PEE Draw he speed sensor outwards being careful not to damage the rubber seal ring M Blower belt alternator Disassembly gt See page 22 23 80 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly gt See page 24 25 Blower control pulley Disassembly 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 81 Il Disassembly Reassembly e LE PEN M Remove the timing cover seal
46. WORKSHOP MANUAL 11 LD series engines cod 1 5302 296 5 ed 11 LD 625 3 11 LD 626 3 SERVICE A LOMBARDINI A KOHLER COMPANY REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Drafting Document Model Review ned code N Issue date date Endorsed PREFACE Every attempt has been made to present within this service manual accurate and up to date technical information However development on the LOMBARDINI series is continuous Therefore the information within this manual is subject to change without notice and without obligation The information contained within this service manual is the sole property of LOMBARDINI As such no reproduction or replication in whole or part is allowed without the express written permission of LOMBARDINI Information presented within this manual assumes the following 1 2 person or people performing service work LOMBARDINI series engines is properly trained equipped to safely and professionally perform the subject operation The person or people performing service work on LOMBARDINI series engines possesses adequate hand and LOMBARDINI special tools to safely and professionally perform the subject service operation The person or people performing service work on LOMBARDINI series engines has read the pertinent information reg
47. arding the subject service operations and fully understands the operation at hand This manual was written by the manufacturer to provide technical and operating information to authorised LOMBARDINI after sales service centres to carry out assembly disassembly overhauling replacement and tuning operations As well as employing good operating techniques and observing the right timing for operations operators must read the information very carefully and comply with it scrupulously Time spent reading this information will help to prevent health and safety risks and financial damage Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases 2 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI INTRODUCTION A KOHLER COMPANY This manual contains the most important information for the repair of LOMBARDINI air cooled direct injection Diesel engines type 1LD625 3 11LD626 3 This information is current upto 07 30 2007 TABLE OF CONTENTS 1 GENERAL REMARKS AND SAFETY INFORMATION 7 9 WARRANTY CERTIFICATE pisip tote anced wien tpe t epe cci et Tat eat cd 7 GLOSSARY AND TERMINOLOGY t e e E Pest cx eie e e Sd et he 7 GENERAL SERVICE MANUAL NOTES ertt ceci Auli tci dee tede Do ue DU ee dde tee ede vega 7 SAFETY REGUEATIONS
48. are available with inside diameter size measuring 0 25 and 0 50 less than the standard version Clearance between main journals crank pins and connecting rod bearings EEJ 0 070 0 109 0 195 FB 0 032 0 078 0 150 G C 0 060 0 110 0 195 Main bearing supports 1 Flywheei side 3 2nd central 2 1st central 4 Gear side za 85 785 85 815 152 000 152 020 om 60 000 60 020 with tightened bearing 150 000 150 020 148 000 148 020 oP 77 990 78 010 11 LD Workshop Manual cod 1 5302 296 5 rev 04 41 Disassembly Reassembly A LOMBARDINI KOHLER COMPANY Main bearing housings Dimensions mm 150 000 150 020 152 000 152 020 148 000 148 020 78 000 78 020 Crankshaft end play Dimensions mm 48 200 48 250 47 950 48 000 Check crankshaft end play after refitting the crankshaft pulley and tightening its nut at 300 Nm the crankshaft end play is equal to 0 20 0 30 mm and is not adjustable If this value cannot be obtained check A and B and possibly replace the parts whose size is inadequate CAMSHAFT Camshaft removal To pull out the camshaft simply remove bell 1 gear 2 fuel feeding pump 3 injection pumps 4 and tilt the engine in this position the cam followers is not
49. bled on a machine by technicians who are adequately trained about its operation and the deriving dangers This condition is also essential when it comes to routine and above all extraordinary maintenance operations which in the latter case must only be carried out by persons specifically trained by LOMBARDINI and who work in compliance with the existing documentation Variations to the functional parameters of the engine adjustments to the fuel flow rate and rotation speed removal of seals demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve LOMBARDINI from all and every liability for deriving accidents or for failure to comply with the laws in merit On starting make sure that the engine is as horizontal as possible unless the machine specifications differ In the case of manual start ups make sure that the relative actions can take place without the risk of hitting walls or dangerous objects also considering the movements made by the operator Pull starting with a free cord thus excluding self winding starting only is not permitted even in an emergency Make sure that the machine is stable to prevent the risk of overturning Become familiar with how to adjust the rotation speed and stop the engine Never start the engine in a closed place or where there is insufficient ventilation Combustion creates carbon monoxide an odourless and highly poisonous gas Lengt
50. body 180 keeping the fork in the position shown in figure A 70 A 70 Tighten only one screw on the position sensor to keep it in the right position 96 11 LD Workshop Manual cod 1 5302 296 5 ed 04 e da me ein Disassembly Reassembly Il Set the cover against the crankcase so that the injection pump rod drive pin 1 is inserted between the two prongs of the fork 2 Look through the upper inspection hole on the cover to make sure that the pin 1 is correctly inserted into the fork 2 Operate the stop control lever repeatedly to make sure the system is running smoothly Replace the screws and nuts in the cover in the opposite order to when they were removed and O tighten to 25 Nm 11 LD Workshop Manual cod 1 5302 296 5 rev 04 97 Il Disassembly Reassembly C LOMBARDINI A KOHLER COMPANY MADE IN ITALY A LOMBARDINI 41 1110 625 3 2 4 2193 118 8 193246 3 WM SN 5079565 12 20041 4 colibrotioa Refit the fuel pump after replacing the seal tighten the screws to 25 Nm Correct assembly position of the control unit that runs the engine variator Example of adhesive plate on the control panel 1 Engine type 2 Control panel serial number 3 Version number form K 4 SN plus engine
51. dequate performance Damaged injector Injection pump valve damaged Injector not adjusted Faulty fuel feeding pump Hardened pump control rod Broken or loose supplementary start up Spring Worn or damaged pumping element INJECTION Incorrect tuning of injection components delivery balancing advance Extra fuel control level sticking Oil level too high Oil level low Oil pressure valve blocked or dirty Oil pressure regulator not adjusted Worm oil pump LUBRICATION CIRCUIT Oil sump suction line clogged Faulty pressure gauge or pressure switch Blocked draining pipe Worn or broken blower belt COOLING CIRCUIT Cooling circuit clogged 11 LD Workshop Manual cod 1 5302 296 5 04 11 2 Technical information e L MANUFACTURER AND MOTOR IDENTIFICATION DATA Engine type Serial number Customer code Approval pp code Name plate for EPA rules applied on rocker arm cap LOMBARDINN IMPORTANT ENGINE LOMBARDINI 6 ER IMPORTANT ENGINE FORMATION 12 11 LD Workshop Manual cod 1 5302 296_5 ed_ 04 A LOMBARDINI A KOHLER COMPANY Technical information 2 TECHINICAL SPECIFICATIONS ENGINE TYPE Number of cylinders 3 3 95 95 88 88
52. e 52 Hao nn den i dei a id ie fee ei A elicit 52 Fuel filter te CoU GE ER e HERR RORIS ui o ETE 52 How to check injection pump delivery valve sealing 54 How to check plunger and barrel for nennen nene 54 Injection pump c ERE ie ee ee ee ee es 52 Injection pump only for EPA engines rte tertie tte ERR ep tht aeter int ea arae kso te Rada Phu Re 53 Injection pump only for standard and 97 68 Ce engines iii 53 Injection pump replacement 2 te ewe codec cat EAR e HUE RA HERE Roe e EUER RE conve DR Elo 56 Imector setting EU EE 58 Pl rig r ndi iU RR medida eu 54 Size PInjectOl 3 9d du ese Ih ed ai a lie c nda I ede 57 Size P nozzle vai iiia meae E CU etn det me tbe nderit a 57 lra weXh e pM E 56 Si2Ze S noz2les 5 nette es c TE Een Ee e REDEEM MI 57 Static INjJSCtON TIMING 2 aan ede trece E ere eee e eet tate oe bsc 58 61 Test data for injection pump delivery at the test bench for standard and 97 68 CE engines 55 Test data for injection pump delivery at the test bench only for EPA engines 55 7 ELECTRIC SYSTEM leu 62 67 12V 21A Alternat itn
53. eader should refer to the index Besides disassembly and reassembly operations this chapter also includes checking and setting specifications dimensions repair and operating instructions Always use original LOMBARDINI spare parts for proper repair operations The operator must wash clean and dry components and assemblies before installing them operator must make sure that the contact surfaces are intact lubricate the coupling parts and protect those that are prone to oxidation Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely For safety and convenience you are advised to place the engine on a special rotating stand for engine overhauls Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved order to fix assemblies and or components securely the operator must tighten the fastening parts in a criss cross or alternating pattern Assemblies and or components with a specific tightening torque must initially be fastened at a level lower than the assigned value and then subsequently tightened to the final torque RECOMMENDATIONS FOR OVERHAULS AND TUNING N Important To locate specific topics the reader should refer to the index Before any intervention the operator should lay ou
54. ector press the locking spring Remove the connector from the sensor O Loosen screw M6 When refitting tighten to 8 Nm Remove the sensor from the support taking care not to damage the O ring 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 91 Il Disassembly Reassembly C LOMBARDINI A KOHLER COMPANY 30 24 30 26 mm 52 55 VA Le Components 1 Dial indicator 2 Support for dial indicator 3 Sensor control gauge measurement 30 24 30 26 mm 4 Control master measurement 30 24 30 26 mm for sensor gauge If replacing the phase sensor check the length of the sensor pin using the tool in figure A_52 Check by measuring the distance between magnetic end and the sensor support surface 30 24 30 26 mm gt serial numbers of special tools are on page 103 Resetting the dial indicator Assemble the dial indicator 1 onto support 2 Attach the support with the dial indicator to the gauge 3 Insert the master 4 into the gauge 3 and reset the dial indicator Sensor test Remove the master 4 from the gauge 3 insert the phase sensor and check that the sensor falls within tolerance measurements of 30 015 30 035 mm See fig A_53 A_ 54 92 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly
55. edle valve sealing by slowly moving hand pump until approximately 180 bar Replace nozzle in case of dripping only for size S injectors Static Injection timing Remove the rocker arm cover Use a 14 mm box wrench to lock the injector union and a 17 mm box wrench to loosen the union of the injector pump high pressure pipe Use a 19 mm box wrench to lock the injection pump union and a 17 mm box wrench to loosen the union of the injector pump high pressure pipe 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI 6 KOHLER COMPANY Fuel system Assemble tool serial no 1460 266 made up of lever 2 serial no 1460 275 of a dial indicator 1 serial no 1460 274 inserted in a dial indicator holder serial no 1460 270 The function of lever 2 is to reduce the effort required against the resistance of the spring when the valve lowers and comes into contact with the piston crown near the top dead centre The dial indicator tracer 1 rests against the upper spring bearing ring of the valve sum up as pressure is placed on lever 2 the valve goes into contact with the piston since the dial indicator 1 is applied to the valve allowing to know precisely every movement of the piston from and towards the TDC which is very important for the following operation Unscrew the fuel supply union for the injection pump of the cylinder which is to be worked on To the i
56. ee TO AED REO AA IRE 19 PRESCRIBED LUBRICANT baes Sonano eeen anit ese code ga eth dat deep da PS ce tins cce vid ene nat 19 FUEL SPEGIFIGATIONS n cite rez rye aee pete ab EE S Dore et ie co epe di 20 4 DISASSEMBLY REASSEMBLY nitri ate ead eee TEREE ai 22 48 Air shroud and baffles nnne nnne nnns 25 Belt tension adjustment sce ice dece E e ne Monter 24 Blower assermibly 2 d tippen Rai bep C seien 25 Blower assembly components with 14 26 Blower assembly components with 21 mener nennen nnne 26 Blower belt alternator ness nere Ln UH in nte de eec Cette eir e oe ee 24 Blower belt alternator Reassembly 4 08 25 Blower control pulley Disassembly sinistres 26 Blower control pulley diameter tipi teda EE SE cepe suae cos etre ev ets 27 EC 42 iir D E HR AD ERN 43 Camshat geari EE 38 Camshaft removal cists Nee e pelle ad o te led Sil ed oblate 42 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 3 A LOMBARDINI INTRODUCTION KOHLER COMPANY GCa mshatttimind 23 act
57. er 41 Mainibearing housirids 5 5 eain eevee E ot ihe er n ee De gui E ie te ede bcp Go Eee 42 Main bearing support flywheel side sise 39 Main bearing support gear side 38 bearing SUppotts nier RE UR ERE 41 Main journal and crank pin diameter cre cde Dre ek eer 40 Mechanical speed Mies ai een eileen tide E 47 Mechanical speed governor components issues 47 Mechanical speed governor components for special generating sets 48 Mechanical speed governor operation ie 47 Mechanical speed governor setting ii 48 Metal snap rings End gaps iie eer em a te pe e ueri vies tee d en Eee ae ee 35 Metal snap rings Pistori grooves nene Rr Re E Ha HEU aH RR 35 Metal snap rings Fittirig Sequerice uc dete ee e datent ee de iet ege alee e tt nn egeta 35 Oil PUMP gear te tative aviv in IHRE Pee 38 Oil bath air cleaner ae
58. er arm cover side plug and measure clearance A should be 0 30 0 40 mm Rocker arm assembly Components 1 Rocker arm axle lubrication hole 2 Lubrication tube A 18 032 18 050 mm B 17 989 18 000 mm Replace the axle and the rocker arm if clearance A B is greater than 0 135 mm When refitting check that lubrication tube 2 perfectly fits into centering bore 1 O Tighten screws at 25 Nm Disassembling size P injector The injector is attached to the cylinder head via a forked bracket To release the injector union from the high pressure pipe use two box wrenches 14 and 17 mm 11 LD Workshop Manual cod 1 5302 296 5 ed_ rev 04 29 4 Disassembly Reassembly e LE POEM Unscrew the screw fastening the clamp of the high pressure pipe using a 4 mm hexagon screwdriver Remove the forked bracket fixing the injector to the cylinder head using a 5 mm hexagon screwdriver see photo 29 30 These operations are necessary when checking injector calibration or when replacing it O The fixing bracket screws must be tightened to 10 Nm using a torque wrench 30 11 LD Workshop Manual cod 1 5302 296 5 ed 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 KER NNSD B 14 35 3
59. er to thoroughly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the first time Remove the oil sump and internal oil filter Remove connecting rocis and check as follows AN Important All connecting rod piston units should be fitted back into the corresponding cylinders mark them to avoid mistakes gt page 35 fig 71 for specifications as to the tightening of the connecting rod big end bearing 36 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 67 69 Connecting rod small end bearing and pin Dimensions 22 Clearance Limit value C D C D A 141 95 142 05 iom 25 020 25 030 0 020 0 035 24 995 25 000 with driven and machined bearing When refitting the bearing of the connecting rod small end as you drive in make sure that the lubrication hole on the connecting rod coincides with the hole on the bearing Connecting rod alignment Check alignment of small end and big end bearing bores using fitted mandrels axial mis alignment A 0 02 mm maximum limit 0 05 mm Moderale warpage may be corrected by gradually working with a press Connecting rod weight Weight connecting rods whe
60. ermediate advance regulating the oil pressure When the set level is reached the oil exerts the right force to compress the spring at the right height to move the plunger appropriately thus achieving the required rotation angular advance 11 LD Workshop Manual cod 1 5302 296 5 rev 04 73 DISASSEMBLY REASSEMBLY Q LOMBARDINI Solenoid valve assembly diagram COMPONENTS TABLE Cylindrical 1 4 gas union Union bolt M 12x1 5 Connection screw M 14x1 5 Nut M 5 Copper seal 13 5x19x2 Seal Seal 14x19x1 5 Adjustable union d 12 Screw TCEI M 5x65 10 Pressure switch 11 Spacer 12 Bolt for two adjustable unions M 12x1 5 13 OilSistem solenoid valve block 14 Variator lubrication jet 15 Pressure switch union 16 Solenoid valve block support 17 Solenoid valve block oil filter pipe 18 Variator oil loading pipe 19 Variator oil bypass pipe 20 Variator oil draining pipe 21 OTECO clic 66 clamp OOANOORWND 74 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly Il After loosening the screws remove the alternator belt guard Overall view of variator speed sensor and hydraulic circuit Components 1 Pressure switch 2 Pressure switch union 3 Solenoid valve block oil filter pipe Components 1 Variator oil loading pipe 2 Var
61. es refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 5 Power decreases by approximately 1 every 100m di altitude and by 2 every 5 C above 25 N Important Non approval by Lombardini for any modifications releases the company from any damages incurred by the engine Note Consult LOMBARDINI for power torque curves and specific consumptions at rates differing from those given above 11 LD Workshop Manual cod 1 5302 296 5 04 15 2 Technical information e L MBARDINI OVERALL DIMENSIONS DIMENSIONI mm MESURES mm DIMENSION mm DIMENSIONE mm DIMENOC ES A 601 D 212 G 82 L 247 110 173 0 230 X 94 X1 237 B 612 E 47 H 4 M 278 P 45 S 305 65 Y 60 Y1 400 400 F 421 525 N 110 Q 132 T 65 2 46 Note Dimensions shown mm 16 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 Q LOMBARDINI MAINTENANCE PRESCRIBED LUBRICANT REFILLING ROUTINE ENGINE MAINTENANCE A Important Failure to carry out the operations described in the table may lead to technical damage to the machine a
62. et ee eee 33 Valve guides and cylinder head housings 32 Malve malterlal 5 n ot E BR AED a e BRE ed D ee 32 Valve seat lapping 5 5 aeo Ee eam Atte eter artt te aan ce Di queer a ia Boi ee ede te 33 5 aee aesti ei ted bea ee Spe utet ux e i Se a cete a 33 ValVe Springs 5 EE 32 Valve stem sealing rings Reassembly 32 Vale timing check RR 44 Valve timing without considering timing sise 44 VEIT 31 5 LUBRICATION SYSTEM rein ele ae ne nant tentes 49 51 LUBRICATION SYSTEM 5 neo Ue chin detain det sin rte dr piede aide ee dat ee ae 49 ere eae eel ale ein 50 Oil pressure check rere T ETE ER UNT CR RAE RC RPM 50 Oil press re curve atifull speed 2 oct ce t tec ee tet a Pe i Asi aede 2e der exec Br t De ke des 51 Oil pressure c rve atidling speed eee ea tt 51 relief valvis ne ien iee eie 50 OI NI PRINCEPS 50 6 FUEL SYSTEM oie ice rer na eee eerte 52 61 Fuel feeding purnp 3 EE M eerte a gi oh pies eid ae ee E ree Di
63. ever 6 offset the weights 1 centrifugal force Balance between the two forces keeps speed at an almost constant level in spite of load variations 11 LD Workshop Manual cod 1 5302 296 5 rev 04 47 Disassembly Reassembly A LOMBARDINI A KOHLER COMPANY 110 112 Mechanical speed governor components for special generating sets 1 Spring anchoring rocker arm 2 Governor springs 3 Journal 4 Governor control lever 5 Governor control lever ball bearing 6 Lever 7 Bearing 8 Plate Note Two types of governor springs 2 are available one for full speed regulation at 1500 r p m and the other for full speed regulation at 1800 r p m in this case governor weights are heavier Mechanical speed governor setting Lift finkage A Loosen screw B Push lever C to the right and check that speed governor weights are closed Shift injection pump delivery control yoke D to the right for maximum delivery Tighten screw B Spring for extra fuel supply at starting The device is operated automatically when the engine is stopped spring 1 acts on injection pump control yoke 2 providing maximum fuel delivery until the speed governor starts operating 48 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 O LOMBARDINI LUBRICATION SYSTEM 5 A Danger Attention The engine can be damaged if al
64. g valve half collets 1460 113 Tool for mounting the spring on the tappet rod protection pipe 1460 009 Only for engines with advance variator Tool for measuring air gap 1 Dial indicator 2 Dial indicator support 3 Gauge 4 Master 5 Base Overall 1460 272 1460 274 1460 270 2003 021 1460 269 1460 268 Only for engines with advance variator Tool for checking phase sensor 1 Dial indicator 2 Dial indicator support 3 Gauge 4 Master Overall 1460 271 1460 274 1460 270 2003 020 1460 267 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 105 LOMBARDINI A KOHLER COMPANY 42100 Reggio Emilia Italia ITALY Via Cav del Lavoro Adelmo Lombardini 2 Cas Post 1074 Tel 39 0522 3891 Telex 530003 Motlom Telegr Lombarmotor R E A 227083 Reg Impr RE 10875 Cod fiscale e Partita IVA 01829970357 CEE Code IT 01829970357 E MAIL atl lombardini it Internet http www lombardini it
65. hat operations are carried out properly and safely It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual Holes must be lined up methodically and with the aid of suitable equipment Do not use your fingers to carry out this operation to avoid the risk of amputation Some phases may require the assistance of more than one operator If so it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved Do not use flammable liquids petrol diesel etc to degrease or wash components Use special products Use the oils and greases recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify assess and monitor the influence of its own activities products services etc on the environment Procedures for identifying the extent of the impact on the environment must consider the following factors Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials a
66. hy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death 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 Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation Fuel is inflammable The tank must only be filled when the engine is off Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil Make sure that no soundproofing panels made of porous material are soaked in fuel or oil Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil Fully tighten the tank plug each time after refuelling Do not fill the tank right to the top but leave an adequate space for the fuel to expand Fuel vapour is highly toxic Only refuel outdoors or in a well ventilated place Do not smoke or use naked flames when refuelling The engine must be started in compliance with the specific instructions in the operation manual of the engine and or machine itself Do not use auxiliary starting aids that were not installed on the original mach
67. iator oil bypass pipe 3 Variator oil draining pipe 4 Solenoid valve block oil filter pipe 11 LD Workshop Manual cod 1 5302 296 5 rev 04 75 LO Il Disassembly Reassembly e w pi Rp Components 1 Variator load solenoid valve 2 Variator unload solenoid valve N Important Do not invert cables during reassembly To remove connectors press the stop tabs and draw upwards gt Referto page 78 to identify the pipes Loosen the union screw of pipes 17 and 19 On the opposite end of the block of pipe 19 is the variator lubrication jet attached to the pipe by a click clamp 76 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly Il Variator lubrication jet complete with banjo union Unscrew the union of variator oil discharge pipe 20 View of the unassembled solenoid valve block with two spacers between the block and the bracket 11 LD Workshop Manual cod 1 5302 296 5 04 77 Il Disassembly Reassembly A LOMBARDINI A KOHLER COMPANY Speed sensor and variator assembly diagram COMPONENTS TABLE OONOORWND Oil seal ring 20x30x7 Washer 6x12xSp1 Screw TCEI 5x10 Screw UNI 5931 M 6x10 Screw
68. il is taken from the engine oil circuit and its pressure acts on a sort of hydraulic piston that moves from one side to the other The hydraulic plunger is attached on the inside by means of a straight groove and on the outside via a spiral shaped groove Thus movement from left to right or vice versa causes rotation from the driving gear and the camshaft In other words the plunger translates and at the same time rotates and thus varying the angular position of camshaft that is connected to it The gear timing variation is managed by an ECU which receives electric signals from two speed sensors the temperature sensor and the load sensor which reads the position of the injection pump control The ECU memory contains the maps of the injection timing variation strategies Fig A_1 Injection timing device in Resting position y SR 72 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 e Advance variator operating principle Fig 2 Injection timing device during actuation of an advance max value 4 59 The oil yellow goes into the system and moves the plunger blue that activates the camshaft anticlockwise Dh 7 Fig A 3 Injection timing device moving from actuation of an advance to resting position The oil yellow goes out and releases the spring to move the plunger blue which in turn activates the camshaft clockwise Our system is able to actuate any int
69. in contact with the camshaft thus making its removal possible How to measure camshaft bearing and journal inside diameter Dimensions Clearance Limit value mm mm mm ae A 43 940 43 960 Measure A using an internal dial indicator and B with an external micrometer When repiacing the bearing make the lubrication hole 1 match with the corresponding crankcase bore 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 e ME Disassembly Reassembly 4 Bye Ax D E F 41 940 41 960 Dimensions of camshaft journals and housings Dimensions Clearance EN 42 000 42 025 41 000 41 025 33 200 33 220 0 040 0 085 40 940 40 960 33 140 33 160 94 Checking intake exhaust cam height Use an outside micrometer gauge to measure camshaft lobe height Intake exhaust cam height 1 1st cylinder intake cam x 4 S1 1st cylinder exhaust cam H A2 2nd cylinder intake cam S2 2nd cylinder exhaust cam 3rd cylinder intake cam S3 3rd cylinder exhaust cam oom 33 65 33 55 for engines EPA 97 68 CE Exhaust and intake cams feature the same height A3 S3 A2 S2 Ai Si Replace camshaft if H is 0 1 mm below the given value Note Engines 11LD 625 3 626 3 in the slow speed version 1500 2000 r p m features a camshaft with H 33 765 33 865 mm 96 Camshaft end play
70. inductor air gap should be 0 55 0 63 mm 62 11 LD Workshop Manual cod 1 5302 296 5 rev 04 LOMB A E A Electric system 7 Alternator battery charger curve 12 5 V 14A The curve was obtained at room temperature of 25 C with 12 5V battery voltage Note The r p m shown in the table refers to the engine Giri 1 1200 p m T min U min 151 12 V 21 A Alternator Features a fixed armature winding housed in the bell inside the blower stator The rotating permanent magnet inductor is located in the fan spindle See page 24 wal a Ref Dimensions mm A A 111 701 111 788 Pu 49 500 52 000 6 76 226 76 300 77 400 77 474 152 Note Clearance between armature winding and inductor air gap should be 0 47 0 63 mm Alternator battery charger curve 12 V 21 A The curve was obtained at room temperature of 25 C with 12 5V battery voltage Note The r p m shown in the table refers to the engine Giri 1 1200 p m 1400 T min U min 153 11 LD Workshop Manual cod 1 5302 296 5 rev 04 63 Electric system A LOMBARDINI A KOHLER COMPANY 154 15
71. ine e g Startpilot Before starting remove any tools that were used to service the engine and or machine Make sure that all guards have been refitted 8 11 LD Workshop Manual cod 1 5302 296_5 ed_ 04 A LOMBARDINI A KOHLER COMPANY General remarks and safety information 1 e During operation the surface of the engine can become dangerously hot Avoid touching the exhaust system in particular Before proceeding with any operation on the engine stop it and allow it to cool Never carry out any operation whilst the engine is running e The coolant fluid circuit is under pressure Never carry out any inspections until the engine has cooled and even in this case only open the radiator plug or expansion chamber with the utmost caution wearing protective garments and goggles If there is an electric fan do not approach the engine whilst it is still hot as the fan could also start operating when the engine is at a standstill Only clean the coolant system when the engine is at a standstill e When cleaning the oil cooled air filter make sure that the old oil is disposed of in the correct way in order to safeguard the environment The spongy filtering material in oil cooled air filters must not be soaked in oil The reservoir of the separator pre filter must not be filled with oil e The oil must be drained whilst the engine is hot oil T 80 C Particular care is required to prevent burns
72. keep it in this position 3 Push plate A to the right until it touches rod B and stop 4 Release rod B and push plate A to the right so that rod B has a stroke of 1 mm Tighten both bolts Note Under these conditions no damage can be caused to the injection pump rack rod stops by sudden impacts due to the available control solenoids 68 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 A LOMBARDINI A KOHLER COMPANY NOTES 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 69 NOTES Q LOMBARDINI 70 11 LD Workshop Manual cod 1 5302 296 5 ed 04 e LOMBARDINI APPENDIX FOR ENGINE WITH ADVANCE VARIATOR 11 LD 625 3 626 3 ENGINE with advance variator 11 LD Workshop Manual cod 1 5302 296 5 04 71 l ADVANCE VARIATOR OPERATING PRINCIPLE Q LOMBARDINI INJECTION TIMING DEVICE OPERATION In order to meet EPA tier 2 limits the engine 11LD 625 3 626 3 has been equipped with a variable injection timing device The system consists of an electro hydraulic actuated mechanical device that allows changing the injection timing by rotating the camshaft against its driving gear The change takes place using the oil whose pressure is regulated by a pair of electric valves which allow a rotation between 0 and 4 5 The maximum variation of the injection timing is 4 5 camshaft degrees O
73. l system The capillary tube shows when the fuel is flowing out thanks to its small transparent slot 146 After finding the delivery start point when fuel stops flowing from the capillary press the lever and use the dial indicator to check how many millimetres the piston has moved from the top dead centre Check static injection advance using the conversion table from millimetres to degrees If it is necessary to change static advance add the seals G in figure 129 to delay or remove the seals G in figure 129 to advance from between the injection pump surface and the crankcase surface The same operation must be performed for each cylinder Conversion table from degrees into millimetres 147 Qe ____ Rem 8 0 56 29 2400 99 19 99 0 71 di 10 0 87 7 0 43 i 97 68 CE 2500 2800 8919 8 0 56 5 9 0 71 69 89 gt 0 56 3000 99 19 99 gt 0 71 3 10 gt 0 87 8 4 gt 0 14 99 2400 2800 59 19 5 gt 0 22 6 0 32 10 119 12 Table static advance values for engines with S size injectors 13 ENENE 13 gt 1 47 2 1500 2200 14 1 149 gt 1 71 16 15 gt 1 96 1 75 159 gt 1 47 220123000 16 1 16 1 71 18 17 1 96 age 20 11 LD Workshop Manual cod 1 5302 296_5 rev 04 ELECTRIC SYSTEM A LOMBARDINI
74. low completely Reinsert the drain plug Carry out motor oil refilling to the upper level of the rod using the oil recommended by the manufacturer for a normal engine operation 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 101 14 MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS Cy LOMBARDINI A KOHLER COMPANY MAIN TORQUE SPECIFICATIONS Diameter and pitch COMPONENT mm Sealants Tank bracket vibration dampers 8x1 25 Loctite 270 Connecting rod 8x1 Injection pump delivery valve union 18x1 5 Bell flywheel side 10x1 5 Central support collar 8x1 25 Intake manifold 8x1 25 Exhaust manifold 8x1 25 Air shroud 8x1 25 Throttle control cover 8x1 25 Rocker arm cover 8x1 25 Timing cover 8x1 25 Cover hydraulic pump flange 1P 8x1 25 Oil pump casing 8x1 25 Blower pulley nuts 6x1 Oil pump nut or union 8x5 Loctite 270 Oil pump gear threading Loctite 270 Tank bracket gasket LoctitelS 495 Air filter Oil filter Internal oil filter Hydraulic pump flange Nozzle cup Blower assembly Camshaft gear Oil pump gear Timing gear Injector cylinder head fastening nuts for S size screw for P size Injection pump control lever Starting motor Oil radiator nipple Loctite 270 Oil filter cartridge nipple Loctite 270 Rocker arm pin Governor control external lever pin Stop control external lever pin Engine mounting foot Injector stud bolt Starter motor stud bolt Fuel feeding pump Blower housing s
75. lowed 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 Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston rings to jam and will lead to rapid wear on the cylinder liner the bearings and all other moving parts Engine life will also be notably reduced The oil viscosity must suit the ambient temperature in which the engine operates Danger Attention 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 8 1 2 9 3 10 4 11 5 12 13 P 14 7 113 Components 1 Rocker arm shaft 6 pump 11 Oil pressure relief valves 2 Connecting rod big end bearing 7 Drain plug 12 Pump intake pipe 3 dipstick 8 Crankshaft main journal 13 Internal strainer 4 Camshaft 9 Crankshaft 14 Drain plug 5 Crankshaft journal 10 Cartridge filter 11 LD Workshop Manual cod 1 5302 296 5 04 49 5 Lubrication system A LOMBARDINI A KOHLER
76. m value prescribed Note Oversize pistons of 0 5 and 1 0 mm are available 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 221 60 Piston weight Weigh pistons when replacing them in order to avoid unbalance The difference in weight should not exceed 6 g Metal snap rings End gaps Insert the snap rings in the lower part of the cylinder then measure the distance between the tips 1 Compression snap ring chrome plated 0 40 0 65 mm Snap ring conical internal torsional Ring oil scraper 0 25 0 50 mm Metal snap rings Piston grooves EE gu A omom omo B osoo ors Metal snap rings Fitting sequence A Compression snap ring chrome plated B Snap ring conical internal torsional C Ring oil scraper Note before inserting the piston in the cylinder rotate snap rings so that cuts are misaligned by 120 from one to the next AN Important Assemble the segments with TOP facing the piston crown 11 LD Workshop Manual cod 1 5302 296 5 04 35 4 Disassembly Reassembly A am MS EH Piston Refitting Caution Warning Lubricate the following parts with oil before mounting the piston pin the piston the cylinder and the big end
77. more frequently PRESCRIBED LUBRICANT Fuel with low sulphur content CF4 CG4 Fuel with high sulphur content API CF CD CE The countries in which diesel normally has a low sulphur content are Europe North America and Australia Fuels for low temperatures It is possible to run the engine at temperatures below 0 C using special winter fuels These fuels reduce the formation of paraffin in diesel at low temperatures If paraffin forms in the diesel the fuel filter becomes blocked interrupting the flow of fuel Fuel can be Summer up to 0 C Winter up to 10 C Alpine up to 20 C Arctic up to 30 C For all fuel types the cetane number cannot be lower than 51 Aviation kerosene and RME fuels biofuels The only Aviation fuels that may be used in this engine are JP5 JP4 JP8 and JET A if 5 oil is added For more information on Aviation fuels and Biofuels RME RSME please contact the Lombardini applications department Capacities standard fuel tank Litres As for filters tanks and special crankcases please refer to LOMBARDINI instructions 20 11 LD Workshop Manual cod 1 5302 296 5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 21 4 DISASSEMBLY REASSEMBLY Q LOMBARDINI RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING A Important To locate specific topics the r
78. n replacing them in order to avoid unbalance The difference in weight should not exceed 10 g Connecting rod big end bearing Both centering notches A and B must be on the same side when refitting O Tighten bolts at 40 Nm gt See page 39 for dimensions 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 37 4 Disassembly Reassembly A LOMBARDINI A KOHLER COMPANY 2 2 AY WIN SM Camshaft gear Remove nut 1 and washer 2 Then remove camshaft gear 3 The cylindrical type of coupling makes gear removal easier since no puller is required O Tighten nut 1 at 25 Nm gt Page 42 for timing Oil pump gear Remove nut 1 and washer 2 Then remove oil pump gear using a puller with two M 8x1 25 bolts length 60 mm O Tighten the nut at 35 Nm Timing gear The timing gear can be easily pulled out thanks to the cylindrical 1 type of coupling However if resistance is felt use a bearing puller Main bearing support gear side Remove crankshaft key and thrust bearing Loosen the three fixing bolts and remove the main bearing support on gear side using two M 8x1 25 screws with fully threaded length of 60 mm Note To avoid distortion it is not recommended to repiace the bearing bushing Complete assemblies of bushing and support are available in standard 0 2
79. nd natural resources Regulations and directives regarding environmental impact In order to minimise the impact on the environment the manufacturer now provides a number of indications to be followed by all persons handling the engine for any reason during its expected lifetime All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution When discontinuing use of the engine select all components according to their chemical characteristics and dispose of them separately 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 9 2 TECHNICAL INFORMATION DR POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN 1 The engine rpms suddenly increase and decrease 2 A sudden and unusual noise is heard 3 The colour of the exhaust fumes suddenly darkens 4 The oil pressure indicator light turns on while running TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation Always perform these simple checks before removing or replacing any part TROUBLE POSSIBLE CAUSE does Non uniform consumption High noise No acceleration Excessive oil Engine not
80. nd or system EXTRAORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING HOURS Engine oilreplacement Oil filter replacement ORDINARY MAINTENANCE FREQUENCY x HOURS OPERATION DESCRIPTION 250 500 1000 LEVEL ENGINE LUBRICANT DRY AIR CLEANER OIL BATH AIR CLEANER BLOWER BELT TENSION VALVE ROCKER ARMS CLEARANCE ADJUSTMENT SETTING AND INJECTORS CLEANING FUEL PIPES RUBBER INTAKE HOSE AIR FILTER INTAKE MANIFOLD ENGINE OIL RADIATOR CLEANING IN THE APPLICATIONS WHERE IT IS PRESENT FUEL TANK CLEANING COOLING SYSTEM CLEANING ENGINE LUBRICANT OIL FILTER FUEL FILTER BLOWER BELT FUEL PIPES REPLACEMENT RUBBER INTAKE HOSE AIR FILTER INTAKE MANIFOLD SEXTERBAL AFTER 6 CHECKS WITH CLEANING CARTRIDGE DRY AIR CLEANER INTERNAL CARTRIDGE OVERHAUL PARTIAL OVERHAUL INSPECTION TOTAL OVERHAUL AFTER 3 CHECKS WITH CLEANING In case of low use every year of low use every 2 years The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates The air filter must be cleaned and replaced more frequently in very dusty conditions 11 LD Workshop Manual cod 1 5302 296 5 04 17 Maintenance Prescribed lubricant
81. ng hours LOMBARDINI will have no further responsibility for warranty and will consider its here above mentioned obligations for warranty complete Any warranty request related to a non conformity of the product must be addressed to the LOMBARDINI Srl service agents GENERAL SERVICE MANUAL NOTES 1 Use only genuine Lombardini repair parts Failure to use genuine Lombardini parts could result in sub standard performance and low longevity 2 All data presented are in metric format That is dimensions are presented in millimeters mm torque is presented in Newton meters Nm weight is presented in kilograms Kg volume is presented in liters or cubic centimeters cc and pressure is presented in barometric units bar GLOSSARY AND TERMINOLOGY For clarity here are the definitions of a number of terms used recurrently in the manual Cylinder number is the timing belt side piston Rotation direction anticlockwise viewed from the flywheel side of the engine 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 7 A LOMBARDINI A KOHLER COMPANY 1 General remarks and safety information SAFETY AND WARNING DECALS Caution Warning Important remarks and features of the text are highlighted This indicates that it is necessary to take proper precautions using symbols which are explained below to prevent any risk to the health and safety of individuals and avoid financial damage
82. njection pump connect the high pressure pump serial no 1460 273 supplied by a tank whose fuel level is at least 100 mm above the injection pump Insert the capillary tester serial no 1460 024 onto the injection pump union where the high pressure pipe is usually connected from the pump to the injector 11 LD Workshop Manual cod 1 5302 296 5 04 59 6 A LOMBARDINI Fuel system KOHLER COMPANY Components 1 Fuel supply pipe from the tank 2 High pressure pipe 3 Capillary tester 4 Valve lowering lever with dial indicator showing piston movement VA Rotate the crankshaft clockwise on the timing belt side and position the relevant cylinder piston at top dead centre Press the lever to bring the valve into contact with the piston crown By joggling back and forth clockwise and anticlockwise find the dead centre via the dial indicator and then reset to zero 144 Rotate the crankshaft anticlockwise until diesel starts to flow out from the capillary when the high pressure lever is pressed Change direction of rotation of the crankshaft to clockwise from the timing belt side Press the high pressure lever and rotate the crankshaft until fuel stops flowing from the capillary 60 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI 6 KOHLER COMPANY Fue
83. r and length 1x1 5 mm Clean nozzle tip with a brass brush Check that holes are not obstructed using a mandrel with steel wire with 0 28 mm diam O When refitting tighten ring nut at 70 Nm Size P injector Components 1 Injector housing 2 Intake fitting 3 Shim 4 Spring 5 Pressure rod 6 Taper pin 7 Nozzle 8 Cup 9 Needle valve 10 Sump 11 System duct 12 Overflow pipe O When refitting tighten ring 8 nut at 50 Nm Size P nozzle Features Hole number and diameter 5 x 0 23 mm angles cette 150 Needle valve elevation 0 200 0 205 mm Hole 1 Sump diameter length 2 x 2 5 mm Clean nozzle tip with a brass brush Check that holes are not obstructed using a mandrel with steel wire with 0 23 mm diam O When refitting tighten ring nut at 55 65 Nm 11 LD Workshop Manual cod 1 5302 296 5 04 57 6 Fuel system C LOMBARDINI A KOHLER COMPANY 134 Injector setting Connect injector to high pression pump and check that setting pressure is 210 220 bar for size S injector and 245 255 bar for size P injector To change injector setting replace the shim over the spring When replacing the spring setting should be performed at a 10 bar greater pressure to allow for bedding during operation Check ne
84. r internal leakage This operation is only diagnostic since pressure changes depend on the pumping speed Connect the delivery union with a 600 bar pressure gauge with safety valve Adjust rack rod at half stroke Turn flywheel according to its direction so that the plunger puts the circuit under pressure Replace plunger if the displayed pressure is below 300 bar Repeat the same operation for the other plungers 131 54 132 How to check injection pump delivery valve sealing Components 1 Valve 2 Seat Adjust pump rack at half stroke Turn flywheel according to its direction of rotation so that the plunger puts the circuit under pressure During this operation the displayed pressure will gradually reach a peak followed by a sudden drop which corresponds to valve closing Pressure drop should be 30 50 bar Replace the valve if pressure drop is below this value Repeat the same operation for the other two pumps 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Fuel system 6 Test data Rod stroke from pump axis mm towards max towards stop Camshaft r p m Test data for injection pump delivery at the test bench for standard and 97 68 CE engines 1 Rack rod lock to be removed after pump fitting to the engine 2 Injection pump axis Delive
85. ry mm stroke stamped A stamped Ax stamped B stamped Bx stamped C stamped Cx stamped D The above test data refer to pump with plunger dia of 7 500 mm Test data for injection pump delivery at the test bench only for EPA engines Test dala Rod stroke from pump axis mm towards max towards stop Camshaft Delivery mm stroke stamped A stamped Ax stamped B stamped Bx stamped C stamped Cx stamped D The pump class is indicated by the full delivery value at 1 mm stroke from 5 to 14 Plunger diameter size 7 500 mm Note All pumps are tested and set in order to obtain the same delivery at full speed After the tests carried out at idle speed pumps are subdivided into classes marked with references in letters or numbers These reference marks are very clearly stamped on the upper pump body If replacing make sure that the new pumps have the same references letters or numbers as the previous ones 11 LD Workshop Manual cod 1 5302 296 5 ed rev 04 55 Fuel system A LOMBARDINI A KOHLER COMPANY 129 AWN j 130 AN RG Z RE SSI AS LS Injection pump replacement 1 Rack rod lock 2 Reference mark pump class A 82 80 mm C Injection cam radius D Injection pump support A Important Whe replacing this type
86. s Within the above stated periods LOMBARDINI Srl directly or through its authorized network will repair and or replace free of charge any own part or component that upon examination by LOMBARDINI or by an authorized LOMBARDINI agent is found to be defective in conformity workmanship or materials Any other responsibility obligation for different expenses damages and direct indirect losses deriving from the engine use or from both the total or partial impossibility of use is excluded Therepair or replacement of any component will not extend or renew the warranty period LOMBARDINI warranty obligations here above described will be cancelled if LOMBARDINI engines are not correctly installed and as a consequence the correct functional parameters are not respected and altered LOMBARDINI engines are not used according to the instructions reported in the Use and Maintenance booklet supplied with each engine A Any seal affixed to the engine by LOMBARDINI has been tampered with or removed parts used are not original LOMBARDINI Feeding and injection systems are damaged by unauthorized or poor quality fuel types A Electrical system failure is due to components connected to this system which are not supplied or installed by LOMBARDINI Engines have been disassembled repaired or altered by any part other than an authorized LOMBARDINI agent Following expiration of the above stated warranty periods and worki
87. see page 49 11 LD Workshop Manual cod 1 5302 296_5 ed_ rev 04 A LOMBARDINI A KOHLER COMPANY Lubrication system 5 bar 5 4 3 2 1 60 70 80 90 100 120 C 120 bar 5 4 3 2 1 60 70 80 90 100 120 C 121 Oil pressure curve at idling speed The curve is obtained at the oil filter level with constant engine speed of 1200 r p m in no load conditions and at a room temperature of 25 C Pressure is given in bar and temperature in centigrades Oil pressure curve at full speed The curve is obtained at the oil filter level with engine working al 3000 r p m al the N power Room temperature is 25 C Lube oil peak temperature should be below 120 C for engines without oil cooler and below 110 C for engines with oil cooler Pressure is given in bar and temperature in centigrades 11 LD Workshop Manual cod 1 5302 296 5 04 51 6 FUEL SYSTEM Q LOMBARDINI Fuel feeding injection circuit Components 1 Tank 2 Filter 3 Fuel feeding tube 4 Fuel feeding pump 5 Injection pump 6 Injection line 7 Injector 8 Injector leak off line and self bleeding system 9 Bowl Fuel filter 1 Components 1 Bleeder 2 2 3 Seal element eae 4 Union 5 Cartridge 4 3 if Cartridge characteristics 5 Filtering paper PF 904
88. serial number plus date 98 11 LD Workshop Manual cod 1 5302 296 5 ed 04 A LOMBARDINI A KOHLER COMPANY NOTES 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 99 13 STORAGE C LOMBARDINI When the engines are not used for more than 3 months they must be protected by the measures described below STORAGE External engine protection Start the engine and heat it Remove the drain plug and let the oil flow completely Replace the oil filter with a new one screw manually the new filter Clean the oil drain plug and after having assembled a new gasket tighten it Carry out the oil refilling to the upper level of the rod using AGIP RUSTIA C for Countries in which this product is not available find an equivalent product on the market Start for about 10 minutes and verify any possible oil leakage then stop the engine m rn ny Injection systems protection Empty the fuel tank NN Replace the fuel filter with a new one MA NT Carry out the filling of fuel using 10 of AGIP RUSTIA NT special additives After having performed the air bleeding start the engine verify any possible fuel leakage then stop the engine External engine protection ti am l ae
89. ssary Check that flange welds are free of defective spots O When reassembling tighten the fastening nuts of the air filter to the intake manifold to 25 Nm Oil bath air cleaner components Caution Warning Replace if irreparably clogged 1 Bowl 7 Cover clamp 2 External seal ring 8 Cap 3 Lower filtering element 9 Centrifugal pre filter 4 Internal seal ring 10 Centrifugal pre filter clamp 5 Gasket 11 Oil level mark 6 Cover 12 Upper filtering element polyurethan sponge Note Thoroughly clean the lower tank and the metal filter element using diesel fuel then blow compressed air into them The upper filter element in polyurethane foam is cleaned by washing it in soapy water after washing dry completely using compressed air After cleaning refill the engine oil tank up to the indicated level See page 17 for the maintenance or replacement instructions Exhaust manifold Danger Attention Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns Make sure that the inside is properly clean and is free from cracks or breakage Always replace the seals between the manifold and the exhaust pipes O When assembling tighten the nuts in sequence and gradually before the final torque to 20 Nm 11 LD Workshop Manual cod 1 5302 296 5 ed_ 04 23 4 Disassembly Reassembly C
90. start Engine starts but stops Black smoke White smoke Too low oil pressure Overheats Inadequate performance Obstructed fuel line Fuel filter clogged Air or water leaks in fuel system FUEL CIRCUIT The tank cap vent hole is clogged No fuel Discharged battery Cable connection uncertain or incorrect Faulty starting switch SYSTEM Faulty starting motor Clogged air filter Excessive idle operation Incomplete run in Overloaded engine 1 2 lt 2 LE 2 lt Non conforming engine oil Incorrect governor linkage adjustment Governor spring broken or unhooked Low idle speed Rings worn or sticking Worn cylinder Worn main con rod rocker arm bearings Badly sealed intake valve Head tightening nuts loose Damaged cylinder head gasket SETTINGS REPAIRS Excessive valve rocker arm clearance Noclearance between valves and rocker arms Valves sticking Defective timing system Bent rods 10 11 LD Workshop Manual cod 1 5302 296 5 ed 04 Q MEER Technical information 2 TROUBLE does POSSIBLE CAUSE Non uniform consumption High noise No acceleration Excessive oil level Engine not start Engine starts but stops Black smoke White smoke Too low oil pressure Overheats Ina
91. t all equipment and tools in such a way as to enable him to carry out operations correctly and safely operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine Before carrying out any operation clean the assemblies and or components thoroughly and eliminate any deposits or residual material Wash the components with special detergent and do not use steam or hot water Donotuse flammable products petrol diesel etc to degrease or wash components Use special products Dryall washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them Apply alayer of lubricant over all surfaces to protect them against oxidation Check all components for intactness wear and tear seizure cracks and or faults to be sure that the engine is in good working condition Some mechanical parts must be replaced en bloc together with their coupled parts e g valve guide valve etc as specified in the spare parts catalogue A Danger Attention During repair operations when using compressed air wear eye protection 22 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 e Disassembly Reassembly 4 Oil bath air cleaner A Danger Attention Do not blow the paper filter element with compressed air to clean Caution Warning Check gaskets and replace as nece
92. tery terminal voltage is 12 5 V The r p m shown on the table refers to the engine 0 600 1000 1400 7800 arise 400 800 1200 1600 2000 2400 2800 rpm 2200 2600 3000 U min 161 66 11 LD Workshop Manual cod 1 5302 296 5 ed 04 A Ies MEO Electric system 7 Starting motor type Bosch JF R 12 V class 2 5 RH direction of rotation 23 24 mm Ring gear plane Flange plane Vorsicht Warnung The flywheel should not project from ring gear plane B Note Apply to Bosch Service Centers for any type of repair 162 Characteristic curves for starting motor type Bosch JF R 12 V P M nh y Kw Nm gin T v 4 8 604 4800 Curves were obtained at room temperature of 20 C with 88 is H bat 44504 4000 teries 5 7 az V Motor terminal voltage in Volt Power in kW Torque N m N Motor speed in r p m 12 J Absorbed current in Ampere 084 104 5004 4 0 4 4004 2 4 o 05 700 200 300 400 500 600 700 800 900 1000 1100 1200 163 Starting motor layout A Parking lights B Stop C Run D Start 164 11 LD Workshop Manual cod 1 5
93. th of the sensor pin and depth between the sensor support surface and the camshaft and specifications Example of where to insert the air gap adjustment shims 11 LD Workshop Manual cod 1 5302 296 5 rev 04 93 Il Disassembly Reassembly e CE Remove the connector from the position sensor the injection pump control rod Unscrew the two screws to disassemble the fuel pump O when refitting tighten the flathead screws the nuts and hexagonal head screws to 25 Nm When reassembling replace the sealing gasket 94 11 LD Workshop Manual_cod 1 5302 296_5 ed_ rev 04 e m TEE Disassembly Reassembly Il Remove the conical inspection plug Unscrew the two screws to disassemble the injection pump rod position sensor Remove the three flanged nuts and the flathead screw Unscrew the last screw flathead after rotating the sensor anticlockwise 11 LD Workshop Manual cod 1 5302 296 5 rev 04 95 Il Disassembly Reassembly e E EE Remove the cover supporting the sensor and the fuel pump Rotate the position sensor shaft to direct the fork on the side opposite the connector Insert the fork into the slot in the support Rotate the sensor
94. tud Loctite 270 Main bearing support fixing stud bolt flywheel side Loctite 270 Head stud Loctite 270 Crankcase stud bolt Loctite 270 Injection pump Loctite 270 102 11 LD Workshop Manual cod 1 5302 296_5 ed_ 04 Q LOMBARDINI MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS 14 MAIN TORQUE SPECIFICATIONS Diameter and pitch COMPONENT Sealants Oil sump 10 Loctite 270 Belt guard 8x1 25 Blower crankshaft pulley 16x1 5 Fan pulley 12x1 5 Fuel filter union 14x1 5 Fuel pump union 10x1 Radiator union 14x1 5 Injector high pressure pipe union 12x1 5 Speed governor support shaft 8x1 25 Main bearing support gear case side 8x1 25 Main bearing support flywheel side 8x1 25 Center main bearing support 10x1 5 Hydraulic pump gear support 8x1 25 Governor control internal lever support 8x1 25 Fuel tank bracket 8x1 25 Drain plug 14x1 5 Cylinder head 10x1 5 Camshaft axle housing screws Flywheel 12x1 25 USE OF SEALANTS ONLY FOR ENGINES WITH VARIATOR POSITION SEALANTS Pump cover C Loctite 5205 Speed sensor support Loctite 209079 Phase sensor support fastening screws Loctite 242 Speed sensor support fastening screws Loctite 242 11 LD Workshop Manual cod 1 5302 296_5 ed_

11 LD 625-3 11 LD 626-3

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