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1. PEL AE API CF CD CC SA SB SC SD SE SF SG SH SJ Heavy Diesel fuels CCMC G 2 Required levels CCMC G 3 SL CCMC PD 1 PD 2 A1 96 4 CCMC D 2 A2 96 zd CCMC D 3 A3 96 MIL L 2104D 2 MIL L 2104E B1 96 MIL L 46152 B2 96 MIL L 46152 D E 226 1 MB 227 1 Eye MB 228 1 mme o VW 501 01 VW 505 00 _ VOLVO VDS MAN QC 13 017 R T5 d 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M Revision 01 ZN 1 5302 286 50494 06 88 30 03 200 Ef COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII DISASSEMBLY AND REASSEMBLY WARNINGS m During repair operations when Besides disassembly and reassembly operations this chapter also includes checking and setting specifications dimensions repair and using compressed air wear eye operating instructions Always use original LOMBARDINI spare parts protection for proper repair operations Oil bath air cleaner Check gaskets and replace if necessary Check that flange weld is free of porosity or defective spots Carefully clean bowl and filtering element with Diesel oil and blow through with compressed air Top up with engine oil to the mark When refi
2. WORK SHOP MANUAL 9 LD series Engine code 1 5302 286 9 LD 561 2 9 LD 561 2 L 9 LD 625 2 2 edition SERVICE DATE OF ISSUE A LOMBARDINI 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 continuos 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 The person or persons performing service work on Lombardini series engines is properly trained and equipped to safely and professionally perform the subject operation 2 The person or persons performing service work on Lombardini series engines possesses adequate hand and Lombardini special tools to safely and professionally perform the subject service operation 3 The person or persons performing service work on Lombardini series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand GENERAL SERVICE MANUAL NOTES 1 Use only genuine Lombardini repair parts Failure to use genuine Lombardini parts could result in sub standa
3. M REVISION PS ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII CAMSHAFT How to measure camshaft journals and housings Use an inside micrometer gauge for housings and an outside micrometer gauge for journals Dimensions of camshaft journals and housings mm ta A 41 940 41 960 Y SS B 27 940 27 960 C 42 000 42 025 D 28 000 28 020 Clearance mm C A 0 040 0 085 C A limit value 0 160 D B 0 040 0 080 D B limit value 0 150 How to measure intake exhaust cam height A1 1 st cylinder intake cam S1 1 st cylinder exhaust cam A2 2nd oylinder intake cam S2 2nd cylinder exhaust cam Exhaust and intake cams feature the same height H For 9LD561 2 and 9LD561 21L H 33 95 34 05 mm For 9LD625 2 H 33 55 33 65 mm Replace camshaft if H is 0 1 mm below the given value R T5 d 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M Revision 01 ZN 1 5302 286 50494 06 88 30 03 200 VIII DISASSEMBLY REASSEMBLY Camshaft end play End play should be 0 10 0 26 mm check by means of a dial gauge pushing or pulling camshaft as required Camshaft timing Fit camshaft gear by making timing mark 1 coincide with timing mark 2 on the crankshaft timing gear Tighten camshaft boll at 6 Kgm Valve timing without considering timing marks Locate piston 1 on flywheel side at the top dead centre Position two small cylinders A of the
4. DELIVERY VALVE TIGHTNESS VALVE AND ROCKER ARM CLEARANC INJECTOR SPRAY PATTERN REPLACEMENT OIL FILTER CARTRIDGE FUEL FILTER CARTRIDGE DRY AIR CLEANER CARTRIDGE O OVERHAUL PARTIAL Geen INSPECTION COMPLETE Under special working conditions clean daily Under extremely dusty conditions clean every 4 5 hours See reccomended oil type Includes checking cylinders piston rings guides springs grinding valve seats scaling heads and cylinders as well as checking injection pump and injectors O When clogging indicator shows the need for replacement CAPACITIES liters Standard fuel tank 10 0 mum amp aa REVISION ZN 1 5302 286 50494 06 88 30 03 200 E MAINTENANCE RECOMMENDED OIL TYPE REFILLING VII The engine could be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed Use a suitable oil in order to protect the engine The lubrication oil influences the performances and life of the engine in an incredible way The risk of piston seizure jammed piston rings and rapid wear of the cylinder liner the bearings and all moving parts increases if oil whose characteristics differ from the recommended type is used or if the oil is not regularly changed All this notably reduces engine life Oil viscosity must suit the ambient temperature
5. V Motor terminal voltage in Volt SI P Power in kW C Torque in N m N Motor speed in r p m J A Absorbed current in Ampere 1000 1200 153 R TE d 20 REG CODE MODEL N DATE OF ISSUE DATE poi eh revision 01 ZN 1 5302 286 50494 06 88 30 03 200 SETTINGS 1 Idling speed setting in no load conditions After filling with oil and fuel start the engine and let it warm up for 10 minutes Adjust idling speed at 1200 1300 r p m by turning setscrew 1 then tighten lock nut NAO Va wu TA 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 oniy 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 in r p m Unscrew limiting device C by 1 turn Tighten lock nut Note If the engine under full load generates too much smoke tighten C if no smok
6. po re obs revision 01 ZN 1 5302 286 50494 06 88 30 03 200 TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS DESCRIPTION Diameter per Pitch R gt 800 N mm2 R gt 1000 N mm2 R 1200 N mm2 mm Nm Kgm Nm Kgm Kgm 4x0 70 3 6 0 37 5 1 0 52 0 62 5x0 80 7 0 72 9 9 1 01 1 22 6x1 00 12 1 23 17 1 73 i 2 08 7x1 00 2 02 2 84 3 40 8x1 25 3 02 4 25 5 10 9x1 25 3 88 5 45 10x1 50 5 36 7 54 12x1 75 9 09 12 80 14x2 00 13 80 19 40 16x2 00 21 00 29 50 18x2 50 26 30 37 00 20x2 50 36 60 51 50 22x2 50 44 40 62 40 24x3 00 56 90 80 00 a COMPILER 77 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED MV pin els Revision 01 PNE Z 1 5302 286 50494 06 88 30 03 200 e LOMBARDINI 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 La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione Lombardini se reserve le droit de modifier n importe quel moment les donn es report es dans cette publication Data reported in this issue can be modified at any time by Lombardini Lombardini vo
7. Components 1 Bore 2 Lubrication tube Dimensions mm A 18 032 18 050 B 17 989 18 000 If clearance A B exceeds 0 135 mm replace shaft and rocker arms When retitting check that lubrication tube perfectly matches with the journal bore Tighten screws al 2 5 Kgm DATE 30 03 200 io QI VIII DISASSEMBLY REASSEMBLY Injector Clean injector and cheek calibrated pressure as indicated on page 55 When refitting cheek that it correctly protrudes from the cylinder head plane Tighten the fixing nuts at 1 Kgm Injector projection The end of nozzle A should project 3 0 3 5 mm from the cylinder head VAN plane SS Adjust injector projection by means of copper shims B measuring 0 5 Em and 1 00 mm in thickness CYLINDER HEAD Do not remove it when hot to avoid deformation If cylinder head is deformed level it off by removing a maximum of 0 3 mm When refitting tighten only if sure that rocker arm lubrication tube is well inside its holes and that both heads are well in line Always replace copper head gasket see page 32 for choosing the right thickness Progressively tighten nuts in the 1 2 3 4 sequence at 5 5 Kgm M prim elle REVISION ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII Valves Components 1 Intake valve 2 Spring seat 3 Valve stem oil seal 4 Spring 5 Retainer 6 Half collets To remove half collets firmly press down
8. Absorbed current in Ampere 149 2 Bosch starting motor type GIF 12 V class 1 5 RH direction of rotation A 29 5 31 5 mm B Ring gear plane C Flange plane Warning Flywheel should not project from ring gear plane B l M REVISION ZN 1 5302 286 50494 06 88 30 03 200 Characteristic curves for starting motor type Bosch GF 12 V class 1 5 kem co Curves are obtained at room temperature of 20 C with 66 Ah battery V Motor terminal voltage in Volt P Power in kW C Torque in N m N Motor speed in r p m6 J A Absorbed current in Ampere 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 151 3 Starting motor type Bosch DW R 12 V 1 7 kW RH direction of rotation Note This motor is of the epicyclic type with reduction ratio of 3 3 1 between rotor and pinion gear 29 5 31 5 mm B Ring gear plane C Flange plane Warning Flywheel should not project from ring gear plane B 152 Characteristic curves for starting motor type Bosch DW R 12 V 1 7 kW iine ew m Y 32004 32 arg 6 Curves were obtained at the temperature of 20 C with 88 Ah battery
9. To avoid flange breakage check that heads are in line before tightening nuts Replace gaskets Tighten nuts at 2 Kgm Pulley guard Shroud Side plates Components 1 Pulley guard 2 Shroud 3 Side plates The pulley guard is made of sound deadening material it reduces the noise that both the pulley and the fan tend to amplify Shroud and side plates are made of ANTIFON an elastic layer which absorbs the noise caused by the plate vibrations Cooling fan Carefully clean and check all blades if any are damaged replace the whole fan See page 13 for cooling air volume Em REG CODE MODEL N DATE OF ISSUE 01 DATE rN mum amp aa REVISION ZI 1 5302 286 50494 06 88 30 03 200 LN VIII DISASSEMBLY REASSEMBLY Hub Components 1 Hub 2 Alternator rotor 3 Fan 4 Bolt The hub holds the alternator rotor and the cooling fan Unscrew the bolt clockwise and tighten at 16 Kgm when refitting Alternator Remove stator and place it inside the rotor to prevent metal particles from being attracted by the magnets When refitting tighten rotor screws and stator bolts at 1 Kgm See page 56 57 for alternator characteristics Shroud support Gear cover plate Loosen screws and remove shroud support very carefully to avoid da mage to the oil seal ring When refitting check that gaskets A and oil seal ring B are well inside their housings Tighten screws at 2 5 Kgm Tank Remove
10. e Pay attention to the temperature of the oil filter when the filter itself is replaced e 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 e Only check belt tension when the engine is off e 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 R ny REG CODE MODEL N DATE OF ISSUE DATE pein eh revision 01 ZN 1 5302 286 50494 06 88 30 03 200 AA m MODEL NUMBER AND IDENTIFICATION Tipo motore Type moteur Engine type Motortype Tipo motor Matricola identificazione motore Codice cliente Matricule d identification moteur Code client Serial number Customer code K No Motornummer Kundennummer Matricula identificaci n motor i MADE IN ITALY EN C digo cliente 12 d HAA REVISION
11. 12 V rated voltage Max current 33 A at 7000 alternator r p m RH direction of rotation 145 Alternator type Bosch G1 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 146 14 V 33 A Bosch G1 alternator battery charger curve The curve was obtained at room temperature of 25 C Battery terminal voltage is 12 5 V The r p m shown on the table reters to the engine 200 600 1000 1400 1800 2200 2600 3000 400 800 1200 1600 2000 2400 2800 T min M min 147 R REG CODE MODEL N DATE OF ISSUE DATE d op Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 ELECTRIC SYSTEM STARTING MOTOR Made by MARELLI and BOSCH Apply to their distributors for any type of repair 1 Magneti Marelli starting motor type E100 1 5 12 V RH direction of rotation A 29 5 31 5 mm B Ring gear plane Flange plane Warning The fiywheel should not project from ring gear plane B 148 Characteristic curves for starting motor type Magneti Marelli E100 1 5112 V N C P V IG 1HN mN Kw V Curves were obtained at room temperature of 20 C with 88 Ah batteries V Motor terminal voltage in Volt P Power in kW C Torque in N m N Motor speed in r p m I A
12. Piston clearance A Piston clearance B Copper head gasket A 0 65 0 7 mm is determined by placing the piston at top dead center and measuring with a feeler gauge and straight edge the distance the piston is below or above the cylinder face A copper gasket available in various thicknesses is them selected to ensure the clearance is correct Gaskets are available in the following thicknesses 0 45 0 5 0 55 0 6 0 65 0 7 0 75 0 8 0 85 0 9 0 95 1 00 mm EI du CONNECTING ROD Remove oil pan Remove connecting rods and check as follows Both connecting rod piston units should be fitted back into the corresponding cylinders mark them to avoid mistakes See page 33 for specifications as to the tightening of the connecting rod big end bearing Connecting rod small end bushing Dimensions and clearance mm C 25 020 25 030 with machined bushing in place 24 995 25 000 C D 0 020 0 035 C D maximum worn limit 0 070 52 32 COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE tENDORSED MT poise eb revision 01 ZI 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII 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 Moderate warpage may be corrected by gradually working with a press Connecting rod weight Weigh connecting rods when replacing them i
13. ZN 1 5302 286 50494 06 88 30 03 200 ES TECHNICAL DATA CHARACTERISTICS 9 LD 561 2 9 Id 561 2 L 9 LD 625 2 ENGINE TYPE Number of cylinders 2 Bore 95 Stroke 88 Displacement 1120 1248 Compression ratio 17 51 17 51 R P M 3000 3000 N DIN 70020 19 0 25 8 21 28 5 Power KW CV NB DIN 6270 16 9 23 0 13 30 18 0 19 2 26 0 NA DIN 6270 15 4 21 0 12 00 16 3 17 7 24 0 Max torque 6 55 6 0 7 5 2200 2000 2200 Max torque at 3rd p t o 3 0 3 0 3 0 Specific fuel consumption 198 179 Tank capacity 10 10 Oil consumption 0 050 0 050 Oil sump capacity 3 0 3 0 Dry weight 110 110 Combustion air volume at 3000 r p m 1440 1056 Cooling air volume at 3000 r p m 24000 17600 Max permissible driving shaft axial load in both directions 300 300 momentary 35 35 Max inclination lasting up to 1 h permanent Referred to max NB power i At 2200 r p m Depending on the application Note For engines type 9LD560 2 currently out of production follow the same repair instructions listed above R TEO 2D REG CODE MODEL N DATE OF ISSUE DATE M revision 01 ZN 1 5302 286 50494 06 88 30 03 200 5 NOTE COMPILER T 20 REG CODE MODEL N DATE
14. 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 R TB REG CODE MODEL N DATE OF ISSUE DATE f ORSEB 00 0 lt LE ei som 1 5302 286 50494 06 88 30 03 200 A 91 VOLTAGE REGULATOR Type LOMBARDINI supplied by SAPRISA and DUCATI Voltage 12 V max current 26A References for SAPRISA connections with the corresponding DUCATI connections G 137 To avoid wrong connections 3 different sizes are supplied CONNECTION SIZE mm SAPRISA DUCATI WIDTH THICKNESS 138 The voltage regulator fits to both circuits with and without battery charging light in the latter case connections LE SAPRISA and L DUCATI are not used 139 140 COMPILER Y 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED MV pore ela revision 01 ZN 1 5302 286 50494 06 88 30 03 200 How to check voltage regulator for proper operation Check that connections correspond to the layout Disconnect the terminal from the battery positive pole Connect a d c voltmeter between the two battery poles Fit an ammeter between the positive pole and the corresponding cable 1 terminal Start a couple of times until battery voltage drops below 13 V When battery voltage reaches 14 5 V
15. 12 5 V 14 A Alternator o ooo ol s 56 14 V 33 A Bosch G1 alternator battery charger curve ee 61 Alternator battery charger curve 12 V 18 60 Alternator battery charger curve 12 5 V 14A a a a a a 57 Alternator type Bosch G1 14 V 38A 0 0 0 2 61 Alternator type Bosch 114 33 00 61 Bosch starting motor type GIF 12 V class 1 5 0 022 62 Characteristic curves for starting motor type Bosch DW 12 V 1 7 63 Characteristic curves for starting motor type Bosch GF 12 V class 1 5 2 00 63 Characteristic curves for starting motor type Magneti Marelli E100 1 5 12 62 Checking for cable continuity 200 57 Electrical starting layout with battery charging light 00 56 How to check voltage regulator for proper operation e 59 Magneti Marelli starting motor type E100 1512 2 00 62 Magnetization checking tool Part No 7000 9727 001 0 57 OPTIONAL ELECTRIC EQUIPMENT 60 STANDARD ELECTRIC EQUIPMENT 56 STARTING MOTOR sium oh sed a Ree eee AGRA Gee defem RSG A a 62 Starting motor type Bosch DW 12 V 1 7 63 VOLTAGE REGULATOR f a te 9 caus GSE Sie hans Spy ue PRA aye aoe of an di ue 58 SETTINGS 64 66 cane LARS REL ak DEES PERS It oli DS Full speed setting in no load conditions standard 64 Injection pump delivery setting 64 Injection pump delivery limiting and extra fuel device 0 0 a L 64 Injection pump delivery setting with engine
16. 5302 286 50494 06 88 30 03 200 LUBRICATION SYSTEM OIL PUMP Check that gear teeth are intact and that clearance between gear edge and pump body does not exceed 0 15 mm Further more check that control shaft is free to rotate with end float not exceeding 0 15 mm Oil pump delivery al 3000 r p m is 9 liters min Cil filter cartridge internal Components 1 Plug 2 Seal ring 3 Spring 4 Cartridge Features Type of filtration 70 y By pass valve opening pressure 0 60 0 75 bar Max working pressure 4 5 bar Oil pressure relief valve Components 1 Plug 2 Gasket 3 Spring 4 Valve A 37 mm Carefully clean all components and check spring A length SST TU JA 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 see page 48 R REG CODE MODEL N DATE OFISSUE DATE ENDORSED MNT n A revision 01 A 47 ZN 1 5302 286 50494 06 88 30 03 200 LUBRICATION SYSTEM Cil pressure curve at idling speed The curve is obtained at the oil filter lever 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 60 70 80 90 100 120 C 104 Oil pressure curve at full speed The curve is obtained at the oil filter
17. OF ISSUE DATE ENDORSED Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 CHARACTERISTIC POWER TORQUE AND SPECIFIC CONSUMPTION CURVES CHARACTERISTIC POWER TORQUE AND SPECIFIC CONSUMPTION CURVES 9LD561 2 9LD561 2 L kW CV __ Mes 14 50 13 12 11 10 9 fh 8 g KW 7 250 R PML1000 1400 1800 2200 2600 3000 9LD625 2 R PM 1000 1400 1800 2200 2600 3000 N DIN 70020 Automotive rating intermittent operation with variable speed and variable load NB DIN 6270 Rating with no overload capability continuous light duty operation with constant speed and variable load NA DIN 6270 Continuous rating with overload capability continuous heavy duty with constant speed and constant load C NB Specific fuel consumption at NB power Mt Torque at N at NB power for 9LD561 2 L a Range of application for continuous operation In case of application outside this range please contact LOMBARDINI The above power values 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 C Note Consult LOMBARDINI for power torque curves and specific consumptions at rates d
18. Use an inside micrometer gauge Main bearing and connecting rod big end bearing inside diameter Dimensions mm E 72 070 72 090 45 548 45 578 55 404 55 435 H 55 000 55 020 The above dimensions refer to driven in or tightened bearings Note Both main bearings and connecting rod big end bearings are available with inside diameter size measuring 0 25 and 0 50 mm less than the standard version Clearance between main journals crank pins and connecting rod bearings mm E A 0 070 0 109 limit value 0 195 F B 0 032 0 078 limit value 0 150 G C 0 054 0 104 limit value 0 190 H D 0 050 0 089 limit value 0 180 R TE REG CODE MODEL N DATE OF ISSUE DATE KE ORSEB 00 a men O br AY ZN 1 5302 286 50494 06 88 30 03 200 VIII DISASSEMBLY REASSEMBLY Main bear ng supports 1 Flywheel side 2 Central 3 Gear side Dimensions mm 149 000 149 020 L 76 980 77 020 M 147 010 147 020 N 59 074 59 092 0 75 990 76 010 P 60 000 60 020 Main bearing housings Dimensions mm 149 000 149 020 B 147 000 147 020 C 76 000 76 020 Crankshaft end play When refitting crankshaft check end play by means of a thickness gauge this value should be 0 08 0 38 mm and can be set by changing the thickness of gasket A which is located on the flywheel side main bearings Gaskets with thickness of 0 10 0 20 and 0 4 mm can be supplied
19. and covers Remove antirust by an appropriate solvent or degreaser Remove injectors fili with standard oil turn crankshaft by a few revolutions remove oil pan and drain the protective oil Check injectors valve clearance belt tension head tightening oil filter and air cleaner for proper setting If the engine is stored over a long period of time over 6 months check one of the bushings for corrosion 163 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED MNT n A revision 01 C 67 ZN 1 5302 286 50494 06 88 30 03 200 TORQUE SPECIFICATIONS MAIN TORQUE SPECIFICATIONS Diam and pitch Torque Connecting rod Injection pump delivery valve union Rocker arm cover Center main bearing support Intake manifold Exhaust manifold Air shroud Accelerator cover Oil filter housing Internal oil filter cover Hydraulic pump flange Camshaft gear Oil pump gear Starting motor Blower hub Rocker arm shaft Gear cover plate Engine mounting foot Fuel feeding pump Injection pump Oil pump Nozzle holder Oil pan Starting pulley Main bearing support gear case side Main bearing support flywheel side Center main bearing support Hydraulic pump gear support Governor fork support Fuel tank bracket Cylinder head Blower Flywheel COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED
20. and or system SAFETY INSTRUCTIONS e 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 e 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 e 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 assembled on a machine by technicians who are adequately trained aboutits operation and the deriving dangers This condition is also essential when it comes to routine and above all extraordinary maintenance operations which in
21. bolt Straighten plate 1 and unscrew bolt 2 before removing crankshaft Crankshaft removal LOMBARDINI service To pull out the crankshaft tap lightfy on the timing side end using copper headed hammer When refitting align center main bearing support so that the locating bolt hole coincides with the crankcase hole Crankshaft center main bearing support When refitting both centering notches A and B must be located on the same side Tighten screws at 2 5 Kgm See page 31 for dimensions R T5 d 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M Revision 01 ZN 1 5302 286 50494 06 88 30 03 200 VIII DISASSEMBLY REASSEMBLY Crankshaft lubrication ducts Remove plugs clean duct A with a pointed tool and blow in compressed air Screw plugs again and check for sealing Crankshaft journal radius The radius R connecting journals 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 mm 71 981 72 000 45 500 45 516 55 331 55 350 54 931 54 950 COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII M CUI 2 How to measure main bearing inside diameter
22. control box 45 Electronic speed governor layout i 44 Engine running with electronic speed governor o a 45 Exhaust manifold 5 5 5 5 2 23 FElywheel s rt aria A oso Nat t e Pos M fet T 25 Governor springs with rocker arma 43 M pin elle REVISION ZN 1 5302 286 50494 06 88 30 03 200 INTRODUCTION Governor springs with rocker arm 43 How to measure intake exhaust cam height ee 39 How to measure main bearing inside diameter a a a 2 sn 37 Hubs ur Mitte AE t E i uem eh OS mde Sum de 24 Hydraulic pump pro 42 IP rone ordeo e X pedo Bem px Nes Rasse Fox BAM RDO e 42 INJECTION Si r 26 Injector projection 0 26 Intake manifold 22 Main bearing and connecting rod big end bearing inside diameter 37 Main bearing housings o o lll 38 Main bearing support flywheel side 0 34 Main bearing support gear side 222222220 34 Main bearing supports 0 0 38 Main journal and crank pin diameter Mm 36 MECHANICAL SPEED GOVERNOR ss oo o oo o s 42 Mechanical speed governor o oo ooo s 42 PRISTON a star ed WII UA Dx ao ceri Up turp DESEE 1 1 M A 30 Piston Rerttmg uuo ere een Sk A mad d 3 Ne Most uei NSA Be abes de ud 32 Piston clearance o oa cascca oeio ee 32 Piston rings End
23. fuel filter and loosen clamp screws Completely empty the tank and check that no impurities are found inside Check that cap breather hole is not clogged When refitting tighten bracket screws at 4 Kgm See page 49 for refitting fuel filter COMPILER Tn 00 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M mimea revision 01 ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII pea 19 20 R ny REG CODE MODEL N DATE OF ISSUE pein eh revision 01 ZN 1 5302 286 50494 06 88 Flywheel Remove flywhee with puller 1 part No 7271 3595 048 Check starter ring gear and tapered crankshaft mating surfaces When refitting tighten bolt al 30 Kgm Note To replace starter ring gear heat it up lo 200 250 C and rapidly drive it onto the flywheel Valve rocker arm clearance Remove rocker arm cover and check gaskets for breakage Setting should be performed when the engine is cold bring each cylinder piston to top dead center on the compression stroke and set clearance A al 0 15 0 20 mm When refitting tighten cover screws by 2 Kgm Compression release optional Bring piston to top dead center on the compression stroke Unscrew rocker arm cover side plug and measure clearance A It must be 0 30 0 40 mm For setting purposes remove rocker arm cover unscrew lock nut and set clearance A by adding or removing shims under steel plate point B Rocker arm assembly
24. gaps mm 2 0 5 5 2 31 Piston rings Fitting sequence o o o 31 PIStON Weights Ae s um sn me oue nah a BAR Bite uA oe Bie 31 Pistons ringis Clearance between grooves MM 31 Pulley guard Shroud Side plates 222222220 23 Pushrod 29 Rocker arm assembly 25 Shroud support Gear cover plate 00 0o ooo 24 Spring for extra fuel supply at starting gt 2222222220 43 Starting with electronic speed governor 45 A A a A BG 24 Valve rocker arm clearance e 25 Valve guide insertion 28 Valve guides and valve guide housings 28 Valve material ct meom mcg D pw PONOECNO SRO RAS lus Soap QoS wA Pod 27 Valve seat grinding a a 29 Valve seats and housings ooo oo ssl 29 Malv Springs E Wee diri xe Oh d e Beret da ben e hoy 27 Valve timing check 41 Valve timing without considering timing Marks o loo sl 40 MalVesi atti A A ad cH Gh ge manes qnd 27 LUBRICATION SYSTEM 46 48 Lubrication 5 go p p d Re n 46 sd Sp dus ora VUES he PUES RUM A ems Ven M EET 47 Oil filter cartridge internal 47 Oil pressure relief valve 47 Oil pressure check suus rca due ee doe pred AE te ege aor dede a 47 Oil pressure cur
25. in which the engine operates A Old 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 inevitable you are advised to thoroughly wash your hands with soap and water as soon as possible Appropriate protective gloves etc should be wore during this operation Old oil is highly polluting and must be disposed of in the correct way Do not litter RECOMMENDED OIL GRADE eee AGIP SUPERDIESEL MULTIGRADE 15W40 specifications API CF 4 e BRA AUTE SG ACEA E2 B2 MIL L 46152 D E 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 In the countries where AGIP products are not available use oil API SAE 10W SJ CF for Diesel engines or oil corresponding to the military SAE 20W specification MIL L 46152 D E SAE 30 OIL SUPPLY liters 9 LD 561 2 561 2 L 625 2 SAESU SAE 10W 30 _ SAE 10W 40 filter included 3 3 SAE 10W 60 filter escluded 3 0 ER SAE 15W 40 base minerale SAE 15W 40 base semi sintetica SAE 20W 60 base semi sintetica SAE 5W 30 base sintetica SAE 5W 40 base sintetica SAE 0W 30 base sintetica Air cleaner oil tank 0 3 ACEA SEQUENCES DIESEL BENZINA ESSENCE PETROL A Gasoline Petrol BENZIN GASOLINA
26. level with engine working at 3000 r p m and 25 84 HP at 25 C room temperature Pressure is given in bar and temperature in centigrades 60 70 80 90 100 120 C 105 M REVISION PS ZN 1 5302 286 50494 06 88 30 03 200 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 106 Fuel filter inside fuel tank Components 1 Spring 2 Disc 3 Ring 4 Cartridge 5 Gasket 6 Gasket 7 Cap 8 Ring 9 Bolt ES m 107 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 Characteristics when the control eccentric rotates at 1500 r p m minimum delivery is 64 while self regulation pressure is 4 5 m water column 108 Fuel feeding pump drive rod protrusion Components 1 Drive rod 2 Gasket 3 Camshaft eccentric Drive rod A protrudes 0 8 1 2 mm from the crankcase it can be adjusted by means of gaskets Gaskets are supplied in the following thicknesses 0 50 0 80 and 1 0 mm Note This setting is performed when the rod is on the base of the cam lobe i e minimum protrusion 109 iiio a p En 01 di ir AS 49 mum amp aa REVISION ZO 1 5302 286 50494 06 88 30 03 200 LN INJE
27. weight should not exceed 6 g Piston rings End gaps mm Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap For 9LD561 2 and 9LD561 2 L 1 Chromium plated ring 0 40 0 65 2 Torsional internal tapered ring 0 40 0 65 3 Oil control ring 0 25 0 40 For 9LD625 2 1 Chromium plated ring A 0 40 0 65 2 Torsional internal tapered ring 0 40 0 65 3 Oil control ring A 0 30 0 60 Pistons ringis Clearance between grooves mm For 9LD561 2 and 9LD561 2 L A 0 11 0 15 limit value 0 25 B 0 06 0 10 limit value 0 18 0 05 0 10 limit value 0 18 For 9LD625 2 0 07 0 11 limit value 0 20 B 0 05 0 09 limit value 0 16 C 0 04 0 08 limit value 0 15 Piston rings Fitting sequence A 1 Chromium plated ring B 2 Torsional internal tapered ring C 3 oil control ring C Note Before fitting the piston into the cylinder stagger the ring gaps at 120 45 d 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M prim elite Revision 01 ZN 1 5302 286 50494 06 88 30 03 200 VIII DISASSEMBLY REASSEMBLY Piston Refitting Connect piston to connecting rod in a way that the combustion chamber centre b is at right angle 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
28. 1 Extra fuel spring 2 Injection pump control yoke 3 Governor spring 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 engine starts and the governor controls the iniection cea MCT pump rack DO d 20 REG CODE MODEL N DATE OF ISSUE DATE pein eh revision 01 ZN 1 5302 286 50494 06 88 30 03 200 VIII DISASSEMBLY REASSEMBLY gt Z N IRS 2 ANS NZ 227 Mss NO m NB 1222 SSO EA N ELECTRONIC SPEED GOVERNOR optional A Actuator S r p m sensor An electronic speed governor can be fitted upon request to engines with serial number greater than 2907859 The crankcase features a hole for sensor S introduction Electronic speed governor Components 1 Injection pump 2 Delivery control lever 3 Actuator A mounting flange 4 Mobile retainer 5 Actuator magnet 6 Stator coils 7 Stator 8 Cable ends for connection to control box E 9 Electromagnet Electronic speed governor layout Components A actuator C key P potentiometer T electromagnet S sensor The device consists of an actuator A controlling injection pump rack an r p m sensor S and an electromagnet T controlling fuel delivery and supplying extra fuel at starting Control box E see page 35 controls fuel delivery as a function of the load and of the speed set through potentio
29. 200 SAFETY AND WARNING DECALS SAFETY INSTRUCTIONS EN e 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 forthe machine e To prevent fire hazards always keep the machine at least one meter from buildings or from other machinery e Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation e 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 e 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 e Fuel vapour is highly toxic Only refuel outdoors or in a well ventilated place e Do not smoke or use naked flames when refuelling e 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 machine e g Startpilot e
30. Before starting remove any tools that were used to service the engine and or machine Make sure that all guards have been refitted e During operation the surface of the engine can become dangerously hot Avoid touching the exhaust system in particular e 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 Do not allow the oil to come into contact with the skin e Make sure that the drained oil the oil filter and the oil it contains are disposed of in the correct way in order to safeguard the environment
31. CTION PUMP The Bosch injection system consists of a single body pump with plungers featuring constant stroke and feeding one cylinder each The pump mounted on the crankcase is directly operated by the camshaft Speed governor extra fuel and stop device are separate from the pump see page 42 43 and 66 Injection pump Components 1 Pump body 2 Fitting 3 Seal ring 4 Filter 2 5 Shim 6 Spring 7 Delivery valve 8 Seat 3 9 Gasket 10 Plunger 11 Barrel 12 Rack rod 9 13 Sector gear 14 Spring 15 Upper retainer 16 Lower retainer 17 Tappet 18 Tappet roller m il LU Wa e ml G y S Plunger and Barrel Assembly 1 Barrel 2 Fuel feeding port 3 Control helix 4 Plunger 5 Retardation notch only for 9LD625 2 Plunger diameter is 7 mm for 9LD561 2 and 9LD561 2 L and 7 5 mm for 9LD625 2 Note Every plunger matches with its own barrel For this reason they are not interchangeable COMPILER VEGUJATL pp REG CODE MODEL N DATE OF ISSUE DATE FENDORSEB Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 CESA ES 10 500 d 20 REG CODE MODEL N DATE OF ISSUE DATE pein eh revision 01 ZN 1 5302 286 50494 06 88 30 03 200 How to check plunger and barrel for internal leakage This operation is only indicative since pressure changes depending on the pumping speed Connect the delivery union with a 600 bar pressure gauge with safety valve Adjust rack rod at ha
32. RSED M Revision 01 ZN 1 5302 286 50494 06 88 30 03 200 VIII DISASSEMBLY REASSEMBLY CYLINDER Measure diameter size between two diametrically opposed points at three different heights For 9LD561 2 and 9LD561 2 L 90 00 90 02 mm For 9LD625 2 95 00 95 02 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 cylinder roughness The cylinder should show no blowholes or porosities Seal both ends of cylinder and pressurize with compressed air at 4 Bar for 30 secs Immerse in water and check for leakage 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 p PISTON Remove circlips and remove piston pin Remove piston rings and clean grooves Measure diameter at 2 mm from the bottom of skirt For 9LD561 2 and 9LD561 2 L Y 89 90 89 92 mm 9LD625 2 Y 94 93 94 95 mm In case of diameter wear above 0 05 mm replace piston and piston rings Note Oversize pistons of 0 5 and 1 0 mm are available COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII Piston weight Weigh pistons when replacing them in order to avoid unbalance The difference in
33. as shown in the figure Note Valve stem oil seal 3 must be fitted to the intake valve only Valve springs Measure free length with a gauge Using a dynamometer check that the spring length under two different loads corresponds to the values below Engine type 9LD561 2 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 Engine type 9LD625 2 Free length A 47 mm Length B compressed by a 20 6 Kg weight 36 4 mm Length C compressed by a 40 6 Kg weight 26 1 mm Replace spring if length is 1 mm or more below the stated values Valve material Intake valves A Material X 45 Cr Si 8 UNI 3992 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 8 UNI 3992 5 Portion made of X 70 Cr Mn Ni N 216 UNI 3992 45 15 45 25 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED WT A revision 01 A 27 ZN 1 5302 286 50494 06 88 30 03 200 VIII DISASSEMBLY REASSEMBLY Valve guides and valve guide housings Starting from engine No 2883619 intake and exhaust valve guides are both made of phosphoric cast iron Components 1 Exhaust valve guide 2 Intake valve guide Dimensions mm A 42 0 B 48 5 for 9LD561 2 and 9LD561 2 L 53 5 for 9LD625 2 C 14 000 14 018 D 14 050 14 060 Valve g
34. at the torque dynamometer 65 Required settings as most commonly applies 2 52 5 50 525055522 ss sl 65 SIOp setting i soie e 48a edem aed Al o ho Bae bak tea domo dom Deb b dosi ds do eei aln 66 STORAGE 67 STORAGE an PTT 67 Temporary protection 126 months 22222222020 67 Permanent protection over 6 months o a ooo ss 67 How to prepare the engine for operation 22 00 67 TORQUE SPECIFICATIONS 68 69 MAIN TORQUE SPECIFICATIONS 222222200 68 STANDARD BOLT TORQUE SPECIFICATION ooo o s sss 69 COMPILER XO 00 REG CODE MODEL N DATE OF ISSUE DATE FENDORSEB M revision 01 D ZN 1 5302 286 50494 06 88 30 03 200 NE R TE REG CODE MODEL N DATE OF ISSUE DATE KE ORSEB M m REVISION 01 TO CA 7 7 5 1 5302 286 50494 06 88 30 03 2003 0 0 f COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 POSSIBLE CAUSES AND TROUBLE SHOOTING EN POSSIBLE CAUSES AND TROUBLE SHOOTING The following table contains the possible cause of some failures which may occur during operation Always perform the simplest checks before removing or replacing any part TROUBLE POSSIBLE CAUSE Clogged pipings Clogged fuel filter Air inside fuel circuit Clogged tank breather Faulty feed pump Stuck injector Stuck injection pump valve Wrong injector setting Sticking injection pump ra
35. ck Wrong injection pump setting Be Too high oil level Stuck pressure relief valve Incorrect relief valve setting Worn oil pump Air inside oil suction pipe Faulty pressure gauge or switch Clogged oil suction pipe Battery dis charged Wrong or inefficient cable connection Defective starter switch Defective starter Engine does not start a starts acceleration Non uniform speed Black smoke Withe smoke Too low oil pressure LUBRICATION FUEL CIRCUIT 9 tc LU LU Clogged air filter Excessive idle operation Incomplete running in Engine overloaded Advanced injection Retarded injection Incorrect governor linkage adjustment Broken or loose governor spring Too low idle speed Worn out or stuck piston rings Worn out cylinders Sticking valves Worn out bearings Governor linkage not freely operating Crankshaft not turning freely MAINTE SETTINGS REPAIRS NANCE CODE MODEL DATE OF ISSUE DATE 00 ZN 1 5302 286 50494 06 88 EA EN SAFETY AND WARNING DECALS SAFETY INSTRUCTIONS SAFETY AND WARNING DECALS DANGER CAUTION Failure to comply with the Failure to comply with the instructions could result in instructions could lead to damage to persons and technical damage to the property machine
36. d shim under the pump to make C match with B Note By adding or removing a 0 1 mm shim under the pump C is delayed or advanced by approximately 3 mm 126 127 M mimea REVISION ZN 1 5302 286 50494 06 88 30 03 200 INJECTOR Components p 277 1 Intake fitting x 2 Nozzle holder ro 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 128 Nozzle Features Hole number and diameter 4x0 28 mm Jet angles 160 Needle valve elevation 0 20 0 22 mm Hole length 0 7 mm Sump diameter and length 1x1 5 mm Injector setting Conect injector to a hand pump and cheek that setting pressure is 210 220 bar make the required adjustments if any by changing the shim over the spring When replacing the spring setting should be performed at a 10 bar greater pressure 220 230 bar to allow for bedding during operation Check needle valve sealing by slowly moving hand pump until approximately 180 bar Replace nozzle in case of dripping Es REG CODE MODEL N DATE OF ISSUE 01 DATE Lag mum amp aa REVISION ZO 1 5302 286 50494 06 88 30 03 200 mo LN 131 132 133 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 O
37. e is observed at the exhaust and the engine cannot reach its full power unscrew C Injection pump delivery limiting and extra fuel device Limiting device C limits the injection pump maximum delivery It also acts as a torque setting device since spring N opposes the resistence of spring M inside the cylinder through lever L The torque setting device allows lever L to move over stroke H corresponding to 0 15 0 25 mm This consequently increases injection pump delivery with torque reaching its peak value Note In generator sets and power welders the torque setting device acts as a delivery limiter only It therefore does not feature spring M or Stroke M REVISION P ZN 1 5302 286 50494 06 88 30 03 200 157 Injection pump delivery setting with engine at the torque dynamometer 1 Bring engine to idling speed 2 Unscrew delivery limiting device C see page 64 3 Bring engine to the power and r p m required by the manufacturer of the device 4 Check that consumption falls within the table specifications see below If consumption is not as indicated change balance conditions at the torque dynamometer by varying the load and adjusting the governor Under stable engine conditions check consumption again 5 Tighten limiting device C until the engine r p m decreases Lock the limiting device by means of lock nut In versions with manually operated mechanical extra fuel feeding D perform this op
38. eats springs fillers and delivery unions tightening them at 3 5 4 Kgm Fit plungers by making reference points E match with the sector gear D points Fix retainers and springs lock tappet with special stop Check that both plungers have the same delivery by performing the necessary measurements at the test bed if delivery is not the same set screw F How to mount injection pump on the engine Tighten screws at 2 5 Kgm Check that rack rod slides smoothly if not the engine may fail to start or hunt Injection pump mechanical speed governor timing Loosen screw 1 Move injection pump lever 2 to maximum delivery to the right Check that drive rod 3 closes the speed governor keeping lever 2 pressed to the right the drive rod should have no clearance Tighten screw 1 COMPILER T 00 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M mimea revision 01 ZN 1 5302 286 50494 06 88 30 03 200 STATIC INJECTION TIMING Disconnect injection line on cylinder 1 making sure not to loosen the pump delivery union Attach the timing tool shown below Injection timing checking device Components 1 Union 2 Tube 3 Sleeve 4 Transparent body seria No 7271 9727 003 This device allows for immediate monitoring of the fuel flow through its transparent portion Dimensions mm Q1 10 00 02 0 60 O3 2 00 O4 6 50 A 29 00 B 20 00 C 25 00 D 45 00 121 122 Inj
39. ection timing check Top up the tank checking that fuel level is atleast 10 cm above cheeking device Adjust injection pump rack rod at half stroke Turn the flywheel according to the engine direction of rotation and check that fuel reaches the checking device Repeat this last operation during compression proceed slowly and stop immediately when the fuel is seen to pass through the checking device hole bring flywheel back by 5 mm this is the so called static injection timing R T5 d 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M Revision 01 ZN 1 5302 286 50494 06 88 30 03 200 Injection timing reference marks on crankcase and flywheel A Piston reference mark at the top dead centre B Injection timing reference mark compared to A A B Distance in mm C Piston reference mark in injection timing position a Reference angle in degrees Engine type mm ci 9LD561 2 61 66 24 26 9LD561 2 L 56 61 22 24 9LD625 2 63 5 685 25 27 124 Check window for injection timing reference mark Components 1 Window 2 Injection timing reference mark A window is provided to identify the reference mark corresponding to the above mark C 125 Injection timing correction If reference mark C does not match with B follow examples 1 and 2 1 Example of late injection timing remove shims under the pump to make C match with B 2 Example of early injection timing ad
40. eration keeping drive rod E as shown in the figure 6 Release brake completely and check at what speed the engine becomes stable Speed governor should comply with the requirements of the class indicated by the manufacturer of the device 7 Stop the engine 8 Check valve clearance when the engine has cooled down Required settings as most commonly applies Specific fuel consumption Engine R P M HP kW Time sec h 100 g kW h 8028 208 RS 25 De a 228 910 625 2 poe 8905245 Theindicatedspecificfuelconsumptionreferstotheperiodfollowing approximately 30 working hours 158 159 R T5 d 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED WMT ism els Revision 01 A2 ZN 1 5302 286 50494 06 88 30 03 200 SETTINGS Stop setting 1 Completely turn lever C counterclockwise and keep it in this position Retainer F should not be in contact with lever C 2 Unscrew nut G and bring retainer F in contact with lever C 3 Push retainer F so that lever C is moved backwards clockwise by 1 0 1 5 mm 4 Lock retainer F by screwing nut G Note Under these conditions no damage can be caused to the injection pump rack rod stops by sudden impacts due to the available electric stops 160 COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 STORAGE STORAGE Prepare engi
41. iffering from those given above R TE d 20 REG CODE MODEL N DATE OFISSUE DATE ENDORSED Tpirmelas revision 01 WO ZN 1 5302 286 50494 06 88 30 03 200 OVERALL DIMENSION 9 LD 561 2 9 LD 561 2 L Stat A Ao zog pa LAN Si x 5 m D Log ANS e COMPILER T 00 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M prim elle revision 01 D ZN 1 5302 286 50494 06 88 30 03 200 OVERALL DIMENSION 9 LD 625 2 5 i it an 5 SEE e 19 JU LL 2 to 8 77 30 TET 454 486 d R TE d 20 REG CODE MODEL N DATE OF ISSUE DATE pein eh revision 01 ZN 1 5302 286 50494 06 88 30 03 200 VII MAINTENANCE RECOMMENDED OIL TYPE REFILLING Failure to carry out the operations described in the table may lead to technical damage to the machine and orsystem ENGINE MAINTENANCE 9 LD 561 2 561 2 L 625 2 INTERVAL HOURS OPERATION COMPONENT 8 100 300 2500 5000 OIL BATH AIR CLEANER FEED PUMP FILTER CLEANING HEAD AND CYLINDER FINS FUEL TANK INJECTORS INTERNAL OIL FILTER AIR CLEANER OIL CRANKCASE OIL
42. il pressure warning light 7 Key switch 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 12 V voltage and capacity not below 70 Ah 12 5 V 14 A Alternator Features a fixed armature winding mounted on the air shroud bracket The rotating permanent magnet inductor is located in the fan spindle Dimensions mm A 158 80 159 20 B 27 50 27 90 Note Clearance between armature winding and inductor air gap should be 0 48 0 60 mm COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE FENDORSEB pein eh revision 01 ZN 1 5302 286 50494 06 88 30 03 200 r p m T min U min 134 135 Alternator battery charger curve 12 5 V 14A The curve was obtained at room temperature of 25 C with 12 5 V battery voltage 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 slider so that its reference line coincides with the casing reference line Release slider if no attraction occurs the rotor is demagnetized therefore replace
43. led on the gear side 3rd p t o Hydraulic pump p t o 1 Components 1 Seal ring 2 Centering ring 3 Coupling 4 Half coupling 5 Flange 6 Gear 7 Bracket 8 Thrust washer 9 Stop ring 10 Cover The maximum total torque is thus 3 Kgm corresponding to 12 5 HP at 3000 r p m Reduction ratio 1 1 MECHANICAL SPEED GOVERNOR Weight type governor housed inside the camshaft drive gear Mechanical speed governor Components 1 Gear 2 Weight 3 Mobile bell 4 Stop ring 5 Thrust washer 6 Yoke 7 Lever 8 Drive rod 9 Governor spring 10 Rack control lever Weights are moved to the periphery by the centrifugal force and thus axially shift a mobile bell connected to the injection pump rack control lever by a linkage A spring placed under tension by the accelerator control offset the weight centrifugal force Balance between the two forces keeps speed at an almost constant level in spite of load variations See page 44 for timing COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE FENDORSEB Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII Governor springs with rocker arm The system features two springs anchored to a rocker arm and allows for minimal r p m changes at low speed levels Governor springs with rocker arm Components 1 Rocker arm for spring anchoring 2 Governor springs 3 Plate 4 Link 5 Lever Spring for extra fuel supply at starting Components
44. lf stroke Turn flywheel according to its direction of rotation 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 plunger How to check injection pump delivery valve sealing Components 1 Valves 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 plunger Test data for injection pump delivery For 9LD561 2 and 9LD561 2 L Rod stroke SE from max RPM dELIVERY ys bad deliv point Dee om ene mme Check only maximum plunger difference by positioning rack rod according to the indicated delivery value For 9LD625 2 Control rod Rod siroke Max plunger max force Trom max peler es deliv point az 0 150 3 i 51 FUEL SYSTEM How to reassemble injection pump components After replacing the worn out components reassemble the pump as follows Introduce sector gears into the pump body by making reference points C match with the B points on the rack Fix barrels with the eccentric screws F on the pump body Fit valves with s
45. meter P The potentiometer can be fitted on the control box or on the control panel P1 see page 35 The whole system makes it possible to keep the engine speed constant independently of the load conditions It detects speed through the r p m sensor mounted on the crankcase at the ring gear level As the number of revolutions changes the device immediately performs the required corrections by means of the actuator acting on the injection pump Electromagnet T responds to max fuel delivery fuel flow setting and when energized enables the injection pump rack rod to reach its maximum stroke extra fuel supplied at starting M mimea REVISION ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII Starting with electronic speed governor see lay out on page 44 In position O the engine is not working and no part is energized The rack rod is in stop position retained by two springs 10 inside actuator A By rotating key C to position 2 the electromagnet with draws allowing the rack rod to reach its highest delivery being connected to the actuator at its max level of energization When the engine immediately after starting reaches 1000 r p m the controller reduces the actuator position after 1 second switches off the electromagnet T and after more 0 5 seconds returns at his normal position with the engine speed set as per position of potentiometer P1 Engine running with electronic speed governor The engi
46. n 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 Tighten bolts at 4 Kgm See page 32 for dimensions REG CODE MODEL N DATE OF ISSUE DATE d op pein eh revision 01 ZN 1 5302 286 50494 06 88 30 03 200 A VIII DISASSEMBLY REASSEMBLY Crankshaft timing gear Use tool 1 Part No 7560 4000 052 and puller 2 Part No 7271 3595 048 to remove the gear Main bearing support gear side Remove main bearing by means of two M8x1 25 screws with fully threaded length of 40 mm or a puller Part No 7271 3595 048 Note To avoid deformation it is not recomended to replace the bearing bushing complete assembly s of bushing and support are available in standard 0 25 mm and 0 50 mm undersize configurations as spare parts See page 32 for dimensions Main bearing support flywheel side Remove it by means of two M8x1 25 screws with fully threaded length of 40 mm Check oil seal ring and replace if warped hardened or worn out When refitting tighten nuts at 2 5 Kgm See end float on page 31 for gasket replacement detaiis See page 31 for dimensions COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE FENDORSEB MYT pein eh revision 01 ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII CRANKSHAFT Center main bearing support locating
47. ne starts running at the pre set speed Potentiometer P is located either inside the control box E or on control panel P1 In case of an external potentiometer P1 the engine speed can be set at any point between the idling and full speed in on load conditions setting performed on the control box in the test room The electronic control box E controls actuator A by sending or cutting off the power supply to keep the speed set through P1 constant independently of the absorbed load Control box E prevents the engine from starting or stops it in case of no power supply or in case connection with r p m sensor S is broken or short circuited Electronic speed governor control box Control box E features four setscrews which must be positioned on the test bed torque dynamometer along with the engine a Setscrew for speed control r p m b Setscrew for sensitivity adjustment when the engine is running at full speed C Setscrew for sensitivity adjustment at low speed d Setscrew for extra fuel release once correctly positioned this set screw is generally sealed R REG CODE MODEL N DATE OFISSUE DATE d op Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 LUBRICATION SYSTEM The engine can be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed Use suitable oil in order to
48. nes as follows for storage over 30 days Temporary protection 1 6 months Let engine work at idling speed in no load conditions for 15 minutes Fill crankcase with protection oil MIL 1 644 P9 and let engine run at 3 4 f ull speed for 5 10 minutes When engine is warm empty oil pan and fill with standard new oil Remove fuel tube and empty the tank Remove fuel filter replace cartridge if dirty and refit Carefully clean cylinder fins heads and fan 161 Seal all openings with tape Remove injectors pour a spoonful of oil type SAE 30 into the cylinders and rotate manually to distribute the oil Refit injectors Spray oil type SAE 10W into exhaust and intake manifolds rocker arms valves tappet etc Grease all unpainted parts Loosen belt Wrap the engine in a plastic film Store in a dry place if possible not directly on the soil and far from high voltage electric lines Permanent protection over 6 months The following is recommended apart from the above instructions For the lubrication and injection system as well as for moving parts use rustproof oil type MiL L 21260 P10 grade 2 SAE 30 Ex ESSO RUST BAN 623 AGIP RUSTIA C SAE 30 Let the engine run with rustproof oil and drain any excess Coat external unpainted surfaces with antirust type MIL C 16173D grade 3 Ex ESSO RUST BAN 398 AGIP RUSTIA 1001F How to prepare the engine for operation Clean engine outside Remove protections
49. or quality fuel types 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 working 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 R TEO 2D REG CODE MODEL N DATE OF ISSUE DATE M revision 01 ZN 1 5302 286 50494 06 88 30 03 200 io BS INTRODUCTION This manual contains pertinent information regarding the repair of LOMBARDINI air cooled direct injection Diesel engines type 9 LD 561 2 9 LD 561 2 L 9 LD 625 2 updated March 30 2003 TABLE OF CONTENTS TROUBLESHOOTING Pag 9 Il SAFETY DECALS SAFETY INSTRUCTIONS 10 11 I MODEL NUMBER AND IDENTIFICATION 12 IV TECHNICAL DATA 13 V CHARACTERISTIC CURVES e 15 VI OVERALL DIMENSIONS 16 17 MAINTENANCE RECOMMENDED OIL TYPE REFILLING 18 19 Vill DISASSEMBLY REASSEMBLY 21 45 Oil vapour separator 2 5 5505 2 2 s s 22 Oil bath air cleaner 21 Alleato ae ros ias Meath Pot te sb o ate E a HS e 24 CAMSHARD St aad ro Led ile a be S
50. po a ox You 39 Camshaft end play gt 00 40 Camshaft timing 0 0o o 40 Checking main journals and crank 0 aL 36 Checks and cylinder roughness A E aA G Lia Rag 30 Clearance between main journals crank pins and connecting rod bearings 37 Clogging indicator 0 2 55 5502 s 22 Compression release optional 5 ls 25 CONNECTING ROD 0o oo oo o 32 Connecting rod alignment o 33 Connecting rod big end bearing a ooo oS 33 Connecting rod small end bushing 32 Connecting rod weight 0 2 a L 33 Cooling 23 a eects resin Lom Won uui ee ino Mm pen ed te ne EI EE UE OR oe px quem 35 Crankshaft center main bearing support 35 Crankshaft end play 0 0o ooo 38 Crankshaft journal radii 0 0 0 oo oo 36 Crankshaft lubrication ducts a o oo o s 36 Crankshaft removal 0 050 20 ooo 35 Crankshaft timing gear o 34 CYLINDERN sume cut tees t EL n Gne PR i MON 2 30 CYLINDER HEAD ooo ooo ls 26 Dimensions and clearance between guides and valves mm 28 Dimensions of camshaft journals and housings mm 39 Dry airclearner zm aya pue 1 RE Rd Wok M Gud hoe dones de Ede E d 21 ELECTRONIC SPEED GOVERNOR sss dd oo oo o s 44 Electronic speed governor 2 20 0005 5005050552552 2 2 ss 44 Electronic speed governor
51. 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 Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time Wear protective gloves to avoid touching used oil 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 LUBRICATION SYSTEM ANDBREATHERRECIRCULATION SYSTEM 1 9 2 10 3 11 4 12 5 13 6 14 T 15 8 16 97 Components 1 Oil pressure switch 2 Breather 3 Connecting rod big end bearing 4 Crankshaft main bearing on gear side 5 O l pressure relief valve 6 Fitting tor pressure gauge connecl lon 7 Cartridge filter 8 Oil pump 9 Oil fill plug 10 Rocker arm shafts 11 Pushrod protection tube 12 Hydraulic pump gear 13 Camshaft joumal on fiywheel side 1 Cil dipstick 15 Drain plug 16 Internal filter COMPILER D REG CODE MODEL N DATE OF ISSUE DATE ENDORSED pul sl eo ge hr mum AAA REVISION 01 1
52. qualified personnel only The list of the 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 agreements 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 The repair 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 Any seal affixed to the engine by Lombardini has been tampered with or removed Spare parts used are not original Lombardini Feeding and injection systems are damaged by unauthorized or po
53. rbehalt alle Rechte diese Angabe jederzeit verandern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicaci n COMPILER TECH MODEL N DATE OF ISSUE DATE ENDORSED i 22 Tpirmelas revision 01 LN 02 286 0494 06 88 30 03 200
54. rd 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 SERVICE WARRANTY CERTIFICATE 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 To ensure the engine warranty is valid the engine installation considering the product technical features must be carried out by
55. 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 Engage camshaft gear with crankshaft gear COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE FENDORSEB Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII Valve timing check Check valve timing at the crankshaft The values shown are checked at the flywheel circumference with flywheel of 291 mm diameter each degree corresponds to 2 5 mm Set valve clearance at 0 65 0 70 mm after checking restore the value at 0 1520 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 a intake valve opening advance referred to top dead centre S and B intake valve closing delay referred to bottom I dead centre Follow the same procedure for exhaust valves checking y exhaust valve opening advance and 6 exhaust valve closing delay in the case of 9LD625 2 6 is advanced by 1 compared to S 9LD561 2 2 34 34 6 2 9LD625 2 a 1 21 23 1 R TE d 2D REG CODE MODEL N DATE OF ISSUE DATE M revision 01 ZN 1 5302 286 50494 06 88 30 03 200 VIII DISASSEMBLY REASSEMBLY Hydraulic pump p t o A hydraulic pump of group 1 1 P or 2 2P can be instal
56. the ammeter current suddenly drops down to almost zero Replace regulator if recharge current is zero with voltage below 14 V Warning 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 might damage it No electric welding on engine or application 141 iiio po po En 01 di ir NEA 59 mum amp aa REVISION ZO 1 5302 286 50494 06 88 30 03 200 mo LN OPTIONAL ELECTRIC EQUIPMENT 12 V 18A Alternator Only two yellow cables are at output Dimensions mm A 158 80 159 20 B 27 50 27 90 Note Clearance between armature winding and inductor air gap must be 0 48 0 60 m m 142 Alternator battery charger curve 12 V 18 A This curve is obtained at 25 C with 12 5 V battery voltage Giri T 1200 1600 2000 2400 2800 3200 3600 1800 2200 2600 3000 3400 12 V 24 A special voltage regulator The special LOMBARDINI SAPRISA voltage regulator is of the bridge type See page 48 for tag dimensions 144 M pen elite REVISION ZN 1 5302 286 50494 06 88 30 03 200 Alternator type Bosch G1 14 V 33A The alternator is of the claw pole rotor type with built in voltage regulator The rotating motion is conveyed by the engine through a V belt and sheave Features
57. the latter case must only be carried out by persons specifically trained by Lombardini and who work in compliance with the existing documentation e 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 e 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 thatthe 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 e Make sure that the machine is stable to prevent the risk of overturning e Become familiar with how to adjust the rotation speed and stop the engine e Neverstart the engine ina closed place or where there is insufficient ventilation Combustion creates carbon monoxide an odourless and highly poisonous gas Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death COMPILER T 20 REG CODE MODEL N DATE OF ISSUE DATE FENDORSEB NV Tpirmelds revision 01 ZN 1 5302 286 50494 06 88 30 03
58. tting tighten nuts at 2 5 Kgm See page 18 for periodic maintenance details Components 1 Bowl 2 Oil level mark 3 Filtering element 4 Seal ring 5 Internal seal ring 6 Cover 7 Clamp 8 Prefilter Dry air cleaner optional for models 9LD561 and 9LD561 2 L 1 Hand wheel 2 Cover 3 Cartridge 4 Seal ring 5 Bracket 6 Clogging indicator Note Replace cartridge immediately when indicator shows that is clogged Em REG CODE MODEL N DATE OF ISSUE 01 DATE oN mum amp aa REVISION ZI 1 5302 286 50494 06 88 30 03 200 mo LN VIII DISASSEMBLY REASSEMBLY Clogging indicator Components 1 Reset button 2 Transparent indicator Note Indicator is calibrated at 600 650 mm column of water Oil vapour separator Fitted to engines with dry air cleaner Screw it out of the shroud bracket carefully wash with gasoline inside and blow out with compressed air When refitting connect with intake manifold by means of the special rubber hose ei EE Intake manifold Check flange surface for warpage and correct if necessary Before refitting check that heads are in line Replace gaskets Tighten nuts at 2 5 Kgm Note In case of low temperature starting we can supply a manifold with possibility of fitting a glow plug with air preheating M mimea REVISION ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII Exhaust manifold Check that the inside is clean
59. uides with outside diameter increased by 0 5 mm are also available in such cases valve guide bore C shouid also be increased by 0 5 mm Valve guide insertion Heat cylinder head up to 160 180 C Press guides considering the A and B distances from the head plane Dimensions mm A 30 80 31 20 24 80 25 20 for 9LD561 2 and 9LD561 2 L C 20 3 20 7 for 9LD625 2 Note If guides are seated with stop ring C first locate the ring in place and then position guides without considering A and B Dimensions and clearance between guides and valves mm A 8 030 8 045 B 7 985 8 000 A B 0 030 0 060 A B limit value 0 15 M REVISION PS ZN 1 5302 286 50494 06 88 30 03 200 DISASSEMBLY REASSEMBLY VIII Valve seats and housings Dimensions mm A 40 000 40 016 intake valve housing dia 40 120 40 140 intake valve seat dia C 34 000 34 016 exhaust valve housing dia D 34 120 34 140 exhaust valve seat dia Press valve seats into the housings and cut ot at 45 Valve seat grinding After cutting grind valve seats with fine emery paste in oil suspension The sealing surface S should not exceed 2 mm Valve recess after grinding D 0 75 1 25 mm maximum worn limit 1 65 mm Pushrod tube When refitting cheek that gaskets A and rocker arm lubrication tube C are well inside their seats y i HUN M R T5 d 20 REG CODE MODEL N DATE OF ISSUE DATE ENDO
60. ve at idling speed 200 48 Oil pressure curve at full speed 0 a a a 48 FUEL SYSTEM 49 55 STATIC INJECTION TIMING iul Le bon Qe E Re a ai 53 Check window for injection timing reference mark 54 Fuel feeding pump oo s 49 Fuel feeding pump drive rod protrusion 0 0 49 Fuel feeding injection circuit L 49 Fuel filter inside fuel tank 49 How to check injection pump delivery valve sealing 0 a a a a L 51 How to check plunger and barrel for internal leakage e 51 How to mount injection pump on the engine 52 How to reassemble injection pump components 000 52 R T5 d 20 REG CODE MODEL N DATE OF ISSUE DATE ENDORSED M Revision 01 4 ZN 1 5302 286 50494 06 88 30 03 200 INTRODUCTION XI XII XIII XIV 6 INJECTION PUMP 222222220 50 Injection pump oa oo oo o o 50 Injection pump mechanical speed governor timing e 52 Injection timing check 0 o o Soa m9 odo TOR eee to eR ee Re 53 Injection timing check 54 Injection timing checking device 53 Injection timing correction 00 54 INJECTOR ti unde de o eie DX Gh oed Ae dede RB dp dh me De de Rh RR 55 Injector setting 55 2726 iii a eA EE Sam n do AA LE ates 2 ADI ote an Aert oto sa Pod 55 Plunger and Barrel Assembly 0 00 00 50 Test data for injection pump delivery 51 ELECTRIC SYSTEM 56 63 12 V 24 A special voltage regulator 60

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