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SERVICE MANUAL

1. Q LOMBARDINI TECHNICALINFORMATION 2 service manual 22 mod 051135 5 LOMBARDINI MALFUNCTIONS 3 3 1 LOOKING FOR MALFUNCTIONS The following information is provided to help identify and correct any irregularities and malfunctions that may arise during use Problem o E 8 2 Q S P 8 S E S o i Q 2 S n 5 S gt cz S o 2 o s o 5 1s L lt 513 855 Probable cause o s S 9j5o 9 R A D S 5 15 512 Els 5 c c S o 3 5 s D S S ELS 5 e 85 8 o S x Lu Clogged pipes Clogged fuel filter Air in the fuel circuit Clogged tank breather Faulty fuel pump Blocked injector Blocked injection pump valve Injector not adjusted Excess leaking in the plunger Jammed injection pump delivery control Wrong injection pump delivery setting High oil level Blocked pressure relief valve Worn oil pump Air in the oil intake pipe Faulty pressure gauge or switch Clogged oil suction hose Burnt fuse on pre heating glow plugs Failure in glow plugs control unit Discharged battery Inefficient or wrong cable connection Faulty ignition switch Faulty starter motor Air filter clogged Excessive idle operation Incomplete running in Overloaded engine Clogged cool
2. LOMBARDINI A ACEA Standards 14 Adjusting injection delivery 60 Adjusting injection delivery with dyno brake 61 Adjusting injection delivery without dyno brake 60 Adjusting minimum and maximum idle speed rpms 60 Adjusting static injection timing 55 Adjusting valve rocker arm clearance 52 Air filter replacing 86 Alternator fan blet replacing 83 Alternator load curve diagrams 13 Alternator replacing 87 API MIL sequences 14 Assembling injection pumps 73 Assembling the belt drive cover 77 Assembling the camshaft 71 Assembling the cooling fan 80 Assembling the crankcase 66 Assembling the crankshaft 66 Assembling the crankshaft flange flywheel side 67 Assembling the cylinder head 71 Assembling the exhaust manifold 80 Assembling the fan belt drive 79 Assembling the fan belt drive pulleys 78 Assembling the flywheel 69 Assembling the intake manifold 80 Assembling the mechanical fuel pump 74 Assembling the precombustion chamber 70 Assembling the rocker arm cover 75 Assembling the rocker arms 75 Assembling the speed governor and flow limiter 72 Assembling the timing belt 76 Assembling the timing belt pulley 76 Assembling the valves 64 B Balancing injection pump delivery 58 Bearings 41 Belt drive cover assembling 77 c Calibrating the injector 53 Cam dimensions table 50 Camshaft dimensions table 49 Camshaft assembling 71 Camshaft c
3. 5 6 2 Disassembling the oil pump 1 Remove the flange D 2 Extract the key E from the crankshaft 3 Bring piston number one flywheel side to the top dead centre with the oil pump activation key in line with break in the flange in order to be able to remove it oil pump activation key crankshaft AN Important You should in no way try to force removal of the pump if its activation key is not lined up with the break in the flange 4 Remove the oil pump F 5 Take off the gasket G service manual 2 37 2 mod 051135 5 LOMBARDINI REMOVING THE ASSEMBLIES D 5 6 3 Disassembling the crankcase and crankshaft 1 Removethe flange H 2 off the gasket L 3 Remove the crankcase M 4 Remove the connecting rod cap N A Caution Warning Before removing the cap mark the area of contact with the connecting rod in order to recognise the right position during reassembly 5 Remove the crankshaft P and place it in a container for washing service manual 38 mod 051135 Q LOMBARDINI REMOVING THE ASSEMBLIES 5 5 6 4 Disassembling connecting rod and piston 1 Extract the connecting rod piston assembly Q 2 Remove the crankshaft half bearings N Caution Warning Before removing the crankshaft half bearings mark the seat position in order to recognise and match it up during reassembly bearing
4. 5 LOMBARDINI 8 10 REPLACING THE COOLANT PUMP AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disassemble the cooling fan see Removing the cooling fan belt drive 3 Disassemble the timing belt drive see Removing the timing belt drive 4 Disassemble the coolant pump 5 Install a new pump and tighten the screws to a torque of 20 Nm AN Important Following a failure the coolant pump cannot be repaired and must be replaced with an original spare 8 11 REPLACING THE THERMOSTATIC VALVE AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Remove the cover 3 Remove the valve and make sure it is working properly AN Important The valve must be heated in order to check weather it is functioning correctly Dip the thermostatic valve in a metal container of water Use a thermometer with a full scale of 150 C to monitor the temperature of the water in the container Heat the water and using the thermometer make sure that the temperature at which the valve begins to open is between 78 and 82 C If the thermostatic valve opens at a different temperature it must be replaced Maintaining the conditions described above heat the water to 94 C and check whether or not the valve is completely open at this temperature
5. 7107 1460 048 Instrument for balancing injection pump delivery Tool for lowering injection advance control valve 7107 1460 030 7107 1460 074 Precombustion chamber extractor 9 gt A e 8 Equipment for injection advance control and injector calibration 7107 1460 029 7107 1460 051 Pin wrench for ring nut pump injector pumping element Driving shaft clamping tool 7107 1460 027 7107 1460 031 Precombustion chamber pin wrench Pivot pin precombustion chamber 7107 1460 047 7271 1460 049 SF Tool for mounting intake exhaust valve guide gasket Tool for adjusting timing belt tension 2 11 TABLE FOR TIGHTENING TORQUES The table shows the tightening torques for standard screws and the main components Tightening torques are provided again along with method and sequence in the instructions for assembling components and or assemblies Tightening torques for standard screws coarse thread Resistance class R Quality Dimensions R gt 400N mm R gt 500 R 600N mm R2800N mm R 1000N mm Diameter Nm Nm Nm Nm Nm Nm 0 5 0 7 0 6 1 1 4 1 9 1 1 1 5 1 4 2 2 2 9 4 1 2 3 3 2 8 4 5 6 8 5 3 8 5 4 7 7 5 10 14 9 4 13 12 19 25 35 18 25 23 37 49 69 32 43 40 65 86 51 68 63 79 98 service manual 19 mo
6. C LOMBARDINI INSTALLATION OF ASSEMBLIES 7 5 2 Assembling the crankshaft 1 Mount the half bearings C and the standard shoulder half rings E flywheel side AN Important Follow the marks made during the removal phase The shoulder half rings must be placed with the lubrication grooves facing outwards 2 Lubrificate the half bearings C the connecting rod big ends D and caps F 3 Carefully lubricate the crankshaft main journals and crank pins 4 Assemble the crankshaft G 5 Replace the connecting rod caps F and put in the screws 6 Tighten the connecting rod cap screws to a temporary torque of 25Nm 7 Tighten the connecting rod cap screws to a final torque of 30Nm 8 Assemble the crankcase see Assembling the crankcase 9 Measure the axial clearance of the crankshaft see Measuring crankshaft axial clearance 7 5 3 Assembling the crankcase AN Important Make sure that the contact surfaces and related pins are perfectly intact and clean Make sure there are no foreign bodies or residual material in the engine block and crankcase 1 Mount the new gaskets H1 H2 for the engine block contact surface with the crankcase 2 Replace the crankcase H and put in the screws L M 3 Tighten the screws L temporarily in a crisscross pattern service manual 66 mod 051135 C LOMBARDINI INSTALLATION OF ASSE
7. 6 Reconnect the electric cable 7 Mount the intake manifold see Assembling the intake manifold service manual 90 mod 051135 LOMBARDINI REPLACING PARTS 6 8 14 REPLACING INJECTOR PUMP PARTS Exploded diagram of the injector pump The figure shows the injector pump parts Caption 1 Tension washer 2 Tappet 3 Stop collar 4 Plunger Spring Screw Support Lever Ring nut 10 O ring 11 Barrel 12 Delivery valve 13 Gland 14 Spring 15 Filler 16 Pin 17 O ring 18 Non return valve 19 O ring 20 Metal gland 25 Preassure rod 30 Plunger guide new type 26 Spring 31 O ring 21 Ring nut 27 Setting adjusting shim 32 Copper gland 23 Nozzle 28 Injector case 24 Spacer 29 Control blade 8 14 1 Pumping element replacement 1 Press down hard on the pump collar to fit the pin A 2 Disassemble the lock ring 1 3 Press down hard on the pump collar to remove the pin A 4 Remove the parts 2 3 4 5 5 Loosen the screws 6 6 Disassemble the support 7 and the lever 8 7 Insert tool 7107 1460 029 and disassemble the ring nut 9 AN Important sealing surfaces Rotate in an alternating way the ring nut during disassembling to avoid damaging 77 B G the O ring 10 delivery valve 12 8 Extract the barrel 11 the valve 12 as well as the parts 13 14 15 service manual 91 mod 051135 A LOMBARDINI
8. 1 Switch off the engine and leave to cool 2 Remove the cover C 3 Extract the cover that is to be replaced D 4 Clean the cover with a jet of air 5 Replace the cartridge with an original spare 6 Mount the cover and hook it carefully into place service manual 86 mod 051135 A LOMBARDINI REPLACING PARTS 8 8 6 REPLACING THE ALTERNATOR AN Caution Warning Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disconnect the battery 3 Disconnect the electrical connectors 4 Loosen the nut A 5 Loosen the belt C by adjusting the alternator B manually 6 Slip the belt C off the alternator pulley 7 Remove the alternator and replace it with anew one 9 Regulate belt C tension see Replacing alternator fan belt 8 Insertthe belt into the alternator pulley 10 Reconnect the electrical connectors 8 7 REPLACING THE STARTER MOTOR A Caution Warning Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disconnect the electrical connectors 3 Remove the starter motor AN Important If in order to take care of the problem it is necessary to remove the motor please refer to an authorised BOSCH service centre 4 Install the starter motor A and tighten the screws 5 Tighten the screws to a final t
9. Check that all components are intact and if necessary replace them with original spares 1 Mountthe levers C and pivot them with the screw D to a torque of 0 70 Nm 2 Install the flow limiter 3 Mount the rotation components onto the camshaft AN Important The rotation components are produced in several versions Consult the diagram when mounting 1 Mount the weights assembly onto the camshaft Carry out this operation with the weights open so that they close on the flat part of the spacing collar 2 Check that all the components of the cover Governor counterweight L are intact and if necessary replace ee entire support them with original spares A Important Make sure that the contact surfaces are perfectly intact and clean 3 Mountthe new O ring on the cover L 4 Mount the cover L and fasten the screws without tightening them 5 Tighten the screws in an alternating pattern to a final torque of 10 Nm AN Important Check that the camshaft has no axial clearance service manual 72 mod 051135 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 6 5 Assembling injection pumps AN Important Check that all components are intact and if necessary replace them with original spares Before replacing the injectors it is always necessary to replace the flameproof bulkhead the copper gasket and the oil and diesel O ring seals Always m
10. Replace worn or damaged parts exclusively with original LOMBARDINI spare parts This will contribute to ensuring better performance and longer product life service manual 6 mod 051135 5 LOMBARDINI Use the oils and greases recommended by the manufacturer Do not mix different brands or oils with different characteristics Use a torque wrench to tighten the main fixing points of engine components Stick to the tightening torques indicated by the manufacturer 1 8 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 1 9 Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact GENERAL REMARKS AND SAFETY 1 Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations The engine has been designed and built to satisfy all the operating conditions described by the manufacturer Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer In order to minimise the impact on the environment the manufacturer now provides a number of indicatio
11. Replacing the air filter 86 Replacing the alternator 87 Replacing the alternator fan belt 83 Replacing the coolant pump 89 Replacing the coolant thermostat 88 Replacing the cooling fan support 93 Replacing the flywheel ring gear 88 Replacing the negative preassure vent valve 90 service manual 96 mod 051135 5 LOMBARDINI Replacing the nozzle injector 93 Replacing the oil filter 85 Replacing the starter motor 87 Replacing the theromstatic valve 89 Replacing the timing belt 85 Rocker arm pin dimensions table 48 Rocker arm valve clearance adjusting 52 Rocker arm cover assembling 75 Rocker arm cover disassembling 33 Rocker arm pin checking and overhauling 48 Rocker arm disassembling 33 Rocker arms assembling 75 Routine engine maintenance 21 S SAE Classification 14 Safety and environmental impact 7 Sealants table 21 Sealing rings pistons pre assembly 63 Sealing rings clearance table 43 Sealing rings dimensional check 43 Sealing rings dimensional table 43 Shaft seals 41 V Valve rocker arm clearance adjusting 52 Valve adjustments 54 Valve guides springs valve stems dimensions table 51 Valve stems springs valve guides dimensions table 51 Valves assembling 64 Valves checking and overhauling 51 Valves disassembling 39 Valves installing 64 Warranty clauses 6 Wiring diagram 17 Special tools a
12. 9 Check the good seal of the delivery valve 12 as well as of the pumping element parts 4 11 If necessary replace them with original spare parts 10 Assemble all parts 15 14 13 11 Assemble the delivery valve 12 AN Important The needle B and the valve seat C must be assembled as shown in the figure 12 Assemble the barrel 11 and tighten the ring nut 9 provided with a new O ring 10 sealing surfaces Important Rotate in an alternating way the ring nut during assembling to avoid damaging the O ring 10 delivery valve 12 13 Assemble in sequence all parts 5 4 3 2 on the support 7 14 Press down part 2 to fit the pin A 15 Reassemble the stop ring 1 16 Rotate the plunger 4 by means of the control blade 29 as shown in the figure 17 Insert the lever 8 and engage it in the plunger 4 AN Caution Warning Check that the position of both lever 8 and plunger control blade 29 isthe same as that shown in the figure If the control blade is positioned ina different way the engine may not run 18 Tighten the screws 6 to join the support to the injector pump case 19 Press down hard on the pump collar to remove the pin A REPLACING PARTS 8 service manual 92 mod 051135 A LOMBARDINI REPLACING PARTS 8 8 14 2 Replacing nozzle injector AN Important Replacement may be carried out with the
13. Piston and connecting rod disassembling 39 Piston disassembling 40 Pistons connecting rods pre assembly 64 Pistons sealing rings pre assembly 63 Pistons and cylinders overhauling 41 Pistons dimensional check and overhaul 42 Pre assembly of connecting rods pistons 64 Pre assembly of sealing rings pistons 63 Precautions when the engine is installed on the machine 7 Precautions when the engine is on the rotating stand 7 Precombustion chamber assembling 70 Precombustion chamber disassembling 34 Pre heating glow plugs replacing 90 Preparing the engine for operation istalled 27 Preparing the engine for operation unistalled 26 Protective treatment 26 Pulleys camshaft and crankshaft disassembling 32 Pumping element replacement 91 Purpose of the manual 5 R Raccomandazioni per l installazione dei gruppi 63 Recommendations for installing the assemblies 63 Recommendations for overhauls and tuning 41 Recommendations for removing the assemblies 29 Recommendations for replacing parts 83 Recommended oil 14 Removing the assemblies recommendations 29 Removing the cooling fan belt drive 30 Removing the crank gear and crank case 36 Removing the cylinder head 33 Removing the exhaust and intake manifolds 29 Removing the timing belt drive 31 Replaceing the pre heating glow plugs 90 Replacing and checking the camshaft 49 Replacing injector pump parts 91 Replacing parts recommendations 83
14. engine installed on the machine 1 Disassemble the injection pump see Disassembling injection pumps 2 Loosen the ring nut 21 3 Extract the nozzle 23 and the parts 24 25 26 27 4 Check that all components are intact and if necessary replace them with original spare parts 5 Reassemble the parts 27 26 25 24 6 Assemble a new nozzle 23 7 Tighten the ring nut 21 to a final torque of 70 Nm AN Important Check the setting see Injector pump setting since 8 Repeatthe same operation on the other injector it could be necessary to replace the adjusting shim 27 and the spring 26 9 Assemble the injector pump see Injector pump assembly 8 15 REPLACING THE COOLING FAN SUPPORT AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disassemble the cooling fan belt drive see Removing the cooling fan belt drive 3 Remove the belt drive cover see Disassembling timing belt casing 4 Remove the support A 5 Install the new support 6 Tighten the screws B to a torque of 20 Nm 7 Mountthe belt drive cover see Assembling the belt drive cover 8 Replace the cooling fan belt drive see Installation of the cooling fan belt drive service manual 93 mod 051135 Q LOMBARDINI REPLACINGPARTS service manual 94 mod 051135
15. 87 7 INSTALLATION OF ASSEMBLIES 8 7 REPLACING THE STARTER MOTOR 87 8 8 REPLACING THE FLYWHEEL RING GEAR 88 7 1 RECOMMENDATIONS FOR INSTALLING THE 8 9 REPLACING THE COOLANT THERMOSTAT 88 ASSEMBLIES ERES 63 8 10 REPLACING THE COOLANT PUMP 89 7 2 PRE ASSEMBLY OF 8 11 REPLACING THE THERMOSTATIC VALVE 89 SEALING RINGS PISTONS 63 8 12 REPLACING THE NEGATIVE PRESSURE VENT 7 38 PRE ASSEMBLY OF VALVE ere tl alee ri eer PC en eee odi 90 CONNECTING RODS PISTONS 64 8 13 REPLACING THE PRE HEATING GLOW PLUGS 90 7 4 INSTALLING VALVES eee 64 8 14 REPLACING INJECTOR PUMP PARTS 91 7 4 4 Assembling the valves 64 8 14 1 Pumping element replacement 91 7 5 INSTALLATION OF CRANK GEAR 8 14 2 Replacing the 221 93 AND CRANKCASE 65 8 15 REPLACING THE COOLING FAN SUPPORT 93 7 5 1 Installing piston connecting rod engine block 65 7 5 2 Assembling the crankshaft 66 INDEX eue T 95 7 5 8 Assembling the crankcase 66 7 5 4 Measuring crankshaft axial clearance 67 7 5 5 Assembling the crankshaft flange flywheel side 67 7 5 6 Installing the
16. Use a gauge to measure the length of the springs see Table of dimensions for springs valve stems valve guides Table of dimensions for springs valve stems valve guides E ca E Wear amp tear limit 7 00527 020 6 960 6 990 valve guide If the length does not correspond to the value shown replace the springs with original spares 2 Use a micrometer to measure the diameters of the valve stems and guides see Table of dimensions for springs valve stems valve guides If the diameters do not correspond to the values show replace the valves and guides with original spares AN Important Take measurements in several places in order to discover possible ovalization and or wear valve seat 3 Thoroughly clean the valves and their seats 8 Use the special tool to put the valve seats in the holder 4 Measure the width of the seal for each valve J and 9 Slide the valves into their seats the indentation W from the flat part of the cylinder head see Table of dimensions for springs valve 10 Measure the degree of indentation of each valve from stems valve guides If the dimensions do not the flat part of the cylinder head see Table of correspond to the values shown replace the valve seat dimensions for springs valve stems valve guides ring with an original spare Se le dimensioni rilevate corrispondono ai valori indicati smerigliare ogni valvola nella propria
17. clearance see Adjusting valve rocker arm clearance 6 10 CHECKING OIL PREASSURE 1 Remove the preassure switch A 2 Mounta union in the hole B and connect to a 10 bar pressure gauge C 3 Start the engine and bring it to the operating temperature 4 Startthe engine and bring itto a speed of 900 RPM while at the same time making sure that the pressure gauge shows a pressure of 1 bar oil temperature 80 120 5 Switch off the engine 6 Remove the pressure gauge C and the union B 7 Replace the pressure switch A and tighten it to a torque of 25Nm AN Important If the engine gives off too many fumes at maximum load loosen the flow limiter screw If it gives off no fumes or does not achieve maximum power tighten the flow limiter screw Table of specific fuel consumption per 100 cc g service manual 61 mod 051135 5 LOMBARDINI OVERHAULS AND TUNING 6 service manual 62 mod 051135 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 1 RECOMMENDATIONS FOR INSTALLING THE ASSEMBLIES Information is given in a logical order in terms of timing For safety and convenience you are advised to place and sequence of operations The methods have been the engine on a special rotating stand for engine selected tested and approved by the manufacturer s overhauls technical experts Before proceeding with operati
18. crankshaft clockwise through 360 in order to make the piston reaching magnetic the balancing top dead centre goniometer Apply a magnetic goniometer on the crankshaft pulley and set it to zero Place two dial indicators on the collars of the intake and exhaust valves then set them to zero Rotate the crankshaft clockwise until the dial indicator moves away from zero Measure the rotation angle of the crankshaft by using the magnetic goniometer The value registered indicates when the intake valve starts opening Go on rotating the crankshaft clockwise until the dial indicator stops at point O Measure the rotation angle of the crankshaft by using the magnetic goniometer The value registered indicates when the intake valve starts closing The values registered must coincide with those indicated on the timing angle diagrams see Distribution timing angle diagram 10 Repeat these procedures on the other valves Exhaust valve OVERHAULS AND TUNING 6 service manual 54 mod 051135 5 LOMBARDINI 6 5 DIAGRAM OF TIMING BELT RATES Rotate the crankshaft clockwise to find out the timing rates of the entire cycle in each cylinder operation and control Timing belt operating angles valve clearance 0 25 mm a 14 before S top ded centre 38 after I bottom dead centre y 34 I bottom dead centre 18 after S top ded cent
19. leave to cool rating 2 Disassemble the cooling fan belt drive see Removing 6 Mount the belt drive cover see Assembling the belt the cooling fan belt drive drive cover 3 Disassemble the timing belt drive see Removing the 7 Replace the cooling fan belt drive see Installation of timing belt drive the cooling fan belt drive 8 4 REPLACING THE OIL FILTER AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Prepare a receptacle to catch leaks 3 Remove the filter A using the special tool 4 Lubricate the new filter seal with engine oil 5 Install and tighten the filter manually AN Important Polluting substances should be disposed of properly in full compliance with the law service manual 85 mod 051135 Q LOMBARDINI REPLACINGPARTS 8 5 REPLACING THE AIR FILTER AS Important Polluting substances should be disposed of properly in full compliance with the law Replacement may be carried out with the engine installed on the machine Filtro a pannello 1 Switch off the engine and leave to cool 2 Remove the cover A 3 Extract the cover that is to be replaced B 4 Clean the cover with a jet of air 5 Replace the cartridge with an original spare 6 Mount the cover and hook it carefully into place Filtro a cartuccia
20. oil 68 7 5 7 Assembling the 69 7 6 INSTALLATION OF CYLINDER HEAD AND COMPONENTS 70 7 6 1 Assembling the precombustion 70 7 6 2 Assembling the cylinder head 71 7 6 3 Assembling the 71 7 6 4 Assembling the speed governor and flow limiter 72 7 6 5 Assembling injection 73 7 6 6 Assembling the mechanical fuel pump 74 7 6 7 Assembling the rocker 75 7 6 8 Assembling the rocker arm cover 75 7 7 INSTALLING THE TIMING BELT DRIVE 76 7 7 1 Assembling the timing belt pulley 76 7 7 2 Assembling the timing 76 7 7 3 Assembling the belt drive 77 7 8 INSTALLATION OF THE COOLING FAN BELT DRIVE itn te eire s 78 7 8 4 Assembling the fan belt drive pulleys 78 7 8 2 Assembling the fan belt 79 7 8 8 Assembling the cooling 80 7 9 INSTALLING INTAKE AND EXHAUST MANIFOLDS 80 7 9 1 Assembling the exhaust manifold 80 7 9 2 A
21. service manual 42 051135 N LOMBARDINI OVERHAULS AND TUNING 6 6 2 4 Dimensional check of sealing rings 1 Place a sealing ring in the cylinder and measure the distance between the two tips using a thickness gauge 2 Repeat for all the sealing rings If the distance between the tips does not correspond to the indicated values replace the sealing ring with an original spare see Dimensional table of sealing rings Dimensional table of sealing rings Sealing distance between Wear amp tear rings tips mm limit mm 0 25 0 45 ge 0 2520 45 1 0 3 0 20 0 45 3 Put the sealing rings on the piston in the order shown in the figure AN Important Place the sealing rings with the markings facing up towards the upper part of the piston crown 4 Using a thickness gauge measure the clearance of each sealing ring If clearance L does not correspond to the values shown replace the sealing rings with original spares see Table of sealing ring clearance Table of sealing rings clearance AN Important Sealing rings cannot be replaced separately Protect the contact surfaces with lubricant oil to prevent them from rusting service manual 43 mod 051135 5 LOMBARDINI 6 2 5 Dimensional check and overhaul of crankshaft Wash the crankshaft thoroughly using suitable detergent Introduce a pipe c
22. 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 Do not use a hammer directly on the gaskets during assembly to avoid damaging them Becareful notto damage the gaskets while joining them to the shaft Do not use a hammer directly on the bearings during assembly to avoid damaging them 6 2 OVERHAULING THE CRANK GEARS AND CRANK CASE 6 2 1 Overhauling cylinders and pistons Before deciding what kind of overhaul needs to be done it is important to carry out a dimensional check and verify the correspondence of cylinders pistons sealing rings crankshaft and connecting rods service manual mod 051135 5 LOMBARDINI 6 2 2 Dimensional check and overhaul of cylinders 1 Place the engine block on the workbench 2 Using amicrometer measure the diameter at points 1 2 3 see diagram 3 Rotate the micrometer 90 and remeasure If ovalization or wear is greater than 0 05mm the cylinder must be ground AN Important The increases recommended by the manufacturer for the cylinder head 0 5 and 1 mm When grinding make sure that the working angle is 45 55 and that the average roughness is Ra 0 5 1 Do sand the internal surfaces of the cylinders using em
23. 0 Fill the sealing ring C with grease and lubricate the rim with oil 11 Mount the new sealing ring C using a special tool A Important Given the particular function played by this sealing ring it is important to use only original spares 12 Mount the rotors H with the referance notches facing upwards so that they are visible 13 Using a thickness gauge measure the clearance between the rotor teeth If clearance is above the 0 25mm limit for wear replace the rotors with original spares 14 Check that the contact surfaces are perfectly clean intact and not deformed 15 Mount the new O ring OVERHAULS AND TUNING 6 Ay Important The O ring must always be replaced with an original spare part whenever the pump is disassembled 16 Replace the plate A and put in the screws L 17 Tighten the screws L to a torque of 10 Nm service manual 46 mod 051135 Q LOMBARDINI OVERHAULS AND TUNING 6 6 2 9 Overhauling the decanting device In order to overhaul the decanting device it is necessary to disassemble the starter motor See Replacing the starter motor for the correct procedure 1 Loosen the clamp and extract the pipe A 2 Remove the cover B 3 Thoroughly clean the inside of the cover and blow compressed air on the decanting device C to eliminate residues 4 Checkthat the decanting device is intact and if necessary replace it wi
24. 00 2000 2200 2400 2600 2800 3000 3200 r p m Power curve diagram 80 1269 CEE 95 1 CE 3600 tr min a Nm kgm g CVh 350 310 270 230 1200 1600 2000 2400 2800 3200 3600 service manual 12 mod 051135 C LOMBARDINI TECHNICAL INFORMATION 2 24 ALTERNATOR LOAD CURVE DIAGRAMS Internal load curve diagram Reading taken after heat stabilisation at 25 C and constant voltage 13 5V Todetermine engine r p m s check the gear ratio adapted 2000 4000 6000 8000 10000 12000 14000 to pulleys External load curve diagram Reading taken after heat stabilisation at 20 C and constant voltage 12 5V 1000 1500 2000 2500 3000 3500 4000 r p m The alternator turns at the same rate as the engines service manual 13 mod 051135 A LOMBARDINI 25 LUBRIFICANTS TECHNICAL INFORMATION 2 5 1 SAE Classification Inthe SAE classification oils differ on the basis of their viscosity and no other qualitative 40 35 30 25 20 15 10 5 0 5 101520253035404550 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 low
25. 5 Check that the engine oil and coolant are up to level 6 Start the engine and keep at minimum speed for a few minutes 7 Checkforleaks and if necessary find and eliminate the cause 8 Switch off the engine service manual 27 051135 5 LOMBARDINI STORING THE ENGINE 4 service manual 28 mod 051135 5 LOMBARDINI REMOVING THE ASSEMBLIES 5 5 1 RACCOMENDATIONS FOR REMOVING THE ASSEMBLIES Information is given in a logical order in terms of timing and sequence of operations The methods have been selected tested and approved by the manufacturer s technical experts This chapter describes procedures for removing assemblies and or individual components in order to carry out work on specific parts of the engine See the chapter entitled Overhauls and tuning for operations involving checks overhauls and tuning of assemblies and or components See the chapter entitled Installation of assemblies for operations involving the installation of assemblies and or components 5 2 REMOVING THE EXHAUST AND INTAKE MANIFLODS AN Important To locate specific topics the reader should refer to the index 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 Before proceeding with operations make sure that appropriate safety conditio
26. 6 mod 051135 5 LOMBARDINI 4 Inserttool 7107 1460 049 in the tensioner holder lever 5 Calibrate the torque wrench to 20 Nm and insert it into the tool with the lever perpendicular to the belt Loosen the nut slightly D Turn the torque wrench clockwise to tighten the belt to 20 Nm Once the specified torque is reached 20 Nm tighten the nut D temporarily without allowing the belt tension to loose Mount the pulley G1 Tighten the nut D to a final torque of 40Nm 1 Rotate the crankshaft a few times to settle and position the belt correctly 11 Before doing so make sure that the pulley notches crankshaft and camshaft are lined up with their respective timing notches 12 Insert the tool again into the lever on the pulley nut support and repeat all the steps to check belt tension 13 Disassemble the pulley G1 7 7 3 Assembling the belt drive cover 1 Mountthe guard without tightening the screws completely 2 Tightenthe screws in an alternating pattern to a final torque of 10 Nm AN Important If replacement of the optional dust guard rings H H1 and the peripheral sleeve becomes necessary for technical or construction reasons please request the pre assembled guard G complete with rings and gaskets INSTALLATION OF ASSEMBLIES 7 tool pk 7107 1460 049 tensioner holder service manual
27. 77 051135 C LOMBARDINI INSTALLATION OF ASSEMBLIES 7 8 INSTALLATION OF THE COOLING FAN BELT DRIVE 7 8 1 Assembling the fan belt drive pulleys 1 Check that all components are intact and if necessary replace them with original spares 2 Mount the pulley G1 and fasten the screws without tightening them 3 Tighten the screws in a crisscross pattern to a final torque of 10 Nm 4 Mount tool 7107 1460 051 to inhibit rotation of the crankshaft 5 Apply some anti seize product to the screw thread L As Caution Warning The screw is left handed Turn anticlockwise to screw 6 Tighten the screw L to a torque of 180 Nm 7 Remove the tool M 8 Install the starter motor N and tighten the screws to a torque of 45 Nm service manual 78 mod 051135 5 LOMBARDINI 9 Mount the pulley P washers and spacer 10 Tighten the screw to a torque of 25 Nm 7 8 2 Assembling the fan belt drive With internal alternator The engine may have an external or internal alternator With internal alternator 1 Install the belt flange and the pulley hub R 2 Tighten the screws to a torque of 10 Nm 3 Carry out belt tension see Replacing alternator fan belt With external alternator 1 Install the flange and the pulley hub 2 Tighten the screws to a torque of 10 Nm 3 Install the belt T 4 Tighten the belt T se
28. 9 mod 051135 Q LOMBARDINI OVERHAULS AND TUNING 6 2 Use a micrometer to measure the maximum dimensions of the involutes of the intake exhaust and injection cams see Table of cam dimensions Table of cam dimensions If the dimensions of cam involutes are lower than the values shown by 0 1mm maximum dimension replace the camshaft with an original spare AN Important Protect the contact surfaces with lubricant oil to prevent them from rusting 3 Replace the camshaft see Assembling tha camshaft 6 3 4 Checking and replacing the fuel pump drive rod Fuel pump To check the drive rod it is necessary to disassemble the fuel pump See Disassembling the fuel pump for the correct procedure 1 Rotate the camshaft until the drive rod is at the most indented point 2 Check that the distance between the drive rod A and the cylinder head is between 1 66 and 2 18mm If the distance does not 1 66 2 18 mm correspond to this value replace the drive E rod with an original spare 3 Assemblethe fuel pump see Assembling the fuel pump service manual 50 mod 051135 LOMBARDINI OVERHAULS AND TUNING 6 6 3 5 Checking and overhaulimg the valves In order to carry out a control of the valves it is necessary to remove them from the cylinder head See Disassembling the valves for the correct procedure 1
29. MBLIES 7 4 Tighten the screws M temporarily in alternating pattern 5 Tighten the screws L in a crisscross pattern to a final torque of 50Nm engine block 6 Tighten the screws M in an alternating pattern to a final torque of 10Nm 7 5 4 Measuring crankshaft axial clearance To measure the axial clearance of the crankshaft it is necessary to assemble the shaft complete with crankcase See Assembling the crankcase for the correct procedure 1 Using a dial indicator measure the axial shift of the crankshaft Axial shift must be between 0 130 and 0 313mm If axial shift is above these values it is necessary to insert uprated shoulder half rings and once again disassemble the crankcase see Dimensional check and overhaul of crankshaft 7 5 5 Assembling the crankshaft flange flywheel side 1 Cleanthe flange and the sealing ring seat N 2 Usingthe special pad insert a new sealing ring N into the flange Q AN Important Given the particular function played by this sealing ring it is important to use only original spares 3 Check that the contact surfaces are perfectly clean and intact service manual 67 mod 051135 C LOMBARDINI INSTALLATION OF ASSEMBLIES 7 4 Slip on anew gasket P 5 Replace the falnge Q and put in the screws R AN Important Be careful not to damage the sealing rings during this operation 6 Tighten the sc
30. NG THE ASSEMBLIES 5 5 3 1 Disassembling the cooling fan belt with external alternator 1 Loosenthe nuts B B1 2 Loosen the belt D by adjusting the alternator C manually 3 Remove the belt D 4 Remove the hub E and flange 5 Remove the pulley F washers Pulley flange spacer 5 3 2 Disassembling the cooling fan belt with internal alternator 1 Remove the hub E and flange 2 Removethe belt D 3 Remove the pulley F washers and spacer 5 4 REMOVING THE TIMING BELT 5 4 1 Disassembling the timing belt casing 1 Disassemble the starter motor 2 Install tool 7107 1460 051 to inhibit rotation of the crankshaft 3 Loosen the screw G Abcaution Warning The screw is left handed Turn clockwise to unscrew tool 7107 1460 051 service manual 31 mod 051135 5 LOMBARDINI REMOVING THE ASSEMBLIES D 4 Loosen the screws and remove the pulley H 5 Remove the casing L 5 4 2 Disassembling the timing belt 1 Twist the pulley nut M to fully loosen the belt N 2 Remove the belt N working it away in sequence first from the pulley and P and then from the others AN Important The timing belt must always be replaced with an original spare part whenever it is removed 5 4 3 Disassembling the pulleys camshaft and crankshaft 1 Remove the pulley P 2 Remove the pulley Q se
31. OMMENDATIONS FOR REPLACING PARTS This chapter describes the procedures for replacing a number of components and or assemblies which are not recommended for repairs Some of these operations are also contained in the user s operation and maintenance manual 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 Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved 8 2 REPLACING THE ALTERNATOR FAN BELT AN Important Replacement may be carried out with the engine installed on the machine The engine may have an external or internal alternator With external alternator 1 Switch off the engine and leave to cool 2 Loosen the nuts B B1 3 Loosen the belt by adjusting the alternator manually and tighten the nut B1 4 Slip off the belt D and replace it with an original spare REPLACING PARTS 8 Alloperations except where expressly stated otherwise must be carried out when the engine is not running and has cooled sufficiently to avoid the risk of burns AN Important To locate specific topics the reader should refer to the index service manual 83 mod 051135 A LOMBARDINI REPLACING PARTS 8 5 Adjust the alternator manually while a
32. OOKING FOR MALFUNCTIONS 23 6 2 3 Dimensional check and overhaul of pistons 42 6 2 4 Dimensional check of sealing rings 43 6 2 5 Dimensional check and overhaul of crankshaft 44 4 STORING THE ENGINE 6 2 6 Dimensional check and overhaul of connecting rods sse me 45 4 1 HANDLING AND LIFTING ossis 25 6 2 7 Checking parallelism of the connecting rod axes 45 4 2 STORING THE ENGINE UNINSTALLED 25 6 2 8 Checking and overhauling the fuel pump 46 4 3 STORING THE ENGINE INSTALLED 25 6 2 9 Overhauling the decanting device 47 4 4 PROTECTIVE TREATMENT 26 6 3 OVERHAUL OF CYLINDER HEAD AND RELATED 4 5 PREPARING THE ENGINE FOR OPERATION COMPONENTS 47 ONINSTALLED ert been 26 6 3 1 Checking and overhauling the cylinder head 47 4 7 PREPARING THE ENGINE FOR OPERATION 6 3 2 Checking and overhauling the rocker arm pin 48 INSTALLED da see Ee 27 6 3 3 Checking and replacing the camshaft 49 6 3 4 Checking and replacing the fuel pump drive rod 50 6 3 5 Checking and overhauling the valves 51 6 3 6 Adjusting valve rocker arm clearance 52 5 REMOVING THE ASSEMBLIES 6 3 7 Checking clearance 52 6 3 8 Calibratin
33. RER AND ENGINE IDENTIFICATION 5 with internal 31 14 GLOSSARY AND TERMINOLOGY 6 5 4 REMOVING THE TIMING BELT DRIVE 31 15 WARRANTY CLAUSES 6 5 4 1 Disassembling the timing belt casing 31 16 GENERAL SAFETY REGULATIONS 6 5 4 2 Disassembling the timing belt 32 1 7 GENERAL SAFETY DURING OPERATING PHASES 6 5 4 8 Disassembling the pulleys 1 8 SAFETYAND ENVIRONMENTAL IMPACT 7 camshaft and crankshaft 32 1 9 PRECAUTIONS WHEN THE ENGINE IS INSTALLED 5 5 REMOVING THE CYLINDER HEAD 33 ON THE MACHINE 7 5 5 1 Disassembling the rocker arm cover 33 1 10 PRECAUTIONS WHEN THE ENGINE IS ON THE 5 5 2 Disassembling the rocker arms 33 ROTATING STAND rode 7 5 5 3 Disassembling the fuel pump 33 5 5 4 Disassembling the injection pumps 34 5 5 5 Disassembling the precombustion chamber 34 2 TECHNICAL INFORMATION Pm T m 21 GENERAL DESCRIPTION OF THE ENGINE 9 ud ee ue I EM 36 22 TECHNICAL SPECIFICATIONS 10 ak HB IUIS 3p 5 6 REMOVING THE CRANK GEAR 2 3 CHARACTE
34. RISTIC CURVE DIAGRAMS 12 AND CRANKCASE 36 2 4 ALTERNATOR LOAD CURVE DIAGRAMS 13 5 6 1 Disassembling the flywheel 36 255 EUBRIGANTS onze een A 14 562 Disassembling the oil PUp CHA vee 87 2 5 4 SAE Classification sese 14 56 3 Disassembling the andserankshatt a 38 2 5 2 API MIL sequences eee 14 5 6 4 Disassembling the connecting rod and piston 39 14 57 DISASSEMBLING THE VALVES 39 26 OPERATING PRINCIPLE FOR LUBRICATION 15 5 8 DISASSEMBLING THE PISTON 40 2 7 OPERATING PRINCIPLE FOR COOLING 15 2 8 OPERATING PRINCIPLE FOR FUEL INJECTION 16 2 9 WIRING DIAGRAM seem 17 6 OVERHAULS AND TUNING 5 MANTENANGE eee eee int89 61 RECOMMENDATIONS FOR OVERHAULS 2 11 TABLE OF TIGHTENING TORQUES PORE MP NONSE 19 AND TUNING Rrasasasnassananensssansnensunensusanuseusunsausususansueunuan 41 242 TABLE OF SEALANTS a arrana rnanan 21 6 1 1 Shaft SAS aa a NGNE a a ANAN KA e Kaba a 41 213 ROUTINE ENGINE MAINTENANCE 21 6 1 2 O rings eI ETT TAN KA PO A CAR ONG rac 41 6 1 3 Bearings aaa pana Lee ect 41 6 2 OVERHAULING THE CRANK GEARS AND CRANKCASE nana dena 41 3 MALFUNCTIONS 6 2 1 Overhauling cylinders and pistons 41 6 2 2 Dimensional check and overhaul of cylinders 42 3 1 L
35. STALLATION OF ASSEMBLIES 7 7 Cleanthe cover H witha a jet of air 8 Checkthe state of the filter cartridge G If necessary remove the cartridge knock it repeatedly against a flat surface to eliminate dirt and clean with a jet of air 9 Return the cleaned filter cartridge or replace it with an original spare A Caution Warning Do not use liquids to clean the filter cartridge 10 Replace the cover H and re hook it carefully into place Filtro a cartuccia 1 Check that the contact surfaces are perfectly clean and intact 2 Eliminate any blockages in the ducts governor spring 3 Slip new gasket L 4 Bring the manifold M up to the cylinder ge D 1 6 eene head and hook on the minimum gt lt a maximum device 5 Install the manifold M without tightening the screws N completely 6 Tighten the screws in an alternating pattern to a final torque of 25Nm 7 Checkthe state of the filter cartridge If necessary remove the cartridge and clean with a jet of air 8 Return the cleaned filter cartridge or replace it with an original spare N Caution Warning Do not use liquids to clean the filter cartridge 9 Replace the filter housing 10 Mount the cover P service manual 81 mod 051135 Q LOMBARDINI INSTALLATION OF ASSEMBLIES service manual 82 mod 051135 5 LOMBARDINI 8 1 RACC
36. ake sure that the injectors are calibrated correctly see Calibrating and replacing the injector 1 Insert the flameproof bulkhead M in the injector seat with the flat part directed as in the drawing 2 Grease the copper gasket N and the oil O ring seals N1 copiously 3 Install the injector pumps and fasten the nuts without tightening them 4 Tighten the nuts to a temporary torque of 10Nm 5 Tighten the nuts to a final torque of 20 Nm 6 Hook the connecting rod R to the adjustment levers and fasten the injector pumps without fully tightening the screws 7 Tighten the screws to a final torque of 1 1 Nm 8 Hook the spring S AN Important The following procedures must be performed only if pumps have been replaced Otherwise go directly to point 13 Prepare the injector pumps for running the engine as explained below 9 Loosen the screws T of every injection pump 10 Move the plates U fully towards the flywheel side in order to maximise the injector delivery service manual 73 mod 051135 C LOMBARDINI INSTALLATION OF ASSEMBLIES 11 Tighten the screws to a torque of 1 1 Nm 12 Balance the injector deliveries see Balancing injector pump deliveries _ a ALL fuel rail 13 Put the new O rings on the injector pumps 14 Apply sealant to the seat of the fuel rail 15 Assemble the fuel rail and fasten the screws without tight
37. al 64 mod 051135 5 LOMBARDINI 4 Mount the collar C the spring D the cup E and the half collets F 5 Pressdown hard on the cup E using the special tool 7107 1460 047 to insert the half collets F into the valve stem groove 6 Release the tool and check that the half collets are positioned correctly If the half collets are not correctly positioned repeat the operation 7 Repeat the same operation on the other valves INSTALLATION OF ASSEMBLIES 7 7 5 INSTALLATION OF CRANK GEAR AND CRANKCASE 7 5 1 Installing piston connecting rod engine block AN Important Make sure that the engine block and the crankcase are perfectly clean and dry 1 Assemble the pipe A with the oil suction filter 2 Mount the new O rings A1 3 Carefully clean and lubricate the cylinders and the connecting rod piston assembly B 4 Rotate the sealing rings so that the cuts have a displacement of about 120 between them AN Important In order not to damage the sealing rings and the contact areas while inserting the piston into the cylinder use the special containment device 5 Mount the connecting rod piston assembly B onto the engine block and position the connecting rod big ends along the axis of the crankshaft AN Important The piston combustion chamber must be assembled on the precombustion chamber service manual 65 mod 051135
38. alternator 31 Disassembling the crankcase and crankshaft 38 Disassembling the cylinder head 36 Disassembling the exhaust manifold 30 Disassembling the flywheel 36 Disassembling the fuel pump 33 Disassembling the injection pumps 34 Disassembling the intake manifold 29 Disassembling the oil pump 37 Disassembling the piston 40 Disassembling the precombustion chamber 34 Disassembling the pulleys camshaft and crankshaft 32 Disassembling the rocker arm cover 33 Disassembling the rocker arms 33 Disassembling the speed governor and flow limiter 35 Disassembling the timing belt 32 Disassembling the timing belt casing 31 Disassembling the valves 39 E Engine and manufacturer identification 5 Engine block piston connecting rod installing 65 Establishing injetion timing conversion table 57 Exhasut and intake manifolds installing 80 Exhaust and intake manifolds removing 29 Exhaust manifold assembling 80 Exhaust manifold disassembling 30 Exploded diagram of the Injector pump 91 Exploded diagram of the speed governor 53 service manual 95 mod 051135 A LOMBARDINI F Fan belt drive pulleys assembling 78 Fan belt drive assembling 79 Flow limiter and speed governor assembling 72 Flow limiter and speed governor disassembling 35 Flywheel ring gear replacing 88 Flywheel assembling 69 Flywheel disassembling 36 Fuel injection operating principle 16 Fuel pu
39. and that 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 GENERAL REMARKS AND SAFETY 1 Piston number one first piston viewed from the flywheel side of the engine Rotation direction clockwise or anticlockwise viewed from the timing belt side of the engine All persons carrying out work on the engine at any point in its life must possess precise technical qualifications and skills as well as experience recognised and gained in the specific sector Non compliance with these requirements may cause damage to the health and safety of individuals Do not tamper with sidestep eliminate or bypass the installed safety devices Non compliance with this requirement may be hazardous to the health and safety of individuals Some phases may require the assistance of more than one operator If so it is important to inform and exercise 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 Keep flames away from the engine to avoid the risk of fire
40. ant Make sure there are no foreign bodies or residual material in the cylinder head cavity Check that the contact surfaces are perfectly clean and intact 1 Slip on anew gasket G 2 Choose the gasket shim to be installed see Check clearance volume 3 Make sure that the length of the screws H does not exceed 92mm otherwise replace 4 Lubricate the screws copiously H 5 Mount the cylinder head L and put in the rH screws H Important 6 Tighten the screws in sequence see If the screws H belong to 10 9 class the tightening diagram to a temporary torque of 40 Nm torque is 60Nm and it is not necessary to tighten them further AN Important Use a torque wrench with an angle torque tool to tighten the screws 7 Tighten the screws further clockwise rotating 90 8 Tighten the screws to their final torque rotating 90 7 6 3 Assembling the camshaft AN Important Make sure that the camshaft and it s housing are perfectly intact and clean 1 Lubricate the camshaft A and its housing 2 Insert the camshaft into its housing 3 Mounta new O ring onto the cover 4 Mountthe cover B and tighten the screws to a torque of 10 Nm service manual 71 mod 051135 Q LOMBARDINI INSTALLATION OF ASSEMBLIES 7 6 4 Assembling the speed governor and flow limiter AN Important Make sure that all components are perfectly clean and dry
41. as to enable him to carry out operations correctly and safely The 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 6 1 1 Shaft seals Clean the shaft thoroughly and make sure that it is not damaged or scored or has become oval shaped in the areas of contact with the seals Lubricate the seal lips and pointing them in the right direction place them in their seat using a special pad 6 1 2 O Rings Lubricate the seal before introducing it to its seat Avoid rolling the gasket during the attachment phase 6 1 3 Bearings Use special extractors or plugs to remove bearings Cleanthe bearings thoroughly Check their condition and if they are fully intact lubricate all over otherwise replace with original spares OVERHAULS AND TUNING 6 Wash the components with special detergent and do not use steam or hot water Do not use 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 a layer of lubricant over all surfaces to protect them against oxidation Check all components for intactness
42. c cable P 2 Remove the preheating glow plugs Q 3 Unscrew the ring nut R using the special pin wrench 7107 1460 027 service manual 34 mod 051135 REMOVING THE ASSEMBLIES 5 5 LOMBARDINI Screw the extractor 7107 1460 030 onto the precombustion chamber S and remove it 4 extractor 7107 1460 027 5 5 6 Disassembling the speed governor and flow limiter 1 Remover the cover T Extract the weights assembly U from the camshaft 2 3 Remove the fuel flow limiter V 4 Unscrew the pin and extract the governor tinkage adjustment pin W mod 051135 service manual 35 C LOMBARDINI REMOVING THE ASSEMBLIES D 5 5 7 Disassembling the camshaft 1 Remove the cover X 2 Extract the camshaft Y from the cylinder head AN Important Make sure the drive rod has been removed and rotate the camshaft gently to remove it easily 5 5 8 Disassembling the cylinder head 1 Remove the cylinder head A 2 off the gasket B 5 6 REMOVING THE CRANK GEAR AND CRANKCASE 5 6 1 Disassembling the flywheel 1 Disassemble the starter motor A tool 7107 1460 027 2 Install tool 7107 1460 051 to inhibit rotation of the crankshaft 3 Remove the flywheel B service manual 96 mod 051135 Z LOMBARDINI REMOVING THE ASSEMBLIES 5 4 Remove the support
43. cal fuel lift pump 40 50 23 Electrical fuel lift pump 11 Glow plugs indicator 12 Coolant temperature indicator service manual NUS mod 051135 A LOMBARDINI TECHNICAL INFORMATION 2 With internal alternator Electric pump version N SS XD tar e BLACK 12 qm BROWN RED YELLOW D Description 40A alternator Starter motor Battery recommended 44Ah 210A DIN Preheating glow plugs Coolant temperature monitoring sensor Glow plug pre heating control box Ignition switch 50A fuses AMBI OO Po 5A fuses Electrostop device or electrical fuel lift pump Glow plugs indicator A N Coolant temperature indicator Ref Description 13 Coolant thermostat indicator light 14 Engine oil preassure lamp 15 Oil preassure gauge 16 Battery load indicator 17 Voltage regulator 18 Coolant thermometer 19 Coolant thermomenter sensor 20 Fuel level light 21 Fuel level indicator 22 25 V 10000 uF condensator 23 Electrical fuel lift pump service manual 18 mod 051135 5 LOMBARDINI 2 10 SPECIAL TOOLS AND EQUIPMENT FOR MAINTANANCE TECHNICAL INFORMATION 2 Serial number Description Serial number Description 7107 1460 127
44. ce m Dimensions wear limit mm mm m 17 989 18 000 0090 18 015 18 030 0 015 0 041 If the diameters do not correspond to the values shown replace the pin and if necessary the rocker arms with original spares If the pin can be re used remove the plugs and clean the inside carefully to eliminate residual dirt 6 Place the new plugs in the pin 7 Carefully clean and lubricate the supports and rocker arms and remount on the pin OVERHAULS AND TUNING 6 service manual 48 mod 051135 LOMBARDINI OVERHAULS AND TUNING 6 8 Insert anew pin E and drive itin 0 1 mm from the flat part of the support 9 Reassemble the rocker arm assembly in the cylinder head see Assembling the rocker arms 6 3 3 Checking and replacing the camshaft In order to carry out a control of the camshaft it is necessary to disassemble it from the cylinder head See Disassembling the camshaft for the correct procedure 1 Using a dial indicator measure the diameters of the seats X and with a micrometer find out the diameters of the camshaft ga b see Table of camshaft dimensions Table of camshaft dimensions Clearance amp wear 37 035 37 060 a b 36 975 37 000 0 035 0 085 If the diameters do not correspond to the values shown replace the camshaft with an original spare service manual 4
45. code 1 5302 727 SERVICE MANUAL S LOMBARDINI 5 LOMBARDINI REGISTERING DOCUMENT MODIFICATIONS This document is made up of 98 pages sides excluding the cover and title page Pages are numbered in progressive order from 051135 01 to 051135 98 Any modifications to this document must be registered by the drafting body and approved by the head of the Quality Management System with completion of the table below Document Replaced Added Eliminated Drafting bod Copyright 2005 Lombardini Reproduction even partial of this document is subject to the manufacturer s written authorisation The manufacturer is committed to a policy of continuing improvement and reserves the right to modify the document with no obligation to notify providing that omission to do so constitutes no safety risk The text may be reproduced in part or in whole providing that the author is cited Text and graphics by IDM Esperti in Comunicazione Tecnica Forli service manual 2 mod 051135 5 LOMBARDINI GENERAL INDEX 1 GENERAL REMARKS AND SAFETY 5 3 REMOVING THE COOLING FAN BELT DRIVE 30 5 3 1 Disassembling the cooling fan belt 11 PURPOSE OF THE MANUAL 5 with external alternator 31 1 2 USING THIS 5 5 3 2 Disassembling the cooling fan belt 13 MANUFACTU
46. ction pumps action of spring using the adjustment shims The 8 adjustment shims are available in 11 sizes between 9 1mm and 2mm uprated at 0 1 mm gaps If after inserting the largest adjustment shim 2mm optimal calibration is still not achieved the spring see Nozzle injector replacement must be replaced 6 3 9 Checking and overhauling the speed governor Disassemble the speed governor before checking or overhauling See Disassembling the speed governor and flow limiter 2 for the correct procedure 1 Verificare con un calibro Use a gauge to make sure that the distance A is between 45 and 46 mm Make sure that the contact surfaces are perfectly level with a deviation of no more than 0 05 mm If the deviation is greater than this replace the speed governor with an original spare Exploded diagram of the speed governor Caption Oil seal Screw Cover O ring Ball bearing Plate Screw Weighted support Spacing collar 10 Fith wheel coupling 11 Nut 12 Idle spring 13 Maximum speed ring 14 Barrel 15 Thrust washer 16 Stop ring 17 Pivot 18 Leverage assembly 19 Clearance ring service manual 53 mod 051135 5 LOMBARDINI 6 4 CHECKING TIMING BELT RATING 6 4 1 Valve adjustments 1 2 Fan drive pulley Bring the piston to the compression top dead centre Adjust the screw A and the lock nut in order to adjust the rocker arm valve clearance to 2 mm Rotate the
47. d 051135 LOMBARDINI TECHNICAL INFORMATION 2 Tightening torques for standard screws fine threads Resistance class R Quality Dimensions R gt 400N mm R gt 500 R 600N mm R2800N mm R 1000N mm Nm Nm Nm Nm Nm Nm M8x1 10 14 13 20 27 38 M 10x1 21 28 26 42 56 79 M 10x1 25 20 26 24 39 52 73 M 12x1 25 36 48 45 71 95 M 12x1 5 38 45 42 68 90 M 14x1 5 56 75 70 M 16x1 5 84 M 18x1 5 M18x2 20x1 5 M20x2 22 1 5 24x2 M27x2 M30x2 Diameter Tightening torques for main components Description Diameter x thread Tightening torque Nm Injector pump connecting rod M 3 sp c 1 2 Aluminium connecting rod 8x1 35 Preheating glow plugs 12x1 25 25 Rocker arm cover 6x1 9 Crankcase screws for fixing crankshaft M 10 30 Crankcase screws for fixing engine block M6 10 Screw for speed governor bearing support cover M6 10 Preheating glow plugs cable nuts 5x0 8 5 Fuel supply pump nuts 8x1 5 24 Nut for synchronous timing belt pulley M 10 40 Injector pump nut 8x1 25 20 Rocker arm support nuts 10x1 5 40 Fuel pump control eccentric 10x1 25 80 Oil sealing ring flange screws flywheel side M6 12 Precombustion chamber ring nut 30x1 5 Governor tinkage adjustment pin 6x1 Crankshaft pulley screw timing belt side 16x1 5 gauche Camshaft pulley screw 10x1 25 Oil pressure switch 12x1 5 Oil plug 12x1 5 Cylinder head screws I
48. d gasket and clearance volume values Table of head gasket and clearance volume values Clearance Number of holes volume mm ous 0 39 0 48 117125 040 048 OVERHAULS AND TUNING 6 service manual 52 mod 051135 5 LOMBARDINI 6 3 8 Calibrating the injector To carry out setting the injector pump must be disassembled from the engine Per conoscere la procedura corretta vedi Smontaggio pompe iniettori 1 Remove the non return valve A and replace it with the plug supplied with the 7107 1460 074 tool Mount the tool head B and fasten with the screws Connect the pump for calibrating the diesel injectors to the head union Press the pump and bring to a pressure of 130 bars for 10 sec in order to check the needle seal Replace the nozzle see Nozzle injector replacement if there is any dripping Press the pump again and check to see whether the fuel comes out at a pressure of 140 155 bars optimal operating calibration If calibration is not optimal it is possible to modify the 7 OVERHAULS AND TUNING 6 After replacing the spring calibrate at 10 bars higher than the optimal operating calibration of 140 155 bars When the spring settles the calibration will level at the optimal value Remove the tool 7107 1460 074 Replace the non return valve 10 Assemble the injection pump on the engine see Assemble inje
49. e Replacing the alternator fan belt INSTALLATION OF ASSEMBLIES 7 With external alternator Ps service manual 79 mod 051135 j LOMBARDINI INSTALLATION OF ASSEMBLIES 7 8 3 Assembling the cooling fan 1 Check that the fan is intact and if necessary replace it with an original spare 2 Install the cooling fan U 3 Tighten the screws to a torque of 10 Nm 7 9 INSTALLING INTAKE AND EXHAUST MANIFOLDS 7 9 1 Assembling exhaust manifold 1 Make sure that the manifold ducts are clean and intact 2 Check that the contact surfaces are perfectly clean and intact 3 Eliminate any blockages in the ducts 4 Putonthe new gaskets A 5 Mountthe manifold B without tightening the nuts completely 6 Tighten the screws in an alternating pattern to a final torque of 25 Nm 7 9 2 Assembling the intake manifold minimum maximum Panel dry air filter 1 Check that the contact surfaces are perfectly clean and intact 2 Eliminate any blockages in the ducts 3 Slip on anew gasket D 4 Bring the manifold C up to the cylinder head and hook on the minimum maximum device or the governor spring 5 Install the manifold C without tightening the screws F completely 6 Tighten the screws in an alternating pattern to a final torque of 25 Nm service manual 80 mod 051135 LOMBARDINI IN
50. e movement of the mechanical parts service manual 69 mod 051135 5 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 6 INSTALLATION OF CYLINDER HEAD AND COMPONENTS 7 6 1 Assembling the precombustion chamber AN Important Check that the contact surfaces are perfectly clean and intact 1 Install the precombustion chamber A so that its hole coincides with the one on the pre heating glow plug 2 Insert tool 7107 1460 031 into the seat ofthe preheating glow plug in order to lock the chamber while the ring nut B is being tightened 3 Apply some anti seize productto the ring nut thread B and to the surface that is in contact with the precombustion chamber 4 Mountthe ring nut B 5 Tighten the ring nutto a temporary torque of 100Nm 6 Make sure that the precombustion chamber protrusion C is between 3 56 4 04 mm If the protrusion C exceeds the recommended value insert a shim D provied ad spare part beneath the precombustion chamber A 7 Tighten the ring nut to a final torque of 180Nm 8 Removethe tool and install the preheating glow plug E 9 Tighten the glow plug to atorque of 20 Nm 10 Repeat the same operations on the other chamber 11 Connect the glow plug power supply cable F service manual 70 mod 051135 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 6 2 Assembling cylinder head AN Import
51. ee Protective treatment after 6 months of inactivity Remove the key from the dashboard and put it in a safe place to avoid acts of vandalism Lock the cabin and the cowls to prevent strangers getting access If the engine is not to be used for more than 1 month it is necessary to apply protective measures that are valid for 6 months see Protective treatment If after the first 6 months the engine is still not to be used it is necessary to carry out a further measure to extend the protection period see Protective treatment service manual 25 mod 051135 A LOMBARDINI 4 4 PROTECTIVE TREATMENT 1 Check that the engine oil and coolant are up to level 2 Start the engine and keep idle at minimum speed for 15 minutes 3 Switch off the engine and leave to cool 4 Take out the lubricant 5 Fillthe casing with AGIP RUSTIA C protective oil 6 Empty the fuel tank completely 7 Replace fuel filter 8 Fill the fuel tank with a mixture made up of 1096 AGIP RUSTIA NT protective oil and 90 fuel 9 Release the air from the fuel supply circuit 10 Start the engine and check for fuel leaks 11 Start the engine and bring to 34 of the maximum speed for 5 10 minutes 12 Switch off the engine 13 Spray SAE 10W oil on the exhaust and intake manifolds STORING THE ENGINE 4 14 Close all openings to prevent foreign bodies from entering 15 Thoroughly clean all exte
52. elt replacing 85 U Uprated shoulder half rings table 44 Using this manual 5 service manual 97 mod 051135 C LOMBARDINI 42100 Reggio Emilia Italy Via Cav del Lavoro Adelmo Lombardini Tel 39 0522 3801 emali atigtiombardin tt www lombarcdini t SERVICE MANUAL code 1 5302 727
53. en when the engine is not in use and so it is important to consider whether they need replacing based not only on the number of hours of use but also on age and wear 13 Install the engine onto the machine make the necessary connections and unions 14 Make sure that electrical contacts are intact and efficient 15 Check that the engine oil and coolant are up to level 16 Start the engine and keep at minimum speed for a few minutes 17 Check for leaks and if necessary find and eliminate the cause 18 Switch off the engine service manual 26 mod 051135 5 LOMBARDINI STORING THE ENGINE 4 4 6 PREPARING THE ENGINE FOR OPERATION INSTALLED After a period of inactivity and before installing and running the engine it is necessary to carry out a few measures in order to ensure that it runs at maximum efficiency 1 Use a cloth soaked in degreasing product to remove the external protective treatment 2 Adjust the alternator fan belt tension 3 Make sure that electrical contacts are intact and efficient 4 Check the filters for aging air oil fuel and if necessary replace them with original spares A Important Over time a number of engine components and lubricants lose their properties even when the engine is not in use and so it is important to consider whether they need replacing based not only on the number of hours of use but also on age and wear
54. ening them 16 Tighten the screws to a final torque of 4Nm 17 Mount the rocker arm cover see Assembling the rocker arm cover 7 6 6 Assembling the mechanical fuel pump AN Important Check that the contact surfaces are perfectly clean and intact Make sure that the length of the drive rod is between 153 15 153 25 mm otherwise replace it 1 Insert the drive rod V 2 Mountanew O ring W 3 Install the fuel pump Z and fasten the nuts without tightening them 4 Tighten the nuts to a final torque of 22Nm 5 Connect the pipes to the pump service manual 74 mod 051135 C LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 6 7 Assembling the rocker arms AN Important Check that the contact surfaces are perfectly clean and intact 1 Press down hard on the pump stroke to insert the pin which facilitates assembly of the drive rods B 2 Mount the rocker arm assembly A 3 Insert the pump injector activation drive rods B 4 Tighten the nuts by hand 5 Tighten the nuts to a temporary torque of 20 Nm 6 Tightenthe screws in an alternating pattern to a final torque of 40 Nm 7 Remove the pins and check that the rocker arms B have been inserted correctly 7 6 8 Assembling the rocker arm cover AN Important Make sure that the rocker arm cover is perfectly clean and dry Check that the contact surfaces are perfectl
55. ery cloth Protect the contact surfaces with lubricant oil to prevent them from rusting The table shows the reference values and their class only applies to new engines 6 2 3 Dimensional check and overhaul of pistons 1 Clean the piston thoroughly D 2 Using a micrometer measure the piston 9mm from the base of the skirt 3 Checkthe table to identify the class from the values detected The class letter is engraved on the piston If clearance between cylinder and piston is greater than 0 05mm the piston and sealing rings must be replaced and rematched according to the diameter of the ground cylinders see Table of cylinder piston classes and dimensions AN Important Before replacing the pistons check that the weight difference does not exceed 4g to prevent weight imbalances OVERHAULS AND TUNING 6 AN Important Pistons with nominal diameter are supplied only in class A spares Those uprated by 0 5 and 1 mm have the uprating referance 072 5 e 973 engraved on the upper part of the piston see Table of cylinder piston classes and dimensions Table of cylinder piston classes and dimensions Dimension Cylinders Pistons clearance mETE mm mm mm 71 990 72 000 71 930 71 940 72 000 71 100 71 940 71 950 0 05 0 07 72 010 72 020 71 950 71 960 72 100 72 120 72 031 72 049 Protect the contact surfaces with lubricant oil to prevent them from rusting
56. es mM service manual mod 051135 5 LOMBARDINI 1 4 GLOSSARY AND TERMINOLOGY For clarity here are the definitions of a number of terms used recurrently in the manual 1 5 WARRANTY CLAUSES LOMBARDINI issues a warranty certificate for each engine giving details of all relevant general terms 1 6 GENERALSAFETY REGULATIONS Indesigning and building its product the manufacturer has paid particular attention to those aspects posing a risk to the health and safety of persons handling the engine In addition to legislative requirements all rules for good technical construction have been applied The purpose of this information is to invite operators to pay particular attention in order to prevent any form of risk Caution is always the best policy Safety is also the responsibility of all operators who handle the engine 1 7 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 Some of these tools are normal workshop equipment while others are specific instruments that have been constructed by the engine manufacturer All tools must be in good working condition so that engine components are not damaged
57. est outside temperature to which the engine will be subject and the highest functioning temperature during summer Single degree oils are normally used when the SAE 10W SAE 20W SAE 30 SAE 40 SAE 10W 30 SAE 10W 40 SAE 10W 60 _ SAE 15W 40 SAE 15W 40 _ SAE 20W 60 running temperature varies scarcely SAE 5W 30 Multi degree oil is less sensitive to temperature SAE 5W 40 changes SAE 0W 30 Mineral base Semi synthetic base Sythetic base Key to abbreviations 1 American Petroleum Institute MIL USA military specifications for engine oils issued for logistic reasons ACEA European Automobile Manufacturers Association 2 5 2 API MIL Sequences DIESEL BENZINA ESSENCE PETROL BENZIN GASOLINA L 2104 D E L 46152 B C D E CORRENTI CURRENT cra zz 2 5 8 ACEA Standards ACEA Sequences IBENI DESDE PETROL LIGHT DIESELS HEAVY DIESELS 1 Low viscosity B1 Low viscosity E1 OBSOLETE for friction reduction for friction reduction E2 Standard 2 Standard B2 Standard Heavy conditions Euro1 Euro2 High performance B3 High performance indirect engines injection 4 Heavy conditions Euro1 Euro2 B4 High q
58. g rods and wrist pins service manual 63 mod 051135 Q LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 3 PRE ASSEMBLY OF CONNECTING RODS PISTONS AN Important Before pre assembly check that the weight difference between the two connecting rod piston wrist pin assemblies does not exceed 10 g to prevent weight imbalances 1 Lubrificate the wrist pin A and the seat ofthe small end of the connecting rod B 2 Place the lock ring C on the piston complete with sealing rings D AN Important Insert the lock rings with the tips pointing towards the base of the piston with a tolerance of 15 3 Insert the wrist pin A into the piston D and install the connecting rod B complete with cap 4 Insert the wrist pin completely and fasten with the lock ring AN Important Make sure the lock rings are positioned correctiy in their seats Lubricate the coupling parts and those that are prone to oxidation 7 4 INSTALLING VALVES 7 4 1 Assembling the valves AN Important Make sure that the cylinder head is perfectly clean and dry Check that all components are intact and if necessary replace them with original spares 1 Lubrificate the valve stem sealing ring A insert it into tool 717 1460 047 and mount it right into the seat of the valve guide 2 Lubrificate the vale stem B 3 Slipthe valve into the seats service manu
59. g the injector 53 5 1 RECOMMENDATIONS FOR REMOVING THE 6 3 9 Checking and overhauling the speed governor 53 ASSEMBLIES e eee 29 6 4 CHECKING TIMING BELT RATING 54 5 2 REMOVING THE EXHAUST AND INTAKE 6 4 1 Valve adjustments 54 MANIFOLDS ient apiid 29 6 5 DIAGRAM OF TIMING BELT 55 5 2 1 Disassembling the intake manifold 29 6 6 ADJUSTING STATIC INJECTION TIMING 55 5 2 2 Disassembling the exhaust manifold 30 6 7 BALANCING INJECTION PUMP DELIVERY 58 service manual mod 051135 A LOMBARDINI GENERAL INDEX 6 8 ADJUSTING MINIMUM AND MAXIMUM 8 REPLACING PARTS IDLE SPEED RPMS 5e n Ee Ite PUER 60 6 9 ADJUSTING INJECTION DELIVERY 60 8 1 RECOMMENDATIONS FOR REPLACING PARTS 83 6 9 1 Adjusting injection delivery without dyno brake 60 8 2 REPLACING THE ALTERNATOR FAN BELT 83 6 9 2 Adjusting injection delivery with dyno brake 61 8 3 REPLACING THE TIMING BELT 85 6 10 CHECKING OIL PRESSURE 61 84 REPLACING THE OIL 85 8 5 REPLACING THEAIR FILTER 86 8 6 REPLACING THE ALTERNATOR
60. haft clockwise until the injection cam acts on the rocker arm that controls the injector pump In these conditions the piston is near the compression top dead centre 11 Place the auxiliary tank at a height higher than that of the injectors 30 40 cm 12 Connect the tank to union H 13 Rotate slowly the crankshaft clockwise keeping the lever L lowered and the valve set on the piston crown until the dial indicator shows the maximum measurement 14 Set the dial indicator to zero In these conditions the compression top dead centre can be identified service manual 56 mod 051135 LOMBARDINI OVERHAULS AND TUNING 6 16 Rotate the crankshaft anticlockwise until liquid leaks from the pipe M and then stop turning when the flow is constant and without air bubbles 17 Then turn slowly the crankshaft clockwise in order to identify the exact point at which liquid stops leaking In these conditions the point which coincides with the static injection timing can be identified 18 Act again on lever L to lower the valve and bring it again on the piston 19 Measure the piston lowering value by using the dial indicator 20 Convert the value registered from millimetres to degrees see Conversion table for establishing injection timing AN Important When converting refer to the table value that is nearest to the registered one see Conversio
61. he connecting rod with an original spare 3 After carrying out all checks and overhauls remount the connecting rods pistons and sealing rings see Pre assembly of sealing rings pistons and Pre assembly of connecting rods pistons AN Important Protect the contact surfaces with lubricant oil to prevent them from rusting connecting rod small end connecting rod connecting rod big end OVERHAULS AND TUNING 6 connecting Table of connecting rod dimensions amp Weal x Dimensions tear limit mm KAE 109 975 110 025 20 010 20 020 Ob c 19 995 20 000 0 01020 025 ES 40 020 40 035 55 000 55 020 service manual 45 mod 051135 A LOMBARDINI 6 2 8 Check and overhaul of the fuel pump Disassemble the oil pump before checking or overhauling See Disassembling the oil pump for the correct procedure 1 Remove the plate A 2 Remove the O ring B 3 Remove the sealing ring C from the flange and clean the seat 4 Unscrew the oil D and extract the gasket E the spring F and the valve 5 Disassemble the rotors H 6 Blowcompressed air into the valve seat to clean it 7 Thoroughly clean all the components 8 Measure the length of the spring F If the length of the spring is not between 27 50 and 27 75mm replace it with an original spare 9 Replace the valve G the spring F the gasket E and the plug D 1
62. he two directions Shift the plate towards the flywheel to increase delivery Shift the plate towards the timing belt to reduce delivery 12 Tighten the screw E to a torque of 1 1Nm 13 Close the cocks and disconnect the assembly 14 Put the new O rings on the injector pumps 15 Apply sealant to the seat of the fuel rail AN Important The O rings must always be replaced with original spares whenever the fuel rail is disassembled 16 Assemble the fuel rail and fasten the screws without tightening them completely 17 Tighten the screws to a torque of 4Nm service manual 59 mod 051135 Q LOMBARDINI OVERHAULS AND TUNING 6 6 8 ADJUSTING MINIMUM AND MAXIMUM IDLE SPEED RPMS 1 Connect a revolution counter to the engine 2 Runthe engine and bring it to the operating temperature 3 Turnthe idle adjusting screw A and set the engine to the minimum speed required 4 Tighten the lock nut B when finished AN Important To decrease the rpm number loosen the screw To increase it tighten the screw 5 Turnthe peak rpm adjusting screw D and set the engine to the maximum speed required 6 Tighten the lock nut C when finished AN Important To decrease the rpm number tighten the screw whereas to increase it loosen the screw 6 9 ADJUSTING INJECTION DELIVERY The adjustment may be performed with the dynamometric brake accurate adjustment or without it approx
63. hecking and replacing 49 Camshaft disassembling 36 Characteristic curve diagrams 12 Checking and overhauling the cylinder head 47 Checking and overhauling the fuel pump 46 Checking and overhauling the rocker arm pin 48 Checking and overhauling the speed governor 53 Checking and overhauling the valves 51 Checking and replacing the camshaft 49 Checking and replacing the fuel pump drive rod 50 Checking clearance volume 52 Checking oil preassure 61 Checking parallelism of the connecting rod axes 45 Checking the timing belt rating 54 Clearance table of sealing rings 43 Clearance volume and head gasket values table 52 Clearance volume checking 52 Clearance valve rocker arm adjusting 52 Connecting rod piston engine block installing 65 Connecting rod and piston disassembling 39 Connecting rod axes checking parallelism 45 Connecting rod dimensions table 45 Connecting rods pistons pre assembly 64 Connecting rods and half bearings table of diameters 44 Connecting rods dimensional check and overhaul 45 Conversion table for establishing injection timing 57 Coolant pump replacing 89 Coolant thermostat replacing 88 Coolinf fan belt drive removing 30 Cooling fan belt drive installation 78 Cooling fan blet with external alternator disassembling 31 Cooling fan blet with internal alternator disassembling 31 Cooling fan support replacing 93 Cooling fan assembling 80 C
64. i e that it has lifted to 7mm REPLACING PARTS 8 Coolant pump thermostatic valve Check whether the valve is completely shut once it has cooled down If the length does not correspond to the value shown replace the valve spring with an original spare 4 Mount the cover and fasten the screws service manual 89 mod 051135 5 LOMBARDINI REPLACING PARTS 8 12 REPLACING THE NEGATIVE PRESSURE VENT VALVE AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 L A Caption oosen nut A Nut Bushin 3 Loosen the clamps and disconnect the Valve body pipes Diaphram Bottom plate 4 Take off the negative pressure vent valve Quicklock ring B O ring Collar O ring 10 Seal collar 11 Spring 6 Tighten the nutto a final torque of 22Nm 12 Gas vent pipe 5 Install the negative pressure vent valve 7 Connectthe pipe to the coupling 8 13 REPLACING THE PREHEATING GLOW PLUGS AN Important Replacement may be carried out with the engine installed on the machine pre heating glow plugs 1 Switch off the engine and leave to cool 2 Remove the intake manifold see Disassembling the intake manifold 3 Disconnect the electric cable 4 Disconnect the preheating glow plugs 5 Install the new preheating glow plugs and tighten the screws to a torque of 20 Nm
65. imate adjustment 6 9 1 Adjusting injection delivery without dyno break 1 Loosen locknut A 2 Firmly tighten the screw B of the flow limiter 3 Startthe engine and bring it to the operating temperature 4 Bring the engine to maximim rpm allowed 5 Loosen the screw B of the flow limiter until the engine speed starts to decrease 6 Retighten the screw rotating it 2 5 revolutions then fasten with the lock nut A service manual 60 mod 051135 5 LOMBARDINI OVERHAULS AND TUNING 6 6 9 2 Adjusting injection delivery with dyno break 1 Start the engine and bring it to the operating temperature 2 Bring the engine to maximim rpm allowed 3 Loosen the locknut A 4 Firmly tighten the screw B of the flow limiter 5 Activate the dyno brake to bring the engine to maximum power and speed 6 Make sure that fuel consumption corresponds to the recommended values see Table of specific fuel consumption If fuel consumption does not correspond to the values shown reduce the load of the dyno brake 7 After afew minutes of running the engine and when it has stabilised slowly unscrew the limiter screw B until the speed starts to decrease 8 Fasten the screw B with the locknut A 9 Deactivate the dyno brake and take note of the stabilized engine speed 10 Switch off the engine and leave to cool 11 Check the valve rocker arm
66. imum tilt while operating no more than 1 minute Maximum tilt while operating no more than 30 minutes Maximum tilt while operating normal operating conditions 0 Volume of air flow at 3600 RPM NI min Volume of cooling air at 3600 RPM m min 36 POWER AND TORQUE Maximum operating speed 3600 Max power N 80 1269 EEC ISO 1585 DIN 7020 9 8 13 4 Max power NB ISO 3046 1 IFN DIN 6270 9 1 12 4 Max power NA ISO 3046 1 ICXN DIN 6270 82 11 2 Maximum torque at 2400 RPM 28 7 Axial load allowed on driving shaft 300 service manual 10 mod 051135 5 LOMBARDINI TECHNICAL INFORMATION CONSUMPTION AT MAXIMUM POWER Specific fuel onsumption g kWh Specific oil consumption Kg h SUPPLY CIRCUIT Indirect injection Car diesel Electric or membrane pump Screw on or in line fispino Filter paper m PF905 Filtering surface cm 2400 Filter capacity u 2 3 Maximum operating pressure bar 4 LUBRIFICATION CIRCUIT Type of lubrication Completely forced Circuit supply Trochoid pump Maximum oil quantity including filter 1 Maximum oil quantity excluding filter 1 Oil pressure at minimum speed with oil temperature of 120 C no lower than 1 bar Oil filter cartridge Maximum ope
67. ing circuit Slack or broken fan control belt Advance injection Delayed injection Incorrect governor tinkage adjustment Broken or loose governor spring Low idle setting Worn or stuck piston rings Worn or scored cylinders Worn valve guides Valves stuck Worn crankshaft connecting rod bearings Non sliding speed governor leverage Driving shaft not turning freely Damaged head gasket Slack pump injector control rod Incorrect pump injector delivery balancing FUEL CIRCUIT LUBRIFICATION a oz E o2 J iu MAINTENANCE ADJUSTMENTS REPAIRS service manual 23 mod 051135 5 LOMBARDINI MALFUNCTIONS service manual 24 mod 051135 5 LOMBARDINI 4 1 HANDLING AND LIFTING STORING THE ENGINE 4 Secure the engine using a lifting device lifting beam of suitable capacity Hookthe lifting device to the points indicated in the drawing Before lifting check the load s centre of gravity A The dimensions of the brackets on the fastening points have been specially conceived to lift the engine and have not been tested for lifting additional weights Do not lift the engine using different methods from those described Non observance of this requirement will invalidate the insurance wa
68. leaner into the lubrication ducts to remove any residual dirt Blow compressed air into the points indicated to free the ducts from oil Check the surfaces of the main journals and crank pins for wear and tear to see whether grinding is necessary Using a micrometer measure the diameter of the main journals A1 and crank pins B1 AN Important Crankshaft half bearings cannot be replaced separately If the crankshaft needs to be ground establish the diameters of the connecting rod and crank pins in order to choose the matching measurements available of connecting rod and half bearing spare parts see Table of diameters of connecting rods and half bearings When grinding the crankshaft it is possible to downrate the crankshaft and connecting rod pins by 0 25 mm and 0 50 mm When grinding the crankshaft it is also necessary to consider grinding the sides shoulder to be able to choose uprated ring replacements see Table of uprated shoulder half rings AN Important Protect the contact surfaces with lubricant oil to prevent them from rusting 3 increase 23 187 23 320 23 450 23 500 b VE Y L OVERHAULS AND TUNING 6 Table of diameters of connecting rods and half bearings Wear amp Dimensions limit mm mm 47 984 48 000 47 900 Clearance mm A2A1 0 032 0 016 39 894 40 000 39 900 B2B1 0 021 0 066 Table of uprated shoulder half rings Dimensions
69. ments etc 1 3 MANUFACTURER AND ENGINE IDENTIFICATION The identification plate shown in the figure can be found directly on the engine It contains the model engine identity and all information needed to operate safely A Manufacturer s identity B Engine type C Engine serial number D Maximum speed E Customer code E Approval data GENERAL REMARKS AND SAFETY 1 Important remarks and features of the text are highlighted using symbols which are explained below Danger Attention This indicates situations of grave danger which if ignored may seriously threaten the health and safety of individuals AN Caution Warning This indicates that it is necessary to take proper precautions to prevent any risk to the health and safety of individuals and avoid financial damage AN Important This indicates particularly important technical information that should not be ignored This final section which is reserved specifically for LOMBARDINI after sales service centres has been prepared with technical and practical considerations in mind However the actual sequence of operations that LOMBARDINI service centres must use may in some cases be different from the ones described in this manual For this reason the reader should refer to the index to find his her topic of interest quickly e MADE IN ITALY LOMBARDIN Type rpm eee O sin JO T
70. mm Standard 22 787 22 920 23 050 23 100 1 increase 22 987 23 120 23 250 23 300 ee 2 increase 23 087 23 220 23 350 23 400 WASU DE br service manual 44 051135 5 LOMBARDINI 6 2 6 Dimensional check and overhaul of connecting rods 1 Check that the contact surfaces are perfectly clean and intact 2 Assemble the cap N onto the connecting rod big end and tighten the screws to a torque of 38 Nm 3 Using a micrometer measure diameters ga b AN Important If the diameter of the conncting rod small end does not match the diameter of the wrist pin the connecting rods must be replaced to achieve the right match see Table of connecting rod dimensions The half bearings are supplied smaller than the nominal dimensions by 0 25 mm and 0 50 mm Before replacing the connecting rods check that the weight difference does not exceed 10g to prevent weight imbalances see Table of connecting rod dimensions Protect the contact surfaces with lubricant oil to prevent them from rusting 6 2 7 Checking parallelism of the connecting rod axes 1 Insert the wrist pin V in the connecting rod small end 2 Use adial indicator to check that there is parallelism between the small end and big end axes Parallel deviation measured at the very tip of the wrist pin must not exceed 0 015 0 030mm If parallel values do not correspond to those indicated replace t
71. mp drive rod checking and replacing 50 Fuel pump checking and overhauling 46 Fuel pump disassembling 33 Fuel pump mechanical assembling 74 G General description of the engine 9 General safety during operating phases 6 General safety regulations 6 Glossary and terminology 6 H Half bearings and connecting rods table of diameters 44 Handling and lifting 25 Head gasket and clearance volume values table 52 1 IIdle speed rpms minimum and maximum adjusting 60 Injection pumps assembling 73 Injection delivery with dyno brake adjusting 61 Injection delivery without dyno brake adjusting 60 Injection delivery adjusting 60 Injection pump delivery balancing 58 Injection pumps disassembling 34 Injector pump parts replacing 91 Injector pump exploded diagram 91 Injector calibrating 53 Injetion timing conversion table for establishing 57 Installation of crankgear and crankcase 65 Installation of cylinder head and components 70 Installation of the cooling fan belt drive 78 Installing piston connecting rod engine block 65 Installing the assemblies recommendations 63 Installing the intake and exhaust manifolds 80 Installing the oil pump 68 Installing the timing belt drive 76 Installing valves 64 Intake and exhaust manifolds installing 80 Intake and exhaust manifolds removing 29 Intake manifold assembling 80 Intake manifold disassembling 29 L Looking for malfunction
72. n table for establishing injection timing For a good engine operation the injection static advance must be as follows Engine with maximum speed up to 3000 rpm 13 1 Engine with maximum speed above 3000 rpm 15 1 Conversion table for establishing injection timing If the static advance does not correspond to the ideal values change the adjustment by means of the screw N To increase the angular value higher static advance turn the screw clockwise qur To decrease the angular value lower static advance turn the screw anticlockwise AN Important Half turn of the screw equals approximately 5 of static angular advance 21 Disassemble all equipment when the injection static advance is reached 22 Fasten and tighten the nut B to a final torque of 40 Nm AN Important Repeat on the other cylinder service manual 57 mod 051135 5 LOMBARDINI OVERHAULS AND TUNING 6 23 Once adjustment is finished assemble the new O rings D on the injector pumps AN Important The O rings must always be replaced with original spare parts whenever the fuel rail is disassembled 24 Apply some silicone sealant on the fuel rail seat 25 Assemble the fuel rail and fasten the screws without tightening them 26 Tighten the screws to a final torque of 4 Nm 27 Slip on a new gasket 28 Reassemble the rocker arm cover
73. nd equipment for maintenance 19 Specific fuel consumption table 61 Speed governor and flow limiter assembling 72 Speed governor and flow limiter disassembling 35 Speed governor checking and overhauling 53 Speed governor exploded diagram 53 Springs valve stems valve guides dimensions table 51 Starter motor replacing 87 Static injection timing adjusting 55 Storing the engine installed 25 Storing the engine uninstalled 25 Tabella classi dimensioni cilindri pistoni 42 Table of cam dimensions 50 Table of camshaft dimensions 49 Table of connecting rod dimensions 45 Table of cylinder piston classes and dimensions 42 Table of diameters of connecting rods and half bearings 44 Table of dimensions for springs valve stems valve guides 51 Table of dimensions pin rocker arm 48 Table of head gasket and clearance volume values 52 Table of sealants 21 Table of sealing rings clearance 43 Table of specific fuel consumption 61 Table of tightening torques 19 Table of uprated shoulder half rings 44 Technical specifications 10 Terminology and glossary 6 Thermostatic valve replacing 89 Tightening torques table 19 Timing belt casting disassembling 31 Timing belt drive installing 76 Timing belt drive removing 31 Timing belt pulley assembling 76 Timing belt rates diagram 55 Timing belt rating checking 54 Timing belt assembling 76 Timing belt disassembling 32 Timing b
74. njector pump head screws TCEI 4x1 5 Flywheel screws 10x1 5 Coolant thermostat Control unit sensor Control unit temperature sensor For more detailed information see Assembling the cylinder head service manual 20 051135 LOMBARDINI TECHNICAL INFORMATION 2 2 12 TABLE OF SEALANTS Area of application Sealant Fuel rail attachment Loctite 638 Oil filter cartridge union M 20X1 5 Loctite 601 Camshaft bearing screw M 6 Loctite 270 Stud bolt for tightening pulley M 10 Loctite 601 Cylinder head plug 18 Loctite 510 Engine and engine block cylinder head plug 30 Loctite 510 2 13 ROUTINE ENGINE MAINTENANCE After the first REGULARITY KM per 1000 Km 500 Km 40 45 50 55 60 65 70 75 80 85 90 95 100 PROCEDURE DETAIL Pump injectors CLEANING Radiator fan Valve and rocker arm clearance Engine oil EVERY 2500 Km Solenoid valve operation Oil vapor recovery CHECK Fuel pipe and connections Coolant Alternator belt Timing belt Alternator Air filter element Engine oil Oil filter EVERY 5000 Km Fuel filter CHANGE Coolant Alternator belt Timing belt EVERY 50000 Km or at every disassembly Fuel pipes EVERY 4 years service manual 21 mod 051135
75. ns are in place in order to safeguard the operator and any persons involved For safety and convenience you are advised to place the engine on a special rotating stand for engine overhauls 5 2 1 Disassembling the intake manifold Panel filter 1 Remove the cover A 2 Remove the intake manifold B D 3 Unhook the minimum maximum device C or the spring C1 4 Remove the gasket D 5 Close the openings and ducts to prevent foreign bodies from entering Cartridge filter 1 Remove the cover E 2 Disconnect the intake and air vent pipes 3 Remove the intake manifold F 4 Unhook the minimum maximum device or the spring 5 Remove the gasket 6 Close the openings and ducts to prevent foreign bodies from entering service manual 29 mod 051135 QQ LOMBARDINI REMOVING THE ASSEMBLIES D 5 2 2 Disassembling the exhaust manifold 1 Remove the dipstick tube 2 Remove the exhaust manifold L 3 Remove the gaskets M 4 Close the openings and ducts to prevent foreign bodies from entering 5 3 REMOVING THE COOLING FAN BELT DRIVE 1 Remove the cooling fan A AN Important with internal alternator with external alternator The cooling fan belt drive comes in more than one version with external or internal alternator service manual 30 051135 5 LOMBARDINI REMOVI
76. ns 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 exhaust pipes in efficient working order to limit the noise level of the engine and reduce environmental pollution When discontinuing use of the engine select all components according to their chemical characteristics and dispose of separately PRECAUTIONS WHEN THE ENGINE IS INSTALLED ON THE MACHINE All operations except where expressly stated otherwise must be carried out when the engine is not running and has cooled sufficiently to avoid the risk of burns Do not keep the engine running in areas that are closed and inadequately ventilated Take all necessary precautions to prevent a build up of exhaust fumes 1 10 PRECAUTIONS WHEN THE ENGINE IS ON THE ROTATING STAND Before removing the engine from the machine on which it is installed disconnect the electric current the fuel supply coolant and all connections including mechanical ones To lift the engine attach the lifting device at the points eyebolts specified by the manufacturer Close all engine openings carefully exhaust intake etc wash the outside and dry with a jet of compressed air Anchor the engine to the rotating stand to facilitate all operations Note the engine may also be placed on the workbench depending on the ty
77. ons make sure that This chapter describes procedures for installing appropriate safety conditions are in place in order to assemblies and or individual components that have been safeguard the operator and any persons involved checked overhauled or replaced with original spare parts order to fix assemblies and or components securely the operator must tighten the fastening parts in a criss Important cross or alternating pattern To locate specific topics the reader should refer to Assemblies and or components with a specific tightening the index torque must initially be fastened at a level lower than the assigned value and then subsequently tightened to The operator must wash clean and dry components and the final torque assemblies before installing them The 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 7 2 PRE ASSEMBLY OF SEALING RINGS PISTONS Thoroughly clean the pistons and lubricate the coupling areas Putthe sealing rings on the piston in the order shown in the figure AN Important Placethe sealing rings with the markings facing up towards the upper part of the piston crown Keep the pistons together with their own connectin
78. ooling operating principle 15 Crank gear and crankcase removing 36 Crank gears and crankcase overhauling 41 Crankcase and crank gear removing 36 Crankcase and crank gears overhauling 41 Crankcase and crankgear 65 Crankcase and crankshaft disassembling 38 Crankcase assembling 66 Crankgear and crankcase installation 65 Crankshaft and crankcase disassembling 38 Crankshaft axial clearanca measuring 67 Crankshaft flange flywheel side assembling 67 Crankshaft assembling 66 Crankshaft dimensional check and overhaul 44 Cylinder piston classes and dimensions table 42 Cylinder head and components installation 70 Cylinder head and components overhaul 47 Cylinder head assembling 71 Cylinder head checking and overhauling 47 Cylinder head disassembling 36 Cylinder head removing 33 Cylinders and pistons overhauling 41 Cylinders dimensional check and overhaul 42 D Decanting device overhauling 47 Diagram of timing belt rates 55 Dimensional check and overhaul of connecting rods 45 Dimensional check and overhaul of crankshaft 44 Dimensional check and overhaul of cylinders 42 Dimensional check and overhaul of pistons 42 Dimensional check of sealing rings 43 Dimensional table of sealing rings 43 Disassembling the camshaft 36 Disassembling the connecting rod and piston 39 Disassembling the cooling fan belt with external alternator 31 Disassembling the cooling fan belt with internal
79. orque of 40 Nm 6 Make sure that the distance B is between 17 5 19 5 mm 7 Reconnect the electrical connectors service manual 87 mod 051135 Q LOMBARDINI REPLACINGPARTS 8 8 REPLACING THE FLYWHEEL RING GEAR In order to replace the ring gear it is necessary to disassemble the flywheel See Disassembling the flywheel for the correct procedure 1 Cut the ring gear A in several places using a chisel and remove it AN Important Remove any debris and carefully clean the ring gear 2 Heatthe new ring gear uniformly and keep it at a temperature of 300 C for15 20 minuti A Caution Warning 4 Leave to the ring gear to cool gently before Risk of burning be careful of hot surfaces reassembling the flywheel 3 Insert the ring gear into its seat and place it carefully on the rim of the flywheel B 8 9 REPLACING THE COOLANT THERMOSTAT AN Important Replacement may be carried out with the engine installed on the machine thermostat 1 Switch off the engine and leave to cool 2 Disconnect the electrical connectors 3 Remove the thermostat AS Important The screw is left handed turn clockwise to unscrew 4 Install the new thermostat 5 Tighten the thermostat to a torque of 30 Nm AN Important The screw is left handed turn anti clockwise to tighten 6 Reconnect the electrical connectors service manual 88 051135
80. pe of work to be carried out service manual mod 051135 A LOMBARDINI GENERAL REMARKS AND SAFETY service manual mod 051135 LOMBARDINI 2 1 GENERAL DESCRIPTION OF THE ENGINE Main components A B C D F G H Cylinder head Engine block Crankcase Timing belt assembly Flywheel and crankshaft assembly Air intake assembly Cooling fan Negative pressure vent valve L M Q R S TECHNICAL INFORMATION 2 Alternator Oil filter Exhaust manifold Starter motor Camshaft Coolant pump Fuel supply pump Oil pump service manual mod 051135 A LOMBARDINI 2 2 TECHNICAL SPECIFICATIONS 1 2 Q TECHNICAL INFORMATION 2 DIMENSIONS mm A 451 353 E 181 H 36 N 340 5 51 R 182 B 491 D 238 213 M 280 P 151 52 S 160 1 with suction fan 2 with blower fan GENERAL DETAILS Operating cycle 4 stroke diesel Number of cylinders Bore x stroke Displacements Compression rate 22 8 Intake Air filter dry Filter capacity um 13 14 Filtering surface cm 4470 Cooling Water Driving shaft rotation Clockwise from distribution side Combustion sequence 1 2 Timing system Synchronous toothed belt Dry weight of engine Kg Max
81. rating pressure bar 7 Maximum combustion pressure bar 20 Filter capacity u 15 By pass valve setting bar 1 5 1 7 Filtering surface cm 730 COOLING CIRCUIT Coolant 50 water 50 antifreeze fluid Thermostatic valve Opening temperature C 83 87 Max stroke at 94 C mm 7 Liquid return 30 80 ELECTRICAL EQUIPMENT Nominal voltage 12 Alternator nominal voltage 14 Internal external alternator nominal current see Alternator load curve diagrams 40 Starter motor power 1 1 Preheating glow plugs Nominal voltage 12 5 Absorption after 5 seconds 12 14 Surface temperature of the sheath 850 Control unit temperature sensor Working field 30 80 Voltage 6 24 Max temperature 150 Oil pressure switch Operating pressure 0 15 0 45 Coolant temperature monitoring sensor Electric circuit Unipolar system Supply voltage 6 24 Absorbed power 3 Closed circuit temperature 107 113 service manual 11 mod 051135 5 LOMBARDINI TECHNICAL INFORMATION 2 2 3 CHARACTERISTIC CURVE DIAGRAMS Power curve diagram 80 1269 CEE 95 1 CE 3000 tr min g kWh g CVh 300 280 260 Legend NB Power curve MB Torque curve Cz Specific consumption curve 240 1200 1400 1600 18
82. re Timing belt control angles valve clearance 2mm 25 after S top ded centre closes 2 dopo I bottom dead centre y 5 after bottom dead centre 6 18 before S top ded centre 6 6 ADJUSTING STATIC INJECTION TIMING In order to adjust injection timing it is necessary to remove the rocker arm cover See Disassembling rocker arm cover for the correct procedure 1 Disassemble the injector pump fuel rail A 2 Selectthe cylinder on which the injection static advance adjustment will be carried out 3 Unscrew the rocker arm support nut B corresponding to the cylinder on which the procedure will be carried out Legenda S piston at top dead centre l piston at bottom dead centre a intake valve open intake valve closed exhaust valve open 6 exhaust valve closed OVERHAULS AND TUNING 6 service manual 55 mod 051135 C LOMBARDINI OVERHAULS AND TUNING 6 4 Assemble the dial indicator on stud bolt C 5 Place the dial indicator tracer on the exhaust valve collar A 6 Remove the O ring D from the little non return valve and replace it with the suitable rubber cap E part of tool 7107 1460 048 dial indicator dial indicator tracer 7 Install the tool metal base plate F 8 Remove the rocker arm cover gasket 9 Fix the tool lever base G on cylinder head 10 Rotate the cranks
83. rews R in a crisscross pattern to a final torque of 12Nm 7 5 6 Installing the oil pump Before installing the oil pump make sure there are no malfunctions see Check and overhaul the oil pump AN Important Check that the contact surfaces are perfectly clean and intact 1 Slip on anew gasket A 2 Insert the oil pump activation key into the crankshaft 3 Bring piston number one flywheel side to the top dead centre with the oil pump activation key in line with break in the flange in order to be able to assemble the pump 4 Install the pump B and put in the screws C AN Important Be careful not to damage the sealing rings during this operation oil pump activation ke service manual 68 mod 051135 j LOMBARDINI INSTALLATION OF ASSEMBLIES 7 5 Tightenthe screws in a crisscross pattern and tighten each of them to their respective final torques see image 6 Insert the key D into the crankshaft 7 Installthe alternator support E and tighten the screws to a torque of 2 2Nm oil pump activation ke 7 5 7 Assembling the flywheel 1 Install the support F and tighten the screws to a torque of 25 Nm 2 Install the flywheel G and put in the screws H 3 Tighten the screws temporarily in a crisscross pattern 4 Tightenthe screws in a crisscross pattern to a final torque of 80Nm AN Important Turn the flywheel manually to check th
84. rnal parts of the engine using suitable products 16 Treat non painted parts with protective products AGIP RUSTIA 100 F 17 Loosen the alternator fan belt 18 If necessary cover the engine with a protective sheet AN Important After a year of engine inactivity the coolant loses its properties and must be replaced 4 5 PREPARING THE ENGINE FOR OPERATION UNINSTALLED After a period of inactivity and before installing and running the engine it is necessary to carry out a few measures in order to ensure that it runs at maximum efficiency 1 Remove the protective treatment 2 Remove any blockages from the exhaust and intake ducts 3 Usea cloth soaked in degreasing product to remove the external protective treatment 4 Remove the intake manifold 5 Inject lubrication oil no more than 2 cm into the valves and replace the intake manifold 6 Adjust the alternator fan belt tension 7 Turnthe flywheel manually to check the movement of the mechanical parts 8 Startthe engine and run at 34 of the maximum speed for 5 10 minutes 9 Switch off the engine 10 Remove the protective oil to replace with engine oil 11 Introduce new oil see Table of lubricants up to the correct level marked on the dipstick Check the filters for aging air oil fuel and if necessary replace them with original spares 12 A Important Over time a number of engine components and lubricants lose their properties ev
85. rranty from any damages caused in this way Important 4 2 STORING THE ENGINE UNINSTALLED If the engine is not to be used for extensive periods check the surroundings and the type of packaging and make sure that they are suitable for correct storage If necessary cover the engine with a protective sheet Avoid storing the engine directly on the ground or in an environment that is humid exposed to bad weather or close to sources of danger including less visible ones such as high voltage power lines etc 4 3 STORING THE ENGINE INSTALLED If the engine has been installed on a machine and is not due to be used for extensive periods it is necessary to carry out a few maintenance measures in order to ensure it remains efficient and to protect its components If the engine is installed on the machine and is not to be used for short periods of time the following measures must be carried out Check the condition of the electrical contacts and protect them if necessary using an anti rust spray Disconnect the battery Empty the fuel tank to prevent the risk of fire Ifthe engine is not to be used for more than 1 month itis necessary to apply the protective measures that are valid for 6 months see Protective treatment first 6 months of inactivity If after the first 6 months the engine is still not to be used it is necessary to carry out a further measure to extend the protection period s
86. rvice manual 32 051135 Q LOMBARDINI REMOVING THE ASSEMBLIES 5 5 5 REMOVING THE CYLINDER HEAD 5 5 1 Disassebling the rocker arm cover 1 Remove the negative pressure vent valve A 2 Remove the rocker arm cover B 3 Remove the gasket 5 5 2 Disassebling the rocker arms 1 Press the rocker arm to fully push the drive rod down E 2 Introduce a pin to interrupt the injector stroke in order to be able to extract the drive rod 3 Letgo ofthe rocker arm and remove the drive rod 4 Repeatthe same operation on the other injector 5 Remove the rocker arm pin and support D 5 5 3 Disassebling the fuel pump 1 Disconnectthe supply pipe G1 from the union 2 Remove the supply pump G 3 Removethe O ring G2 4 Extractthe drive rod H service manual 33 mod 051135 5 LOMBARDINI REMOVING THE ASSEMBLIES D 5 5 4 Disassembling the injection pumps 1 Remove the fuel rail F AN Important Make sura that the injector gaskets remain in position 2 Unhook the spring L AN Important If injector pumps are to be used during installation do not loosen the screws LI in order to not balance injector pump deliveries during tuning 3 Unscrew the screws M 4 Remove the connecting rod M1 5 Dismount the injection pumps 5 5 5 Disassembling precombustion chamber 1 Disconnect the electri
87. s Important Be careful not to damage the half bearing thrust bearings during removal 5 7 DISASSEMBLING THE VALVES 1 Placethe cylinder head on the workbench 2 Press down hard on the cup A using the special tool 3 Removethe half collets B blocking the cup A the spring C the collar D and the gasket E 4 Remove the valves F AN Important Keep components together during the disassembly phase in order to be able to reassemble correctly service manual 39 mod 051135 Q LOMBARDINI REMOVING THE ASSEMBLIES D 5 8 DISASSEMBLING THE PISTON 1 Remove the stop ring B 2 Extract the wrist pin C to separate the piston D from the connecting rod E AS Important Keep each connecting rod together with its piston and wrist pin 3 Remove the stop rings F service manual 40 mod 051135 5 LOMBARDINI 6 1 RECOMMENDATIONS FOR OVERHAULS AND TUNING Information is given in a logical order in terms of timing and sequence of operations The methods have been selected tested and approved by the manufacturer s technical experts This chapter describes procedures for controlling overhauling and tuning assemblies and or individual components AN Important To locate specific topics the reader should refer to the index Before any intervention the operator should lay out all equipment and tools in such a way
88. s 23 Lubricants 14 Lubrification operating principle 15 M Maggiorazioni semianelli di spallamento tabella 42 Maintenance engine routine 21 Maintenance special tools and equipment 19 Malfunctions looking for 23 Manufacturer and engine identification 5 Measuring crankshaft axial clearance 67 Mechanical fuel pump assembling 74 N Negative preassure vent valve replacing 90 Nozzle injector replacing 93 Oil filter replacing 85 Oil preassure checking 61 Oil pump disassembling 37 Oil pump installing 68 Operating phases general safety 6 Operating principle for cooling 15 Operating principle for fuel injection 16 Operating principle for lubrification 15 O rings 41 Overhaul and dimensional check of connecting rods 45 Overhaul and dimensional check Cylinders 42 Overhaul and dimensional check pistons 42 Overhaul and dimensionalcheck crankshaft 44 Overhaul of cylinder head and components 47 Overhauling and checking the cylinder head 47 Overhauling and checking the fuel pump 46 Overhauling and checking the rocker arm pin 48 Overhauling cylinders and pistons 41 Overhauling the crank gears and crankcase 41 Overhauling the decanting device 47 Overhauls and tuning recommendations 41 Parallelismo assi biella controllo 45 Pin rocker arm dimensions table 48 Piston cylinder classes and dimensions table 42 Piston connecting rod engine block installing 65
89. sede 5 Use a pointed tool to take out the valve seats 6 Removeany debris clean the valve seat holder carefully A Important and scrape the mouth Protect the contact surfaces with lubricant oil to prevent them from rusting 7 Lubricate the new valve seats and put them into the holder manually 11 Assemble the valves see Assembling the flywheel service manual 51 mod 051135 5 LOMBARDINI 6 3 6 Adjusting valve rocker arm clearance In order to make the adjustment itis necessary to remove the rocker arm cover See Disassembling the rocker arm cover for the correct procedure AN Important Adjustment of valve clearance must be done when the engine is cold 1 Place the pistons at the compression top dead centre 2 Turn the screw and the lock nut to adjust clearance Adjustment can be made in two different points the contact area between the rocker arm and the camshaft 0 15mm and or the contact area between the rocker arm and the valve 0 2mm 3 Repeat the same operation on the other valves 6 3 7 Checking clearance volume 1 Position the pistons at the top dead centre 2 Measure the distance in four diametrically opposite points on the piston crown 3 Repeat the operation on all pistons The maximum value determines the measurement A Choose the gasket corresponding to the measured value This match determines the value of the clearance volume see Table of hea
90. see Assembling the rocker arm cover 6 7 BALANCING THE INJECTION PUMP DELIVERY AN Importante It is necessary to balance delivery whenever the injection pump is replaced In order to work on the injector it is necessary to remove the rocker arm cover See Disassembling the rocker arm cover for the correct procedure 1 Remove the fuel rail A 2 Mount the 7107 1460 127 tool heads B service manual 58 mod 051135 Q LOMBARDINI OVERHAULS AND TUNING 6 3 Position the assembly 7107 1460 127 above the height of the injectors e gt assembly 4 Connect the outlet and intake pipes of the 7107 1460 127 assembly to the test heads fuel filter AN Important Be careful not to reverse the intake and outlet pipes when connecting 5 Open the cocks C 6 Start the engine and keep it at minimum idle speed 1150 1250 Rpm 7 Turn the equipment switching valve by means of the lever D The engine is supplied by tubes and no more by tool tank 8 Checkthe level of the test heads after 1 minute 9 Make sure the difference in volume is no greater than 1 AN Important If the difference is greater increase delivery of the injector pump with the highest level or reduce the one with the lowest level 10 Loosen the screw E to adjust delivery at the injector 11 Shift the plate F gently in one of t
91. ssembling the intake manifold 80 service manual 4 mod 051135 5 LOMBARDINI 1 1 PURPOSE OF THE MANUAL 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 This information is provided by the manufacturer in its own language Italian and may be translated into other languages to satisfy legislative and or commercial requirements 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 in the operating phases 1 2 USING THIS MANUAL This manual is divided into several chapters The first chapter gives general information and details about safety purpose of the manual safety etc The second third and fourth chapters provide general technical information technical specifications diagrams tightening torques malfunctions etc The fifth sixth seventh and eighth chapters describe the most important operating procedures removal overhaul and tuning installation replace
92. t the same time tightening the screw to regulate belt tension AN Important Use the method shown in the diagram to check belt tension The resultant R must be 10 15 mm 6 Tighten the nuts B B1 to a final torque of 40Nm and 25Nm respectively With internal alternator 1 Switch off the engine and leave to cool fl a 2 Remove the cooling fan cooling fan fan hub pulley 3 Remove the hub and flange 4 Slip off the belt and replace it with an original spare 5 Install the flange and pulley hub 6 Manually rotate the fan to make sure the belt is fitted correctly 7 Tighten the screws to a torque of 10 Nm 8 Regolare la tensione della cinghia AN Important To check the belt tension follow the procedure explained in the figure The resultant must be 10 15 mm If the belt is too tense insert a spacer between the flange and the pulley or remove a spacer if it is too slack service manual 84 mod 051135 A LOMBARDINI REPLACING PARTS 8 9 Install the cooling fan 10 Tighten the screws to a torque of 10 Nm fan fan hub pulley 8 3 REPLACING THE TIMING BELT AN Important 4 Replace the timing belt with an original spare see Replacement may be carried out with the engine Assembling the timing belt drive installed on the machine 5 Check the timing belt rating see Checking timing belt 1 Switch off the engine and
93. th an original spare 5 Slipona new gasket D 6 Replace the cover B and fix it using the screws 7 Replace the pipe A and fasten it using the clamp 8 Mount the starter motor and tighten the screws to a torque 45 Nm 6 3 OVERHAUL OF CYLINDER HEAD AND RELATED COMPONENTS 6 3 1 Checking and overhauling the cylinder head 1 Place the cylinder head on a surface plate and position it with the corners on the stud bolts 2 Using a dial indicator make sure the cylinder head is level AN Important If the level deviation is above 0 1mm the cylinder head must be ground removing not more than 0 2mm 3 Before grinding remove the valves see Disassembling the valves and the precombustion chambers see Disassembling the precombustion chamber service manual 47 mod 051135 5 LOMBARDINI 6 3 2 Checking and overhauling the rocker arm pin 1 In order to carry out a control of the rocker arm assembly it is necessary to disassemble the cylinder head See Disassembling the rocker arms for the correct procedure 2 Bore ahole in the blocking pin A using a 4mm bit to remove it 3 Extract the supports and the rocker arm from the pivot pin B 4 Thoroughly clean the components 5 Using a micrometer measure the diameters of the pivot pin and the rocker arms see Table of dimensions pin rocker arm Table of dimensions pin rocker arm Tear amp Clearan
94. uality direct injection Euro3 E5 High performance in heavy 2 5 4 Recommended oil Oil type Description API Agip SINT 2000 5W40 Engine oil conditions Euro1 Euro2 Euro3 engines Oil characteristics SJ CF ACEA A3 96 B3 96 MIL L 4615 D E service manual 14 mod 051135 5 LOMBARDINI 2 6 OPERATING PRINCIPLE FOR LUBRIFICATION TECHNICAL INFORMATION 2 m Description Pressure switch Rocker arm pin Connecting rod big end pin Oil filter cartridge Main jurnal Oil drain plug Oil dipstick Air vent o Oil refilling pump Camshaft Oil pressure regulating valve Oil pump Crankshaft Oil suction filter N OPERATING PRINCIPLE FOR COOLING 10 11 12 13 14 oO WM D Description Coolant refilling plug Compensation tank Thermostatic valve Cylinder block Liquid temperature monitoring thermostat Circulating pump Fan OM Radiator service manual 15 mod 051135 A LOMBARDINI 2 8 OPERATING PRINCIPLE FOR FUEL INJECTION With mechanical supply pump TECHNICAL INFORMATION 2 Ref Description 1 Tank 2 Fuel filter 3 Suppl
95. y clean and intact 1 Slip on anew gasket C 2 Apply some silicone sealant on the fuel rail seat D 3 Mountthe cover E and fasten the screws without tightening them 4 Tightenthe screws in a crisscross pattern to a final torque of 10 Nm 5 Assemble the negative pressure vent valve F service manual 75 mod 051135 A LOMBARDINI 7 7 INSTALLING THE TIMING BELT DRIVE 7 7 1 Assembling the timing belt pulley 1 Insert the key B into the crankshaft 2 Mountthe pulley A 3 Mountthe pulley and tighten the screw to a torque 80 Nm AN Important To ensure the correct timing line up the reference notches on the pulley A C with the respective gear timing notches X Y 7 7 2 Assembling the timing belt 1 Insert the belt into the pulley C Keeping it taut insert into pulley A AN Important Keep the reference arrows G directed as shown in the diagram The timing belt must always be replaced with an original spare part whenever it is removed 2 Keep the belt inserted into the two pulleys and then mount it onto pulley E and the pulley nut F 3 Tighten the belt using the pulley nut F and fasten temporarily AS Important To maintain engine timing while the timing belt is being installed keep it slotted onto the two pulleys A C which must remain lined up with their notches INSTALLATION OF ASSEMBLIES 7 service manual 7
96. y pipe 4 Supply pump 5 Injection pump 6 Injector 7 Fuel rail 8 Exhaust pipe 9 Plug 10 Solenoid valve Note the tank is supplied complete with filter on request With electrical supply pump D D f Description Tank Fuel filter Supply pipe Electrical supply pump Pump Injector Fuel rail Exhaust pipe Q o jojon olim Plug service manual 16 mod 051135 5 LOMBARDINI 2 9 WIRING DIAGRAM TECHNICAL INFORMATION 2 Electric pump version With external alternator 40A ae 22 NES yar tanto IG 1 wait WEISS Aus 15 ped Ed VERMELHO AZZURRO AZUR BLAU iat 30 25mm 5 o z ATZURRO AZUA B 2 8 Ref Description Ref Description 1 40A alternator 13 Coolant thermostat indicator light 2 Starter motor 14 Engine oil preassure lamp 3 Battery recommended 44Ah 210A DIN 15 Oil preassure gauge 4 Preheating glow plugs 16 Battery load indicator 5 Coolant temperature monitoring sensor 18 Coolant thermometer 6 Glow plug pre heating control box 19 Coolant thermomenter sensor 7 Ignition switch 20 Fuel level light 8 50A fuses 21 Fuel level indicator 9 5A fuses 22 Relay normally closed with a 3 second delay 10 Electrostop device or electri

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