Bosch 5302 Technical information

WORKSHOP MANUAL
Engine Series 3 - 4 LD
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the following table.
Drafting
body
DICOM/ATLO
Document
code
Model
N°
Edition
Revision
Issue date
Review
date
ED0053025560
50839
4°
3
01-94
15.06.2014
Endorsed
Manual’s purpose
•This manual contains the instructions needed to carry out a proper maintenance of the engine, therefore it must always be
available, for future reference when required.
•Safety pictograms can be found on the engine and it is the operator’s responsibility to keep them in a perfectly visible place and
replace them when they are no longer legible.
•Information, description and pictures in this manual reflect the state of the art at the time of the marketing ofengine.
•However, development on the engines is continuous.Therefore, the information within this manual is subject to change without
notice and without obligation.
•LOMBARDINI srl reserves the right to make, at any time, changes in the engines for technical or commercial reasons.
•These changes do not require LOMBARDINI srl to intervene on the marketed production up to that time and not to consider
this manual as inappropriate.
•Any additional section that LOMBARDINI srl will deem necessary to supply some time after the main text shall be kept together
with the manual and considered as an integral part of it.
•The information contained within this manual is the sole property of LOMBARDINI srl. As such, no reproduction or replication
in whole or part is allowed without the express written permission of LOMBARDINI srl.
-2-
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
PREFACE
Every attempt has been made to present within this use and maintenance, accurate and up to date technical information.
However, development on the Lombardini series is continuos.
Therefore, the information within this manual is subject to change without notice and without obligation.
Carefully read and follow all instructions in this booklet as well as all those provided with the equipment on which this engine is used.
The information contained within this service manual is the sole property of Lombardini.
As such, no reproduction or replication in whole or part is allowed without the express written permission of Lombardini.
Information presented within this manual assumes the following the person or persons performing service work on Lombardini
series engines:
1 - is properly trained and equipped to safely and professionally perform the subject operation;
2 - possesses adequate hand and Lombardini special tools to safely and professionally perform the subject service operation;
3 - has read the pertinent information regarding the subject service operations and fully understands the operation at hand.
- For spare parts and after sale assistance contact authorized service centers.
- For any spare parts order please specify following details: ENGINE TYPE AND SERIAL NUMBER
- Version (K) - on the engine name plate
- Tel. No. appears on service booklet or on the website: www.lombardinigroup.it
- Pls contact Service Centers for special applications.
GENERAL SERVICE MANUAL NOTES
1- Use only genuine repair parts. Failure to use genuine parts could result in sub-standard performance and low longevity.
2- All data presented are in metric format:
. dimensions are presented in millimeters (mm),
. torque is presented in Newton-meters (Nm),
. weight is presented in kilograms (kg),
. volume is presented in liters or cubic centimeters (cc)
. pressure is presented in barometric units (bar).
3- To ensure safe operation please read the following statements and understand their meaning.
Also refer to your equipment manufacturer’s manual for other important safety information.
This manual contains safety precautions which are explained below.
WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial
property damage if the warning is ignored.
IMPORTANT This indicates particularly important technical information that should not be ignored.
CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property
damage if the caution is ignored.
GLOSSARY AND TERMINOLOGY
For clarity, here are the definitions of a number of terms used recurrently in the manual.
- Cylinder number one: is the timing belt side piston .
- Rotation direction: anticlockwise «viewed from the flywheel side of the engine».
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
-3-
-
INDEX
This handbook provides the main information concerning the repair of the following LOMBARDINI Diesel engines 3LD 450,
3LD 510, 3LD 451/S, 3LD 510/S, 4LD 640, 4LD 705, 4LD 820, which are air-cooled, provided with direct injection and revised
on the 15-06-2014.
1
GENERAL REMARKS AND SAFETY INFORMATION........................................................................................Pag. 6 - 7
California Proposition 65 .................................................................................................................................................... 7
General safety during operating phases ............................................................................................................................ 8
Regulations for lifting the engine . ...................................................................................................................................... 7
Safety and enviromental impact . ....................................................................................................................................... 8
Safety information ........................................................................................................................................................... 6-7
2
TECHNICAL INFORMATION .................................................................................................................................... 10 - 15
Manufacturer and motor identification data . .................................................................................................................... 10
Capacities in litres - Air filter oil bowl . .............................................................................................................................. 14
Capacities in litres - Standard fuel tanks . ........................................................................................................................ 14
Capacities in litres - Standard oil sump . .......................................................................................................................... 14
Lubricant - ACEA-Regulations sequences ....................................................................................................................... 15
Lubricant - API-MIL sequences ........................................................................................................................................ 15
Lubricant - International specifications . ........................................................................................................................... 15
Lubricant - SAE classification .......................................................................................................................................... 15
Performance diagrams . ................................................................................................................................................... 12
Possible causes and trouble shooting ............................................................................................................................. 13
Routine engine maintenance ........................................................................................................................................... 14
Table of likely anomalies and their symptoms . ................................................................................................................ 13
Technical data ...................................................................................................................................................................11
3
DISASSEMBLY / REASSEMBLY............................................................................................................................... 16 - 29
Camshaft . ......................................................................................................................................................................... 27
Camshaft axial clearance . ................................................................................................................................................ 25
Camshaft intake and exhaust cam height. ........................................................................................................................ 28
Camshaft intake and exhaust cam timing ......................................................................................................................... 27
Camshaft pin and housing dimensions (mm) . .................................................................................................................. 28
Clearance volume ............................................................................................................................................................. 23
Connecting rod equipped with bearings and piston pin .................................................................................................. 24
Connecting rod, big end bearings ..................................................................................................................................... 24
Cylinder and piston ........................................................................................................................................................... 22
Decompression (by request) ............................................................................................................................................. 18
Distance among segment ends (mm) .............................................................................................................................. 22
Distribution timing without following the references ......................................................................................................... 28
Distribution timing ............................................................................................................................................................. 28
Drive shaft ......................................................................................................................................................................... 26
Drive shaft axial clearance ................................................................................................................................................ 24
Drive shaft connecting radius . .......................................................................................................................................... 26
Drive shaft internal diam. crankshaft bearing / connecting rod head
and clearances regarding their respective pins (mm) ...................................................................................................... 27
Drive shaft lubrication ducts .............................................................................................................................................. 26
Drive shaft main journal and crank diametres (mm) ......................................................................................................... 26
Flywheel ............................................................................................................................................................................ 17
Head ................................................................................................................................................................................. 19
Injector, projection ............................................................................................................................................................. 19
Main bearing on flywheel side . ......................................................................................................................................... 24
Oil-bath air filter (standard) ............................................................................................................................................... 16
Piston reassembly . ........................................................................................................................................................... 23
Piston ring - Clearances among slots (mm) ...................................................................................................................... 22
Piston ring assembly order ............................................................................................................................................... 23
Recommendations for disassembling ............................................................................................................................... 16
Rocker arm pin and hole .................................................................................................................................................. 19
Rocker arm pin, extraction ............................................................................................................................................... 18
Side distributor port ........................................................................................................................................................... 25
Silencer (standard) . .......................................................................................................................................................... 16
Speed governor ................................................................................................................................................................ 29
Starting pulley ................................................................................................................................................................... 17
Timing of the speed governor ........................................................................................................................................... 29
-4-
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Index
-
Valve guide dimensions and clearances .......................................................................................................................... 20
Valve guides insertion ...................................................................................................................................................... 20
Valve housings and seats ................................................................................................................................................ 21
Valve seat grinding . .......................................................................................................................................................... 21
Valve/rocker arm clearance . ............................................................................................................................................. 19
Valves . .............................................................................................................................................................................. 19
Valves guides and housings ............................................................................................................................................. 20
Vent plug ........................................................................................................................................................................... 17
5
LUBRICATION CIRCUIT............................................................................................................................................ 30 - 32
Lubrication circuit ............................................................................................................................................................. 30
Oil filter cartridge .............................................................................................................................................................. 31
Oil pressure check ........................................................................................................................................................... 32
Oil pressure curve with the engine at its maximum speed . ............................................................................................. 32
Oil pressure regulating valve ........................................................................................................................................... 32
Oil pump . ......................................................................................................................................................................... 31
Oil pump, difference between clockwise rotation pump and anticlockwise pump . ......................................................... 31
6
FUEL INJECTION CIRCUIT....................................................................................................................................... 33 - 35
Advanced injection (static) .............................................................................................................................................. 34
Advanced Injection references on the conveyor and flywheel protection disk ................................................................ 35
Feeding pump (by request) .............................................................................................................................................. 33
Feeding pump rod projection ........................................................................................................................................... 33
Fuel filter inside the tank (standard) . ............................................................................................................................. 33
Injection pump . ................................................................................................................................................................ 34
Injection pump assembly ................................................................................................................................................. 34
Injector ............................................................................................................................................................................. 35
Injector setting . ................................................................................................................................................................ 35
Standard feeding/injection circuit ..................................................................................................................................... 33
7
ELECTRIC CIRCUIT................................................................................................................................................... 36 - 38
8
12 V 14 A electrical ignition, diagram with voltage regulator , battery recharge lamp and manostat .............................. 36
12,5 V, 14 A alternator battery recharge curve ................................................................................................................. 36
12.5 V 14 A alternator ..................................................................................................................................................... 36
Bosch DW (L) 12 V 1, 1 KW type, starting motor . .......................................................................................................... 37
Bosch JF(L) 12V 2.5 kW type, starting motor ................................................................................................................. 38
Characteristic curves for Bosch DW(L) 12V 1.1 kW type, starting motor .................................................................... 38
Characteristic curves for Bosch JF(L) 12V 2,5 kW type starting motor .......................................................................... 38
Voltage regulator .............................................................................................................................................................. 37
Voltage regulator, running check . .................................................................................................................................... 37
ADJUSTMENT............................................................................................................................................................ 39 - 40
Adjustment of injection pump delivery with braked engine .............................................................................................. 40
Injection pump delivery adjustment (standard) ............................................................................................................... 39
Limiting device for injection pump delivery and torque gearing device ........................................................................... 40
Minimum rpm adjustment at idle running (standard) . ...................................................................................................... 39
Peak rpm adjustment at idle (standard) ......................................................................................................................... 39
Required adjustments (the most demanded) ................................................................................................................... 40
9
STORAGE......................................................................................................................................................................... 41
Protective treatment ......................................................................................................................................................... 41
Preparing the engine for operation after protective treatment ......................................................................................... 41
10
MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS................................................................................ 42 - 44
Tightening torques main . .................................................................................................................................................. 42
Table of tightening torques for standard screws (fine thread) ........................................................................................... 43
Table of tightening torques for standard screws (fine thread) ........................................................................................... 43
Use sealant........................................................................................................................................................................ 44
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
-5-
1
General remarks and safety information
This manual contains safety precautions which are explained
below.
WARNING
Warning is used to indicate the presence of a hazard that can
cause severe personal injury, death, or substantial property
damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or
can cause minor personal injury or property damage if the caution
is ignored.
IMPORTANT This indicates particularly important technical information that
should not be ignored.
SAFETY INFORMATION
GENERAL NOTES
. Lombardini engines are built to provide safe and
longlasting performances, but in order to obtain these
results it is essential that the maintenance requirements
described in the manual are observed along with the
following safety recommendations.
. The engine has been built to the specifications of a machine
manufacturer, and it is his responsibility to ensure that all
necessary action is taken to meet the essential and legally
prescribed health and safety requirements. Any use of the
machine other than that described cannot be considered
as complying with its intended purpose as specified by
Lombardini, which therefore declines all responsibility for
accidents caused by such operations.
. The following instructions are intended for the user of the
machine in order to reduce or eliminate risks, especially
those concerning the operation and standard maintenance
of the engine.
. The user should read these instructions carefully and get to
know the operations described. By not doing so he may
place at risk his own health and safety and that of anyone
else in the vicinity of the machine.
. The engine may be used or mounted on a machine only
by personnel suitably trained in its operation and aware of
the dangers involved. This is particularly true for standard
and, above all, special maintenance work. For special
maintenance contact personnel trained specifically by
Lombardini. This work should be carried out in accordance
with existing literature.
. Lombardini declines all responsibility for accidents or for
failure to comply with the requirements of law if changes
are made to the engine’s functional parameters or to the
fuel flow rate adjustments and speed of rotation, if seals
are removed, or if parts not described in the operating and
maintenance manual are removed and reassembled by
unauthorized personnel.
WARNING
. In addition to all other machine specifications, ensure that
the engine is in a near horizontal position when starting.
lf starting manually, ensure that the necessary operations
can be performed without any risk of striking against walls
or dangerous objects. Rope starting (except for recoil rope
starting) is not permitted even in emergencies.
. Check that the machine is stable so that there is no risk of it
overturning.
. Get to know the engine speed adjustment and machine stop
operations.
. Do not start the machine in closed or poorly ventilated
-6-
environments. The internal combustion process generates
carbon monoxide, an odourless and highly toxic gas, so
spending too long a time in an environment where the engine
discharges its exhaust products freely can lead to loss of
consciousness and even death.
. The engine may not be used in environments containing
flammable materials, explosive atmospheres or easily
combustible powders, unless adequate and specific
precautions have been taken and are clearly stated and
certified for the machine.
. To prevent the risk of fire, keep the machine at a distance of at
least one metre from buildings or other machines.
. Children and animals must be kept at a sufficient distance from
the machine to prevent any danger resulting from its operation.
. Fuel is flammable, so the tank must be filled only when the
engine is turned off. Dry carefully any fuel that may have
spilled, remove the fuel container and any cloths soaked
in fuel or oil, check that any sound-absorbing panels made
of porous material are not soaked with fuel or oil, and make
sure that the ground on which the machine is located has not
absorbed fuel or oil.
. Before starting, remove any tools that have been used for
carrying out maintenance work to the engine and/or the
machine and check that any guards removed have been
replaced. In cold climates it is possible to mix kerosene with
the diesel fuel to make the engine easier to start. The liquids
must be mixed in the tank by pouring in first the kerosene and
then the diesel fuel. Consult Lombardini technical office for
mixture proportions. Petrol may not be used because of the
risk of it forming flammable vapours.
. During operation the surface of the engine reaches
temperatures that may be dangerous. Avoid in particular all
contact with the exhaust system.
. The liquid cooling circuit is under pressure. Do not carry out
any checks before the engine has cooled down, and even
then open the radiator cap or the expansion tank cautiously.
Wear protective clothing and glasses. lf there is an electric
fan, do not approach the engine while it is still hot as the fan
may come on even when the engine is not running. Clean the
cooling system with the engine turned off.
. While cleaning the oil bath air filter, check that the oil is
disposed of in such a way as not to harm the environment.
Any filtering sponges in the oil bath air filter should not be
soaked with oil. The cyclone pre-filter cup must not be filled
with oil.
. Since the oil must be emptied out while the engine is still hot
(approx. 80°C), particular care should be taken in order to
avoid burns. In any case make sure that oil does not come into
contact with your skin because of the health hazards involved.
. Fuel vapours are highly toxic, so fill up only in the open air or in
well ventilated environments.
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
General remarks and safety information
1
. During operations which involve access to moving parts of . In order to move the engine simultaneously use the eyebolts
fitted for this purpose by Lombardini. These lifting points are
the engine and/or removal of the rotary guards, disconnect
however not suitable for the entire machine, so in this case
and insulate the positive cable of the battery so as to
use the eyebolts fitted by the manufacturer.
prevent accidental short circuits and activation of the starter
motor.
. Check the belt tension only when the engine is turned off.
IMPORTANT
. To start the engine follow the specific instructions provided
in the engine and/or machine operating manual. Do not
use auxiliary starting devices not originally installed on the
machine (e.g. Startpilot systems which utilise ether etc.)
. Before carrying out any work on the engine, turn it off and
allow it to cool down. Do not perform any operation while
the engine is running.
. Check that the discharged oil, the oil filter and the oil
contained in the oil filter are disposed of in such a way as
not to harm the environment.
. Close the fuel tank filler cap carefully after each fílling
operation. Do not fill the tank right up to the top, but leave
sufficient space to allow for any expansion of the fuel.
. Do not smoke or use naked flames while filling.
. Take care when removing the oil filter as it may be hot.
. The operations of checking, filling up and replacing the
cooling liquid must be carried out with the engine turned off
and cold. Take particular care if liquids containing nitrites
are mixed with others not containing these compounds
as this may give rise to the formation of nitrosamines
which are a health hazard. The cooling liquid is polluting,
so dispose of in a manner that does not damage the
environment.
Regulations for lifting the engine
- Before removing the engine from the vehicle on which it is installed, disconnect the power supply, detach the fuel and coolant
supply, and all connections including the mechanical ones.
- Attach the engine to a suitable lifting device (lifting beam).
- To move the engine simultaneously use the eyebolts installed, these lifting points are not suitable for the entire machine, then use
the eyebolts installed by the manufacturer.
- Before lifting, make sure the weight is correctly balanced by checking its barycentre.
- Close all engine openings accurately (exhaust, intake, etc.), then wash the outside and dry with a jet of compressed air.
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
-7-
1
General remarks and safety information
GENERAL SAFETY DURING OPERATING PHASES
– The procedures contained in this manual have been tested and selected by the manufacturer’s technical experts, and hence
are to be recognised as authorised operating methods.
– A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of
operations.
– All tools must be in good working condition so that engine components are not damaged and 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.
– Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding
the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.
– Do not use flammable liquids (petrol, diesel, etc.) to degrease or wash components. Use special products.
– Use the oils and greases recommended by the manufacturer.
Do not mix different brands or combine oils with different characteristics.
– Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.
– Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.
SAFETY AND ENVIRONMENTAL IMPACT
Every organisation has a duty to implement procedures to identify, assess and monitor the influence of its own activities
(products, services, etc.) on the environment.
Procedures for identifying the extent of the impact on the environment must consider the following factors:
- Liquid waste
- Waste management
- Soil contamination
- Atmospheric emissions
- Use of raw materials and natural resources
- Regulations and directives regarding environmental impact
In order to minimise the impact on the environment, the manufacturer now provides a number of indications to be followed by all
persons handling the engine, for any reason, during its expected lifetime.
- All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place.
- Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise
pollution.
- When discontinuing use of the engine, select all components according to their chemical characteristics and dispose of them
separately.
-8-
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
-9-
2
TECHNICAL INFORMATION
MANUFACTURER AND MOTOR IDENTIFICATION DATA
- 10 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
2
Technical information
ENGINE TYPE
Cylinders
Bore
Stroke
Displacement
Compression ratio
rpm
N DIN 70020 - 80/1269/CEE - iso 1585
KW Power
NB DIN 6271 - ISO 3046 - 1 IFN
NA DIN 6271 - ISO 3046 - 1 ICXN
Peak torque *
Fuel specific consumption
Oil consumption
Dry weight
Combustion air volume at 3000 rpm
Cooling air volume at 3000 rpm
Max. axial load permissible for drive shaft in two directions
instantaneous
Max.inclination
extended to 1 h.
permanent
N.
mm
mm
Cm³
Nm
RPM
l/h
Kg/h
Kg.
l./1'
l./1'
Kg.
a
α
α
ENGINE TYPE
Cylinders
Bore
Stroke
Displacement
Compression ratio
rpm
N DIN 70020 - 80/1269/CEE - iso 1585
KW Power
NB DIN 6271 - ISO 3046 - 1 IFN
NA DIN 6271 - ISO 3046 - 1 ICXN
Peak torque *
Fuel specific consumption
Oil consumption
Dry weight
Combustion air volume at 3000 rpm
Cooling air volume at 3000 rpm
Max. axial load permissible for drive shaft in two directions
instantaneous
Max.inclination
extended to 1 h.
permanent
N.
mm
mm
Cm³
Nm
RPM
l/h
Kg/h
Kg.
l./1'
l./1'
Kg.
a
α
α
3LD450
3LD510
1
85
80
454
18,1:1
3000
7,5
6,6
6,0
28,5
@ 1700
1,7
0.007
57
560
9000
250
35°
30°
****
1
85
90
510
18,1:1
3000
9,0
7,3
6,6
32,8
@ 1800
1,9
0.008
60
630
9000
250
35°
30°
****
4LD640
4LD705
4LD820
1
95
90
638
17,0:1
3000
10,5
8,8
7,9
38,7
@ 1700
2,4
0.024
100
780
12000
300
35°
25°
****
1
100
90
707
17,0:1
3000
12,0
9,9 D
8,8 D
43,1
@ 2000
2,6***
0,030***
100
770 D
10400 D
300
35°
25°
****
1
102
100
817
17,0:1
3000
13
11,4 D
10,3 D
48
@ 1600
3,0***
0,035***
105
890 D
10400 D
300
35°
25°
****
* It stands for power
** It stands for NB power
*** It stands to NB power at 2600 rpm
**** According to the application D at 2600 rpm
Note: For LDA 450, LDA 510, LDA 96, LDA 97, LDA 820 out-of-production engines, the repair specifications are equal to those of the engines specified in the table. 3 LD 451/S, 3LD 510/S engines,
which are currently produced, not specified in the table, turn anticlockwise ( seen from the flywheel side), and are provided with the same feature as 3LD450 and 3LD510engines.
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 11 -
2
Technical information
PERFORMANCE DIAGRAMS
N (80/1269/EU - ISO 1585) NB (ISO 3046 - 1 IFN) NA (ISO 3046 - 1 ICXN) AUTOMOTIVES POWER : Discontinuous services at variable rpm and load.
NON-OVERLOADABLE POWER:Continuous light services at constant rpm and variable load.
CONTINUOUS OVERLOADABLE POWER: Continuous heavy-duty services at constant rpm and load.
The above mentioned power levels refer to the engine equipped with air filter, standard silencer, suction fan - which previously underwent a
breaking-in period - at 20°C ambient conditions, at 1 bar.
The maximum power is guaranteed with a 5% tolerance.
These powers are reduced of abt. 1% every 100 m height and of 2% for every 5°C exceeding 25°C.
C (NB): Specific fuel consumption at NB power
MT
: Torque at N power
a
: Continuous service field of use. For any purpose out of this field of use, please contact company LOMBARDINI.
- 12 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Technical information
2
POSSIBLE CAUSES AND TROUBLE SHOOTING
THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:
1) - The engine rpms suddenly increase and decrease
2) - A sudden and unusual noise is heard
3) - The colour of the exhaust fumes suddenly darkens
4) - The oil pressure indicator light turns on while running.
TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS
The following table contains the possible causes of some failures which may occur during operation.
Always perform these simple checks before removing or replacing any part.
Oil and fuel leakage from the
exhaust
Excessive
oil
consumption
Oil level
increase
Low
oil
pressure
White smoke
Black smoke
Inconsistent rpm
It does not accelerate
Clogged pipings
Clogged fuel filter
Presence of air in the fuel circuit
Clogged tank breather
Faulty fuel pump
Blocked injector
Blocked injection pump valve
Wrong injector setting
Plunger excessive leakage
Stuck injection pump delivery control
Wrong injection pump delivery setting
High oil level
Blocked pressure relief valve
Worn oil pump
Presence of air inside the oil intake pipe
Faulty pressure gauge or switch
Clogged oil intake duct
Discharged battery
Inefficient or wrong cable connection
Faulty starting switch
Faulty starting motor
Clogged air filter
Excessive idle operation
Incomplete running-in
Overloaded engine
Advanced injection
Delayed injection
Incorrect governor tinkage adjustment
Broken or loose govener spring
Low idling setting
Worn or stuck piston rings
Worn or scored cylinders
Worn valve guides
Sticking valves
Worn crankshaft-connecting rod bearings
Non-sliding speed governor leverage
Crank shaft not turning freely
Cylinder head gasket
M A I N T E ELECTRICAL
EQUIPMENT LUBRICATION
NANCE
SETTINGS AND REPAIRINGS
FUEL CIRCUIT
It starts but does
not stop
PROBABLE CAUSES
It does not
start
TROUBLE
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 13 -
2
Technical information
ROUTINE ENGINE MAINTENANCE
Failure to carry out the operations described in the table may lead to technical damage to the machine
and/or system
MAINTENANCE ENGINES 3LD 450 - 510 - 450/S - 510/S
4LD 640 - 705 - 820
INTERVALS (HOURS)
DETAIL
10 50 125 250 500 1000 2500 5000
AIR FILTER (OIL-BATH) (*)
CLEANING
HEAD AND CYLINDER FINS (*)
FUEL TANK
INJECTORS
AIR FILTER OIL
CHECK
LEVEL SUMP OIL
BATTERY LIQUID
FUEL HOSE COUPLING FASTENING
VALVE AND ROCKER ARM CLEARANCE
INJECTOR SETTING
AIR FILTER(**) (***)
CHANGE SUMP (***)
OIL FILTER CARTRIDGE
FUEL FILTER CARTRIDGE
OVERHAUL
PARTIAL (****)
GENERAL
OPERATION
First replacement.
(*) In particular running conditions even every day.
(**) In particularly dusty environments every 4-5 hours.
(***) See prescribed oil.
(****)It includes the check of cylinders, segments, guides, valve seat springs and grindings, head and cylinder descaling, injection pump and injector checks. CAPACITIES IN LITERS
Standard fuel tank
3LD450, 3LD510, 3LD450/S, 3LD510/S = 5.3
4LD 640, 4LD705, 4 LD 820 = 7.2
Standard oil sump:
3LD450, 3LD510, 3LD450/S, 3LD510/S =1.75
4LD640, 4LD705, 4LD 820 = 2.60
Air filter oil bowl = 0.3
For special filters, tanks and oil sumps, please follow LOMBARDINI instructions.
- 14 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
2
Technical information
LUBRICANT
SAE Classification
In the SAE classification, oils differ on the basis of their
viscosity, and no other qualitative characteristic is taken
into account.
The first number refers to the viscosity when the engine
is cold (symbol W = winter), while the second considers
viscosity with the engine at régime.
The criteria for choosing must consider, during winter, the
lowest outside temperature to which the engine will be
subject and the highest functioning temperature during
summer.
Single-degree oils are normally used when the running
temperature varies scarcely.
Multi-degree oil is less sensitive to temperature changes.
- - - - - - - 40 35 30 25 20 15 10 5
0
+ + + + + + + + + +
5 10 15 20 25 30 35 40 45 50
SAE 10W-30**
SAE 10W-40**
SAE 10W-60**
SAE 15W-40 **
SAE 15W-40 **
SAE 20W-60 **
SAE 5W-30 ***
SAE 5W-40 ***
SAE 0W-30 ***
* Mineral base
** Semi-synthetic base
*** Synthetic base
SAE- Grade
International specifications
They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing
and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.
A.P.I
MIL
ACEA
: ( American Petroleum Institute )
: Engine oil U.S. military specifications released for logistic reasons
: European Automobile Manufacturers Association
Tables shown on this page are of useful reference when buying a kind of oil.
Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different
brands and choosing the kind with the right characteristics.
Usually a specification showing a following letter or number is preferable to one with a preceding letter or number.
An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.
ACEA REGULATIONS - SEQUENCES
LIGHT DUTY DIESEL ENGINES
HEAVY DUTY DIESEL ENGINES
B1 = Low-viscosity, for frictions reduction
E2 = Standard
B2 = Standard
E3 = Heavy conditions (Euro 1 - Euro 2 engines )
B3 = High performances (indirect injection)
E4 = Heavy conditions (Euro 1 - Euro 2 - Euro 3 engines )
B4 = High quality (direct injection)
E5 = High performances in heavy conditions (Euro 1 - Euro
2 - Euro 3 engines )
API / MIL SEQUENCES
API
CH-4
CG-4
CF-4
MIL
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
CF-2
CF CE
CD
CC
L- 46152 D / E
- 15 -
3
DISASSEMBLY / REASSEMBLY
RECOMMENDATIONS FOR DISASSEMBLING
Important
To locate specific topics, the reader should refer to the index.
– 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.
– For safety and convenience, you are advised to place the engine on a special rotating stand for engine overhauls.
– Before proceeding with operations, make sure that appropriate safety conditions are in place, in order to safeguard the operator
and any persons involved.
Oil-bath air filter (standard)
Danger – Attention
Always wear protective goggles if compressed air is used.
Caution – Warning
Never use solvents with a low flash point to clean the filter element. Such action could cause an explosion.
1
Oil-bath type with double filtering mass.
The lower mass is made of metal, while the upper is made of
polyurethan.
Check the gasket conditions and replace them in case they are
damaged.
Make sure that the weldings are not damaged.
Carefully clean the lower body and the filtering masses using
some gas oil, blow the lower mass with compressed air and dry
the upper mass by means of a cloth. Fill with engine oil filter to
the indicated level.
While reassembling, tighten the nuts at 25 Nm (3LD450,
3LD510, 3LD450/S, 3LD 510/S), at 30 Nm (4LD 640, 4LD 705,
4LD 820)
Details:
1 Upper body
4External sealing ring
2 Filtering mass made 5 Filterning mass
of polyurethan
3 Internal sealing ring
6 Bowl
Silencer (standard)
Danger – Attention
Allow the exaust manifold to cool before demounting it in order
to preventscorchingand burns
Make sure that it is free from any carbon and oily residues, if
contaminated, replace it. While reassembling it, replace the
gaskets and tighten the brass nuts at 25 Nm.
2
- 16 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Disassembly / Reassembly
3
Flywheel
Clockwise unscrew nut 1 and remove the flywheel using
the puller 2 Part. no. 7271-3595-050 for 3LD 450, 3LD 451/S,
3LD510, 3LD510/S, while for 4LD 640, 4 LD 705, 4LD 820 use
puller with Part. no. 7271-3595-048.
Check that the starter ring gear, when it is present, and the conic surface of the driving shaft coupling hole are intact.
While reassembling, tighten the screws 1 at 170 Nm for 3LD
450, 3LD 450/S, 3LD510, 3LD 510/s and at 350 Nm for 4LD
640, 4LD 705, 4LD 820.
Note: The flywheels of the left-hand engines (3LD 451/S, 3LD
510/S) have a blading turned in the opposite direction and
the nut 1 shall be anticlockwise unscrewed.
3
Starting pulley
In order to carry out any easier staring, it is necessary to place
the driving shaft at the TDC (Top dead center) and to assemble
the pulley with notch 1 moved back at ( 45°) according to the
rotation direction of the engine, as per picture 4 and 5 .
Tighten the screws at 35 Nm for 3LD 450, 3LD 450/S, 3LD510,
3LD 510/S, at 40 Nm for 4LD 640, 4LD 705, 4LD 820.
4
5
Vent plug
Components:
1 Vent plug and oil refiling
2 O-ring
3 Diaphragm
6
7
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 17 -
3
Disassembly / Reassembly
Valve/rocker arm clearance
Place the piston at the compression top dead centre.
Place thickness gauge 1 between the valve stem and the rocker
arm; cold-adjust the clearance at 0.15 ÷0.20 mm for both valves.
Tighten the rocker arm box cap at 20 Nm.
8
Decompression (by request)
Components:
1 Cover
2 Gasket
3 Lock ring
4 Spring
5 Shaft
6 Pin
7 Ring
8 Lever
9 Pin
The engine rocker arm cover can be equipped with a
decompression device which compresses the exhaust valve
at the TDC (top dead centre), lowering it of abt. 1mm. during
the starting phase. The lowering is adjusted by the gaskest
thickness 2. Make sure that the lever turns for abt. half a stroke
before it actuates the valve.
Warning!
The use of decompression to stop the engine may cause serious
damages.
9
Rocker arm pin, extraction
Before extracting the rocker arm pin in 3LD 450, 3LD 451/S,
3LD 510, 3LD510S engines, unscrew screw 1, as per picture
10.
Extract the pin using tool 2 Part. no. 7276-3595-040, picture 11
also for 4LD 640, 4LD 705, 4LD 820 engines.
10
- 18 -
11
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Disassembly / Reassembly
3
Rocker arm pin and hole
Dimensions (mm)
A = 15.032 ÷ 15.050
B = 14.989 ÷ 15.000
Clearances
(A-B) = 0.032 ÷ 0.061
(A-B) = worn limit = 0.120
12
13
Head
Do not disassemble while it is hot as to avoid any possible
distortion.
If the head surface is distorted, smooth it by removing up to 0.3
mm thickness.
Always replace the copper gasket, see picture 34 for the choice
of thickness.
Gradually tighten the nuts according to the following order 1, 3,
2, 4, at 50 Nm for 3LD 450, 3LD 451/S, 3LD 510, 3LD510/S, and
at 80 Nm for 4LD 640, 4LD 705, 4LD 820.
14
Injector, projection
The projection of the nozzle ends A with respect to the head
surface shall be:
2.5÷3 mm for 3LD 450, 3LD 451/S
3÷3.5 mm for 3LD 510, 3LD 510/S
3.5÷4 mm for 4LD 640, 4LD 705, 4LD 820
Adjust by means of a copper gasket B having a thickness of 0.5
mm, 1 mm, 1.5mm .
15
Valves
1 Valve stem
2 Spring holding disk
3 Spring
4 Cap
5 Cotters
Note: In order to remove the cotters, put a shim under the valve
head and strongly press, as shown in picture 16.
16
17
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 19 -
3
Disassembly / Reassembly
Valves guides and housings
1 Exhaust valve guide
2 Intake valve guide
Dimensions (mm):
3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S
A = 43.80 ÷ 44.20
C = 11.00 ÷ 11.018
B = 55.80 ÷ 56.20
D = 11.05 ÷ 11.06
4LD 640, 4LD 705, 4LD 820
18
A = 47.80 ÷ 48.20
B = 65.80 ÷ 66.20
C = 12.000 ÷ 12.018 D = 12.05 ÷ 12.06
Note: Valve guides with an external dia. increased of 0.5 mm
can be used as spare parts; in this case it is necessary to
increase the housing C of 0.5 mm for the assembly.
Valve guides insertion
Heat the head at 160° ÷ 180°. Force the guides according to A
and B distance with respect to the head surface.
3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S
A = 30.80 ÷ 31.2
B = 18.8 ÷ 19.2
4LD 640, 4LD 705, 4LD 820
A = 35.8 ÷ 36.2
19
B = 17.8 ÷ 18.2
Note: if the guides are supplied with the housing for the lock
ring C, insert the ring, then drive the guides without
worrying about A and B.
Valve guide dimensions and clearances
3LD 450, 3LD 451/s, 3LD 510, 3LD 510/S (mm):
D = 7.030 ÷ 7.050 E = 6.985 ÷ 7.000
(D-E) = 0.030 ÷ 0.065 (D-E) limit= 0.13
4LD640, 4LD 705, 4LD 820
D = 8.030 ÷ 8.050 E = 7.985 ÷ 8.000
(D-E) = 0.030 ÷ 0.065 (D-E) limit =0.13
- 20 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Disassembly / Reassembly
3
Valve housings and seats
3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S (mm);
A = 34.99 ÷ 35.01
B = 35.10 ÷ 35.12
C = 30.99 ÷ 31.01
D = 31.10 ÷ 31.12
4LD 640, 4LD 705, 4LD 820 (mm):
A = 42.99 ÷ 43.01
B = 43.12 ÷ 43.14
C = 36.99 ÷ 37.01
D = 37.10 ÷ 37.12
Drive the seats in the housings and mill at 45°.
20
Valve seat grinding
After milling, grind with fine emery paste in engine oil bath.
The S sealing surface shall not exceed 2 mm.
Embed valves D after grinding for 3LD 450, 3LD 451/S, 3LD
510,
3LD 510/S = 0.55 ÷ 1.05 mm; for 4LD 640, 4LD 705, 4LD 820 =
0.45 ÷ 0.95 mm.
21
22
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 21 -
3
Disassembly / Reassembly
Cylinder and piston
Set a bore gauge to zero with a calibrated ring. Check the dia. Ø
at points A and B at three different heights, see pictures 23 and
24.
In case of wear exceeding 0.06 mm to the maximum value
prescribed, grind the cylinder at the subsequent increased value.
The increases suggested are 0.50 and 1.00 mm.
Measure the piston Q dia. (picture 26) at A height from the skirt
base:
A = 17 mm (3LD 450, 3LD 451/S, 4LD 820)
A = 12 mm (3LD 510, 3LD 510/S)
A = 22 mm (4LD 640, 4LD 705)
23
24
Remove the stop rings and extract the piston pin, picture 25.
Remove the piston rings and clean the slots.
Replace the piston as well as the segments in case the dia. wear
exceeds 0.05 mm as regards to the minimum value prescribed.
Dimensions (mm)
25
26
ENGINES
Ø
Q
(Ø-Q)
3LD 450, 3LD 451/S
3LD 510, 3LD 510/S
85,00 ÷ 85,02
84,925 ÷ 84,945
0,05 ÷ 0,09
4LD 640
95.00 ÷ 95,02
94.88 ÷ 94.90
0.10 ÷ 0.14
4LD 705
100.00 ÷ 100.02
99.83 ÷ 99.85
0.15 ÷ 0.19
4LD 820
102.00 ÷ 102.02
101.85 ÷ 101.89
0.11 ÷ 0.17
Note: Even if 3LD 450, 3LD 450/S and 3LD510, 3LD510/S
pistons have the same bore, they differ in other
dimensions, thus they are not interchangeable.
Distance among segment ends (mm)
Insert the piston ring in the lower part of the cylinder, then measure the distance among the points.
3LD 450, 3LD 451/S, 3LD510, 3LD 510/S
1st piston ring (chromium plated) A = 0.30 ÷ 0.50
2nd piston ring (torsional) A = 0.30 ÷ 0.50
3rd piston ring (scraper ring)
A = 0.25 ÷ 0.50
4LD 640, 4LD 705, 4LD 820
1st piston ring (chromium plated)
2nd piston ring (torsional) 3rd piston ring (torsional) 4th piston ring (oil scraper ring) 27
A = 0.40 ÷ 0.65
A = 0.40 ÷ 0.65
A = 0.40 ÷ 0.65
A = 0.30 ÷ 0.60
Piston ring - Clearances among slots (mm)
3LD 450, 3LD 451/S, 3LD 510, 3LD 510S, picture28
A = 0.08 ÷ 0.09
B = 0.06 ÷ 0.07
C = 0.05 ÷ 0.06
4LD 640, 4LD 705, 4LD 820, picture 29
A = 0.12 ÷ 0.14
B = 0.07 ÷ 0.09
C = 0.07 ÷ 0.09
D = 0.06 ÷ 0.08
28
- 22 -
29
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Disassembly / Reassembly
3
Piston ring assembly order
3LD 450, 3LD 450/S, 3LD 510, 3LD 510/S, picture 30
A = slot for first piston ring (chromium plated)
B = slot for piston ring segment (torsional)
C = slot for third piston ring (oil scraper ring)
4LD 640, 4LD 705, 4LD 820, picture 31
A = slot for first piston ring (chromium plated)
B = slot for second piston ring (torsional)
C = slot for third piston ring(torsional)
D = slot for fourth piston ring(oil scrarper ring)
30
Note: before inserting the piston in the cylinder, oil the piston
ringwith engine oil and turn them, thus the cuts are
misaligned.
31
Piston reassembly
Important
Lubricate the following parts with oil before mounting: the piston
pin, the piston, the cylinder and the big-end bearing.
Couple the piston with the connecting rod, thus the combustion
chamber centre B is perpendicularly under end A of the nozzle
housed inside the head.
Lubricate the piston pin and insert it in the piston, lightly
pressing with your thumb.
Make sure that the two stop rings are well housed inside their
seats.
32
33
Clearance volume
A = Clearance volume
B = Head gasket
The thickness B head gasket determines the clearance volume
A which shall be 0.75 ÷ 0.90 mm for 3LD 450, 3LD 451/S, 3LD
510, 3LD 510/S and 0.80 ÷ 1.00 mm for 4LD 640, 4LD 705, 4LD
820.
Measure the piston crown position as to the cylinder surface
and chose a gasket having a suitable thickness.
Always consider that the piston at the top dead centre could be
at the same level, either under or over the cylinder.
34
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 23 -
3
Disassembly / Reassembly
Connecting rod equipped with bearings and piston pin
For 3LD 450, 3LD 450/S, 3LD 510, 3LD 510/S
Dimensions (mm)
A = 144.05 ÷ 145.05
B = 23.02 ÷ 23.03 (with driven and machined bearing)
C = 42.028 ÷ 42.052 (with bearing tightening at 3 Nm)
D = 22.995 ÷ 23.000
For 4LD 640, 4LD 705, 4LD 820
Dimensions (mm)
A = 162.95 ÷ 163.05
B = 28.02 ÷ 28.03
C = 55.40 ÷ 55.43
D = 27.995 ÷ 28.000
35
The connecting rod big end bearings are supplied either at
nominal value and diminished to 0.25 and 0.50 mm.
Connecting rod, big end bearings
While reassembling, the A and B centering marks should not be
on the same side.
Tighten the screws at 30 Nm for 3LD 450, 3LD 451/S, 3LD 510,
3LD 510/S and at 45 Nm for 4LD 640, 4LD 705, 4LD 820.
36
37
Main bearing on flywheel side
Extract the bearing using three screws, as per picture 38.
While reassembling, replace gasket 1. Check that the oil seal
ring is intact. Tighten the screws at 25 Nm.
Drive shaft axial clearance
After having screwed the main bearing on the flywheel, check
drive shaft axial clearance. Its value is 0.10 ÷ 0.40 mm for 3LD
450, 3LD 450/S, 3LD 510, 3LD 510/S and 0.10 ÷ 0.30 mm for
4LD 640, 4LD 705, 4Ld 820.
The adjustment is carried out by changing the gasket 1
thickness.
38
- 24 -
39
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Disassembly / Reassembly
3
Side distributor port
It can be found in engines equipped with industrial type drive
shaft.
The gaskets 3 and 5, thanks to their thickness, assure the oil
seal and affect the camshaft axial clearance, as well.
For the check, see information hereunder.
Components
For 3LD 450, 3LD 510 picture 40
1 Port
40
41
2 Bush
3 Gasket
Fix the door at its base at 25 Nm.
For 4LD 640, 4LD 705, 4LD 820 picture 41
4 Port
5 Gasket
6 Ball bearing
Fix the port at its base at 40 Nm.
Camshaft axial clearance
Carry out this check before assembling the head. Fix the side
distributor port or bell 1 at 25 Nm. Remove the intake and
exhaust tappets and with an implement operate on the camshaft
forward and backward in an axial direction.
The axial clearance A shall be:
A = 0.20 ÷ 0.60 mm 3LD 450, 3LD 450/S, 3LD 510, 3LD 510/S.
A = 0.15 ÷ 0.65 mm for 4LD 640, 4LD 705, 4LD 820.
42
Adjust the clearance by changing the gasket thickness between
the distributor port (if it is assembled) or bell 1 and the base; it is
forbidden to assemble more than one gasket.
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 25 -
3
Disassembly / Reassembly
Drive shaft
There are two types of standard drive shafts:
A Automotive type (agricultural machines)
B industrial type (motor pumps generating set, etc.)
Note: For left-handed engines, i.e 3LD 510/S, the drive shaft
turns anticlockwise (seen from the flywheel position) and
their thread is clockwise on the power takeoff side as well
as on the flywheel side.
43
Drive shaft lubrication ducts
Caution – Warning
Always wear protective goggles if compressed air is used.
Remove the caps, clean the ducts A and B with a point and
blow them with compressed air.
Replace the caps by caulking them on their seat, then check
their seal.
Drive shaft connecting radius
R = 3 mm
R1 = 3.5 mm
44
Note: When the main journal and the crank are ground, it is
essential to reset R and R1 values in order to avoid any
possible breaking of the drive shaft.
Drive shaft main journal and crank diametres (mm)
3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S
A = 39.990 ÷ 40.000
B = 41.987 ÷ 42.000
C = 41.990 ÷ 42.000
D = 29.990 ÷ 30.000
4LD 640, 4LD 705, 4LD 820
45
- 26 -
A = 44.900 ÷ 45.000
B = 55.340 ÷ 55.353
C = 44.900 ÷ 45.000
D = 29.990 ÷ 30.000
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Disassembly / Reassembly
3
Drive shaft internal diam. crankshaft bearing / connecting
rod head and clearances regarding their respective pins
(mm)
3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S
E = 40.040 ÷ 40.050
G = 42.04 ÷ 42.05
F = 42.028 ÷ 42.052
H = 30.07 ÷ 30.09
A, B, C, D, see picture 45
E - A =
F - B =
G-C=
H-D=
46
0.040 ÷ 0.060
0.028 ÷ 0.065
0.040 ÷ 0.060
0.070 ÷ 0.10
worn limit 0.12
worn limit 0.13
worn limit 0.12
worn limit 0.18
4LD 640, 4LD 705, 4LD 820
E = 45.045 ÷ 45.070 F = 55.40 ÷ 55.43 G = 45.045 ÷ 45.070
A, B, C, D, see picture 45
E - A = 0.065 ÷ 0.080
F - B = 0.051 ÷ 0.10
G - C = 0.45 ÷ 0.080
worn limit 0.16
worn limit 0.18
worn limit 0.16
CAMSHAFT
Components:
1 Base side pin
2 Intake cam
3 Injection cam
4 Exhaust cam
5 Gear
6 Side distributor port pin
Note: The two engine series 3LD 450, 3LD 510 and 4LD 640,
4LD 820 have the same camshaft; it differs in 3LD 451/S
and 3LD 510/S left-handed engines.
47
Camshaft intake and exhaust cam timing
For 3LD 450, 3LD 510, 4LD 640, 4LD 705, 4LD 820, see picture 48.
Clockwise rotation.
TDC = Top dead centre of the piston
A = Intake cam axis
S = Exhaust cam axis
α = 50° 30' ÷ 51° 30'
48
49
For 3ld 451/S, 3LD 510/S, see picture 49
Clockwise rotation
TDC= Top dead centre of the piston
A = Intake cam axis
S = Exhaust cam axis
α = 50° 30' ÷ 51° 30'
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 27 -
3
Disassembly / Reassembly
Camshaft pin and housing dimensions (mm)
A = 18.000 ÷ 18.018 (housing on the base)
B = 17.945 ÷ 17.975
C = 18.000 ÷ 18.018 (housing on the port)
D = 17.945 ÷ 17.975
A-B and C-D = 0.025 ÷ 0.073
Worn limit = 0.13
50
Camshaft intake and exhaust cam height.
The two cam heights are different.
Dimensions (mm) :
H = 33.92 ÷ 34.02 (intake cam)
H1 = 33.42 ÷ 33.52 (exhaust cam)
If the cam wear exceeds the agreed minimum value of 0.1 mm
for H and H1 , replace the camshaft.
51
Distribution timing
assemble the camshaft gear by coinciding reference 1 with
reference 2 of the gear (camshaft key).
52
Distribution timing without following the references
Place piston A at the top dead centre.
Insert the camshaft, thus the intake cam B and the exhaust
cam C are well balanced (while the intake opens, the exhaust
closes).
Insert the respective tappets D and E.
Carry out the check: the intake D and exhaust E tappets laid on
their cams shall be at the same level F.
53
- 28 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Disassembly / Reassembly
3
Speed governor
It has a centrifugal system with 6 balls housed in the gear,
which is directly operated by the drive shaft.
The balls, moved at the gear periphery by a centrifugal force,
axially shift the bell 3, which actuates the fork 2 connected
to lever 1 in order to determine the injection pump rack rod
position. A spring with two plates 4, energized by the accelerator
control 5, opposes the action of the governor cetrifugal force.
The balance between the two forces keeps the rpm rate
constant with the change of load.
54
Timing of the speed governor
Adjust the injection pump control lever 1 thus, when the
governor is closed, it is placed at distance A as to the external
surface of the base.
- Loosen the screw 2.
- Close the governor (move the mobile bell 3 towards the
operator, picture 55).
- Place lever 1 at A distance, picture 56 (22 mm for 3LD 450,
3LD 510, 3LD 451/S, 3LD 510/S and 28 mm for 4LD 640,
4LD 705, 4LD 820).
- Tighten the screw 2.
55
56
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 29 -
4
LUBRICATION CIRCUIT
Danger – Attention
The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because its combustion
may lead to a sharp increase in the rotation speed.
Use suitable oil in order to protect the engine.
Nothing more than lubrication oil can influence the performances and life of an engine.
Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, will cause the piston rings to
jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine life will also be notably reduced.
The oil viscosity must suit the ambient temperature in which the engine operates.
Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil is
unavoidable, you are advised to wash your hands with soap and water as soon as possible.
Dispose of old oil in the correct way as it is highly polluting.
LUBRICATION CIRCUIT
57
Lubrication circuit
Details:
1 Intake pipe
2 Oil pump
3 Oil filter
4 Pressure switch
- 30 -
5 Crankshaft bearing
6 Pressure adjusting valve
7 Tappet rod protection pipe
8 Vent and oil filler plug.
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Lubrication circuit
4
Oil pump
Make sure that the gear teeth are intact and check that the
clearance between the gear periphery and the pump case does
not exceed 0.15 mm and that the drive shaft can easily turn with
an axial clearance not exceeding 0.15 mm.
Check that the gear lubrication holes 1 and 2 are not clogged.
Tighten the pump case at 30 Nm.
Tighten the pump control gear at 20 Nm.
The oil pumps for 3LD 451/S and 3LD 510/S engines, which
turn anticlockwise (from flywheel position), are different, see
information below.
58
59
Oil pump, difference between clockwise rotation pump and
anticlockwise pump
The difference between the oil pump on clockwise rotation
engines and the anticlockwise one is the suction duct provided
either with the pump case and with the base.
See picture 60 for anticlockwise rotation engines from flywheel
position (3LD 451/S, 3LD 510/S).
A =Intake
B = Delivery
Picture 61, for clockwise rotation engines, seen from the
flywheel side (3LD 450, 3LD 510, 4LD 640, 4LD 705, 4LD 820)
C = Intake
D = Delivery
60
61
Oil filter cartridge
Componens:
1 Gasket
2 Assembly
3 Antidrainage rubber cap
4 Filter element
5 Bowl
6 By-pass valve
7 Spring
Features:
Maximum operating pressure: 7 bars
Maximum operating temperature: -25° + 150°C
Filtering degree: 20 µm
By-pass valve setting: 1÷ 1.4
Total filtering surface: 750 cm
2
62
Oil pressure regulating valve
It is housed in the flywheel side main bearing
For 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S, see picture 63
1 Support
4Sheet metal
2 Valve
5 Screw
3 Spring
Tighten the support at 25 Nm.
63
64
For 4LD 640, 4LD 705, 4LD 820,see picture 64
5 Spring
1 Support
2 Gasket 6 Flange
3 Valve support
7 Plate
4 Ball
8 Screw
Tighten the support at 40 Nm.
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 31 -
4
Lubrication circuit
Oil pressure check
After the assembly operation, fill the engine with oil and fuel;
connect a 10 bars pressure gauge to the fitting on the oil filter.
Start the engine and check the pressure reaction according to oil
temperature.
Oil pressure curve with the engine at its maximum speed
65
- 32 -
It is shown on the filter and obtained with the engine at 3000
rpm at N power; the pressure is expressed in bars and the
temperature in degrees Celsius. The curve represents the
pressure minimum value, while its maximum value is 5 bars. The
minimum oil pressure (1200 rpm) with the oil temperature at
100° C shall not be lower than 0.8 bars.
Note: When the engine has been run in, the oil lubrication
maximum temperature shall be lower than the following
addition: ambient temperature + 95° C.
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
FUEL INJECTION CIRCUIT
5
Standard feeding/injection circuit
Components:
1 Tank
2 Filter
3 Pump
4 Pipe
5 Injector
6 Injector waste pipe
66
Fuel filter inside the tank (standard)
Details:
1 Spring
2 Disk
3 Ring
4 Cartridge
5 Gasket
6 Gasket
7 Cover
8 Ring
9 Bolt
Cartridge features:
Filtering degree = 7 µm
Filtering surface = 390 cm2
67
Feeding pump (by request)
Features:
at 1500 rpm of the control eccentric, the minimum delivery is 60
l/h, while the automatic adjustment pressure is 4 ÷ 5 m column
of water.
Feeding pump rod projection
Details:
1 Feeding pump
2 Base
3 Rod
4 Oil pump drive shaft eccentric
68
The check shall be carried out with the eccentric 4 at rest.
The projection A of rod 3 is 0.8 ÷ 1.2 mm; it shall be adjusted
with the following supplied gaskets having a thickness of 0.50;
0.80 and 1.0 mm.
Rod length = 65.4 mm for 3LD 450, 3LD 450/S, 3LD 510, 3LD
510/S and 75.2 mm for 4LD 640, 4LD 705, 4LD 820.
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 33 -
5
Fuel injection circuit
Injection pump
Components:
1 Delivery fitting
2 O-ring
3 Spring
4 Delivery valve
5 Gasket
6 Barrel
7 Pump case
8 Eccentric
9 Sector gear
10 Spring bearing cap
69
70
11 Spring
12 Pumping piston
13 Tappet case
14 External roller
15 Internal roller
16 Pin
17 Lock ring
18 Rack rod
19 Lock pin
20 Collar
Tighten the pump at its base at 30 Nm.
Injection pump assembly
Insert the cylinder 6 in the pump case 7, engaging the slot A in
the eccentric 8.
Insert the delivery valve 4, copper gasket 5, spring 3 O ring 2,
then tighten the fitting at 3.5 ÷ 40 Nm.
Assemble the rack rod 18 and sector gear 9 coinciding points B.
Insert the upper collar 10, spring 11 and piston 12 with
reference C on the same side of the slot A (if it is assembled on
the opposite side, the engine revs out).
Assemble the collar 20, the tappet 13 with rollers 14, 15 and
pin 16.
While pressing on the tappet, insert the pin 19 and the ring 17.
71
Advanced injection (static)
72
73
Disconnect the diesel oil thrust pipe fitting, being careful not to
loosen also the pump delivery fitting 1, then screw the tester for
the advanced injection check 2.
Fill the tank, checking that the fuel level is at least 10 cm above
the tester. Place the accelerator lever halfway.
Turn the flywheel towards the engine rotation direction and make
sure that the fuel arrives at the tester assembled on the injection
pump delivery fitting.
Repeat this operation; during the compression phase, operate
slowly and immediately stop when the fuel moves into the tester
hole; move the flywheel 3 mm back; this is the static advanced
injection.
If C does not coincide with B but comes before, add some
shims under the pump, otherwise, remove the shims if C is
beyond B.
Note: By removing or adding a 0.1 mm shim under the pump, it
is possible to delay or advance C, which is after B.
- 34 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
Fuel injection circuit
5
Advanced Injection references on the conveyor and
flywheel protection disk
A Piston reference at top dead centre
B Injection advance reference as to A
A ÷ B Distance in mm
C Reference of piston in injection advance position
α Reference in degrees
D Flywheel protection disk diameter
ENGINES
(A-B) mm
α mm
3LD
450, 451/S, 510, 510/S
58 ÷ 63
24° ÷ 26°
4LD
640, 705, 820
65 ÷ 70
4LD 820
a 2600 giri/1'
60 ÷ 65
74
D (3LD)
D (4LD)
276
310
mm
mm
22° ÷ 24°
Note: 1° stands for 2.7 mm on dia. D= 310 mm; on dia. D =
276 mm, 1° stands for 2.4 mm.
Injector
Components:
1 Ring nut
2 Nozzle
3 Needle
4 Fitting
5 Nozzle bearing
6 Pressure rod
7 Spring
8 Spring seat
9 Union
10 Ring nut
75
Setting
Connect the injector to a manual pump and check that the
setting pressure is 190 ÷ 200 bars.
If necessary adjust, actuating the union 9.
While replacing the spring, the setting shall be carried out
at a pressure higher than 10 bars (200 ÷210 bars) in order to
counterbalance the running adjustments.
Check the needle valve seal by slowly activating the manual
pump up to abt. 170 bars.
In case of dripping, replace the nozzle.
Tighten the injector to the head at 15 Nm for 3LD 450, 3LD
451/S, 3 LD 510, 3 LD 510/S and at 20 Nm for 4LD 640,
4LD705, 4LD 820.
Note: A new injector is currently assembled, its components are
different, though the setting remains the same.
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 35 -
6
ELECTRIC CIRCUIT
12 V 14 A electrical ignition, diagram with voltage regulator
, battery recharge lamp and manostat
Components:
1 Alternator
2 Starting motor
3 Voltage regulator
4 Battery
5 Oil pressure switch
6 Oil pressure lamp
7 Ignition switch
8 Battery recharge lamp
Note: The batteries, which are not supplied by Lombardini, shall
have a 12 V voltage and the following capacity:
3LD 450, 3lD 451/S, 3LD 510, 3LD 510/S = 45 Ah
4LD 640 = 55 Ah
4LD 705 = 66 Ah
4LD 820 = 70 Ah
76
12.5 V 14 A alternator
It is equipped with a fixed rotor assembled on the main journal,
while the pivoting rotor is housed inside the flywheel.
Dimensions (mm):
A = 159
B = 44.5
C= 4
D = 28.5
Note: The clearance between inductor and rotor (air gap) shall
be 0.5 ÷ 0.6 mm.
77
12,5 V, 14 A alternator battery recharge curve
It is carried out at + 25° C ambient temperature, 12.5 V battery
voltage.
78
- 36 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
6
Electric circuit
Voltage regulator
There are two different types of regulators: one with make
SAPRISA, ALTECNA, NICSA and the other with make DUCATI.
ALTECNA
SAPRISA
NICSA
79
80
Cable
Colours
DUCATI
Tab dimensions
Width
Thickness
~
giallo
G
6,25
0,8
R
rosso
R
9,50
1,2
+
rosso
B
9,50
1,2
LE
verde
L
4,75
0,8
marrone
C
6,25
0,8
Voltage regulator, running check
Make sure that the connections are in compliance with the
diagram.
Remove the respective clamp from the battery positive pole.
Insert a voltmeter with direct current between the two poles of
the battery.
Connect a 20A ammeter at direct current between the positive
pole and cable 1 respective clamp.
Start a few times until the battery voltage goes down to 13 V.
When the battery voltage reaches 14.5 V, the ammeter current
will drop to a value near zero.
If the voltage is lower than 14 V and the recharge current is zero,
replace the regulator.
Note: The voltage regulator does not work when not earthed
and the battery is completely discharged.
Warning: when the engine runs, do not remove the battery
cables and do not take the key off the control board.
Do not place the regulator near heat sources, a
temperature exceeding 75° C could cause damages.
Avoid any electric welding either on the engine and
on the equipment.
81
Bosch DW (L) 12 V 1, 1 KW type, starting motor
For 3LD 450, 3LD 510
Anticlockwise rotation direction (seen from the flywheel side)
A = 29.5 ÷ 31.5 mm (rim surface and motor flange distance)
Note: For any possible repairs, please contact bosch service
centres.
82
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 37 -
6
Electric circuit
Characteristic curves for Bosch DW(L) 12V 1.1 kW type,
starting motor
83
Bosch JF(L) 12V 2.5 kW type, starting motor
For 4LD 640, 4LD 705, 4LD 820
Anticlockwise rotation (seen from the pinion side)
A = 23 ÷ 25 mm
--
84
Characteristic curves for
starting motor
Bosch JF(L) 12V 2,5 kW type
85
- 38 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
ADJUSTMENT
7
Minimum rpm adjustment at idle running (standard)
After filling the engine with oil and fuel, start and warm up the
engine for 10 minutes.
Actuating the adjusting screw 1, set the idling at 1150 rpm; then
fasten the lock nut.
86
Peak rpm adjustment at idle (standard)
After adjusting the minimum rpm, set the screw 2 and adjust the
peak rpm at 3200 rpm at idle; then fasten the lock nut.
Note: The peak rpm standard idle adjustment of 4LD 820 shall
be carried out at 2800 rpm.
87
Injection pump delivery adjustment (standard)
This adjustment shall be carried out with the engine at
dynamometric brake, otherwise the resulting adjustment could
be approximate; in this case operate as it follows. · Unloose the screws 1 and 2 by 1/4 of a turn
· Move the limiting device 3, thus the screw 2 stays in the centre
of the slot. Tighten the screws 1 and 2.
Carry out the exhaust smoke check as it follows:
88
· Abruptly start the accelerator at idle.
In case of a quick pickup with light exhaust smoke to the Bosch
scale index 3, this means that the limiting device is correctly
adjusted.
· In case of a slow pickup without smoke, move the limiting
device towards the left (pumping duration increase).
· In case of a rapid pickup with thick smoke (exceeding index
3 of Bosch scale), move the limiting device towards the right
(pump duration decrease).
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 39 -
7
Adjustment
Limiting device for injection pump delivery
gearing device
and torque
It is housed in the pump control lever A and it is constituted of
a spring on cam B, limiting the stroke of the same lever A.
At the torque rate, the spring flexure, subject to the accelerator
control action, allows a further stroke of lever A, thus an
increased delivery of the injection pump.
89
Adjustment of injection pump delivery with braked engine
1)Bring the engine to its idling point .
2)Move the delivery limiting device 3 towards the left, see
picture 88
3)Operate the engine until it reaches the power and rpm
required by the manufacturer of the equipment.
4)Make sure that the consumption is in compliance with
the values specified in the table of the adjustments (see
information below).
If the consumption is in compliance with the fixed values, it is
essential to change the balance conditions measured on the
brake, operating either on the load and on the regulator.
When the engine is steady, carry out the consumption check
again.
5) Move the limiting device 3 towards the right, as per picture
88, until the engine rpm number descreases. Lock the limiting
device by means of the two screws.
6)Completely release the brake and check the rpm at which the
engine settles. The speed governor performances shall be in
compliance with the class required by the manufacturer of the
equipment.
7) Stop the engine.
8)When the engine is cold, check the valve clearance again.
Required adjustments (the most demanded)
Specific fuel
consumption *
Kw
Engine
Rpm
power
Time secs
r/kW.h
for 100 cc.
3LD 450
3000
N 7,5
140-146
272-283
90
3LD 450
3600
NB 7
143-149
285-299
3LD 510
3000
N9
117-122
272-283
4LD 640
3000
N 10,5
96-100
284-295
4LD 705
3000
N 10,8
96-100
276-287
4LD 705
2600
N 10
108-113
263-277
4LD 820
2600
N 12,1
87-92
258-273
* The specific consumption values indicated are valid after abt.
100 working hours.
- 40 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
STORAGE
8
-If the engine is not to be used for extensive periods, check the
storage area conditions and the type of packaging and make
sure that these are suitable for correct storage.
If necessary, cover the engine with a proper protective
sheet.
-Avoid storing the engine in direct contact with the ground, in
environments that are humid and exposed to bad weather,
near high voltage electric lines, etc.
If, after the first 6 months, the engine is still not used, it
is necessary to carry out a further measure to extend the
protection period (see “Protective treatment”).
PROTECTIVE TREATMENT
1 - Pour in the engine housing AGIP RUSTIA C protective oil
up to the maximum level.
2 - Fill up with fuel containing 10% AGIP RUSTIA NT.
3 - Start the engine and keep it idle at minimum speed for
some minutes.
4 - Bring the engine to ¾ of the maximum speed for 5÷10
minutes.
5 - Turn off the engine.
6 - Empty out completely the fuel tank.
7 - Spray SAE 10W on the exhaust and intake manifolds.
8 - Seal the exhaust and intake ducts to prevent foreign bodies
from entering.
9 - Thoroughly clean all external parts of the engine using
suitable products.
10 - Treat non-painted parts with protective products (AGIP
RUSTIA NT).
11 - Loosen the alternator/fan belt (if present).
12 - Cover the engine with a proper protective sheet.
In countries in which AGIP products are not available,
find an equivalent product (with specifications: MILL-21260C).
Maximum every 24 months of inactivity, the
engine must be started up by repeating all
“Engine Storage” operations.
PREPARING THE ENGINE FOR OPERATION AFTER
PROTECTIVE TREATMENT
After the storage period and before starting up the engine and
preparing it for operation, you need to perform certain operations
to ensure maximal efficiency conditions.
1 - Remove the protective sheet.
2 - Remove any sealing devices from the exhaust and intake
ducts.
3 - Use a cloth soaked in degreasing product to remove the
protective treatment from the external parts
4 - Inject lubricating oil (no more than 2 cm3) into the intake
ducts.
5 - Adjust the alternator/fan belt tension (if present).
6 - Turn the engine manually to check the correct movement
and smoothness of the mechanical parts.
7 - Refill the tank with fresh fuel.
8 - Make sure that the oil is up to the maximum level.
9 - Start the engine and after some minutes bring it to ¾ of
the maximum speed for 5-10 minutes.
10 - Turn off the engine.
11 - Remove the oil drain plug (see “Oil replacement”) and
discharge the AGIP RUSTIA NT protective oil while the
engine is hot.
12 - Pour new oil (see “Table of lubricants”) up to the maximum
level.
13 - Replace the filters (air, oil, fuel) with original spare parts.
Over time, a number of engine components and
lubricants lose their properties, so it is important
considering whether they need replacing, also based
on age (see Replacement table).
Maximum every 24 months of inactivity, the engine
must be started up by repeating all “Engine Storage”
operations.
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 41 -
9
MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS
3LD 450 - 3LD 510 - 3LD 450/S - 3LD 510/S MAIN DRIVING TORQUES
POSITION
Injection pump union
Connecting rod
Clutch bearing bell bolt
Flanging bell
Clutch bell (industrial engine)
Rocker arm box cap
Oil sump
Oil pump case
Air filter
Oil filter
Oil pump gear
Injector towards the head
Rocker arm fulcrum pin for injection pump
Gear pin for speed governor
Engine foot
Injection pump
Distributor side port
Oil pressure switch
Starting pulley
Main bearing on flywheel side
Sump oil drain bolt
Cylinder
Flywheel
REFERENCE
( Picture NO. )
Dia. /Pitch
( mm )
71
36
8
58
1
58
75
69
40
4
63
14
3
18x1.5
8x1.25
14x1.5
8x1.25
16x1.5
8x1.25
6x1
8x1.25
8x1.25
8x1.25
8x1.25
8x1.25
14x1.5
10x1.5
8x1.25
8x1.25
8x1.25
12x1.5
8x1.25
8x1.25
10x1.5
10x1.5
20x1.5
Torque
( Nm )
40
30
250
25
80
20
10
30
25
25
20
15
60
40
40
25
25
35
35
25
35
50
170
MAIN DRIVING TORQUES 4LD 640 - 4LD 705 - 4LD 820
POSITION
Injection pump unit
Connecting rod
4LD 820 clutch bearing bell bolt
4LD 640, 4LD clutch bearing bell bolt
Bolt for hub
Flanging bell
Rocker arm box cap
Oil sump
Oil pump case
Air filter
Oil filter
Oil pump gear
Injetor towards the head
Rocker arm pin for injection pump control
Gear pin for speed governor
Engine foot
Injection pump
Distributor side port
Oil pressure switch
Starting pulley
Main bearing on flywheel side
Sump oil drain bolt
Cylinder head
Flywheel
- 42 -
Reference
( picture no.)
Dia. / Pitch
( mm )
Torque
( Nm )
71
36
8
58
1
58
75
69
41
4
64
14
3
18x1.5
10x1.5
14x1.5
14x1.5
14x1.5
10x1.5
8x1.25
8x1.25
8x1.25
10x1.5
8x1.25
8x1.25
8x1.25
8x1.25
10x1.5
10x1.5
8x1.25
10x1.5
12x1.5
10x1.5
10x1.5
14x1.5
12x1.5
20x1.5
40
45
280
250
280
40
20
25
40
50
25
20
20
30
40
40
30
40
35
40
40
70
80
350
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
9
Main torque specifications and use of sealants
Table of tightening torques for standard screws (coarse thread)
Resistance class (R)
Quality/
Dimensions
Diameter
4.6
4.8
R>400N/mm2
5.6
5.8
R>500N/mm2
6.8
8.8
10.9
12.9
R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
M3
0,5
0,7
0,6
0,9
1
1,4
1,9
2,3
M4
1,1
1,5
1,4
1,8
2,2
2,9
4,1
4,9
M5
2,3
3
2,8
3,8
4,5
6
8,5
10
M6
3,8
5
4,7
6,3
7,5
10
14
17
M8
9,4
13
12
16
19
25
35
41
M10
18
25
23
31
37
49
69
83
M12
32
43
40
54
65
86
120
145
M14
51
68
63
84
101
135
190
230
M16
79
105
98
131
158
210
295
355
M18
109
145
135
181
218
290
405
485
M20
154
205
193
256
308
410
580
690
M22
206
275
260
344
413
550
780
930
M24
266
355
333
444
533
710
1000
1200
M27
394
525
500
656
788
1050
1500
1800
M30
544
725
680
906
1088
1450
2000
2400
8.8
10.9
12.9
Table of tightening torques for standard screws (fine thread)
Resistance class (R)
Quality/
Dimensions
Diameter
4.6
4.8
R>400N/mm2
5.6
5.8
R>500N/mm2
6.8
R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
M 8x1
10
14
13
17
20
27
38
45
M 10x1
21
28
26
35
42
56
79
95
M 10x1,25
20
26
24
33
39
52
73
88
M 12x1,25
36
48
45
59
71
95
135
160
M 12x1,5
38
45
42
56
68
90
125
150
M 14x1,5
56
75
70
94
113
150
210
250
M 16x1,5
84
113
105
141
169
225
315
380
M 18x1,5
122
163
153
203
244
325
460
550
M 18x2
117
157
147
196
235
313
440
530
M 20x1,5
173
230
213
288
345
460
640
770
M 20x2
164
218
204
273
327
436
615
740
M 22x1,5
229
305
287
381
458
610
860
1050
M 24x2
293
390
367
488
585
780
1100
1300
M 27x2
431
575
533
719
863
1150
1600
1950
M 30x2
600
800
750
1000
1200
1600
2250
2700
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 43 -
9
Main torque specifications and use of sealants
USE OF DOPE FOR 3LD 450 - 3LD 510 - 3LD 451/S - 3LD 510/S
TYPE OF SEALANT
POSITION
Clutch bearing bell and embedded hexagonal-head screws
Control pin threading
Coupling nipple for oil filter cartridge
Stud bolt for clamping on engine head
Stud bolt for clamping on main bearing flywheel side
Stud bolt for clamping on distributor port side
Stud bolt on engine bell
Clamping screw for pin regulator
Clamping screw for baffle on air conveyor
Stud bolt for clamping on engine flange bell
Rocker arm fulcrum pin for injection pump control
Bracket clamping screw on side plates
Stud bolt for clamping at feeding pump
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
USE OF DOPE FOR 4LD 640 - 4LD705 - 4LD 820
POSITION
Bearing on port or bell
Regulating pin threading
Stud bolt for clamping on engine head
Stud bolt for clamping on main bearing on flywheel side
Stud bolt for clamping on distribution side
Lock screw for rocker arm pin
Clamping screw for regulating pin
Industrial port
Stud bolt for clamping on feeding pump
- 44 -
TYPE OF SEALANT
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
LOCTITE 270
DOW CORNING Q3 - 7091SILICONE
LOCTITE 270
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 45 -
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
- 46 -
Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev. 03
- 47 -
WORKSHOP MANUAL
cod. __ ED0053025560
La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione.
Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication.
Data reported in this issue can be modified at any time by Lombardini.
Lombardini behält sich alle Rechte vor, diese Angabe jederzeit zu verändern.
La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación.
42100 Reggio Emilia – Italia - ITALY
Via Cav. del Lavoro Adelmo Lombardini, 2 - Cas. Post. 1074
Tel. (+39) 0522 3891 - Telex 530003 Motlom I – Telegr.: Lombarmotor
R.E.A. 227083 - Reg. Impr. RE 10875
Cod. fiscale e Partita IVA 01829970357 - CEE Code IT 01829970357
E-MAIL: atlo@lombardini.it
Internet: http://www.lombardini.it