work shop manual - lombardini service

WORK SHOP

MANUAL

12LD477-2, series engines, p.no. 1-5302-625

12 LD 477/2

1

st

Edition

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

1

FOREWORD

We have done all in our power to give up to date and accurate technical information in this manual. Lombardini engines are, however, constantly developing thus the data in this publication may be liable to modification without prior notice.

The information in this manual is the exclusive property of Lombardini. Neither partial nor total duplications or reprints are therefore permitted without the express authorization of Lombardini.

The information in this manual is given on the assumption that:

1 - the persons who service Lombardini engines have been adequately trained and outfitted to safely and professionally carry out the necessary tasks;

2 - the persons who service Lombardini engines possess the necessary skills and special Lombardini tools to safely and professionally carry out the necessary tasks;

3 - the persons who service Lombardini engines have read the specific information concerning the above mentioned

Service operations and that they have clearly understood the operations required.

GENERAL SERVICE NOTES

1 - Only use genuine Lombardini spare parts. Use of spurious spares may lead to incorrect performance and shorten the life of the engines.

2 - The metric system is used to express all data, i.e. the dimensions are given in millimeters (mm), torque is expressed in Newton-meters (Nm), weight in kilograms (kg), volume in liters or cubic centimeters (cc) and pressure in barometric units (bar).

2

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

WARRANTY CERTIFICATE

WARRANTY CERTIFICATE

The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24 months from the date of delivery to the first end user.

For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed within the setting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned period (24 months) is not expired.

If no hour-meter is fitted , 12 working hours per calendar day will be considered.

For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling system, sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above mentioned period (24 months) is not expired.

For correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the documentation supplied with each engine.

To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be carried out by qualified personnel only.

The list of the Lombardini authorized dealers is reported in the “Service” booklet, supplied with each engine.

Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump), filtering system, turbo-charged models, will require special written warranty agreements.

Within the above stated periods Lombardini Srl directly or through its authorized network will repair and/or replace free of charge any own part or component that, upon examination by Lombardini or by an authorized Lombardini agent, is found to be defective in conformity, workmanship or materials.

Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine use or from both the total or partial impossibility of use, is excluded.

The repair or replacement of any component will not extend or renew the warranty period.

Lombardini warranty obligations here above described will be cancelled if:

- Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected and altered.

- Lombardini engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied with each engine.

- Any seal affixed to the engine by Lombardini has been tampered with or removed.

- Spare parts used are not original Lombardini.

- Feeding and injection systems are damaged by unauthorized or poor quality fuel types.

- Electrical system failure is due to components, connected to this system, which are not supplied or installed by

Lombardini.

- Engines have been disassembled, repaired or altered by any part other than an authorized Lombardini agent.

Following expiration of the above stated warranty periods and working hours, Lombardini will have no further responsibility for warranty and will consider its here above mentioned obligations for warranty complete.

Any warranty request related to a non-conformity of the product must be addressed to the Lombardini Srl service agents.

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

3

INDEX

This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled, indirect injection Diesel engines type

12LD477-2:

updated August 01, 2003.

I

II

TROUBLE SHOOTING __________________________________________________________ Page

SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS ____________________________ ”

MODEL NUMBER AND IDENTIFICATION _____________________________________________ ” III

IV TECHNICAL DATA ______________________________________________________________ ”

CHARACTERISTICS _____________________________________________________________ ” V

VI OVERALL DIMENSIONS __________________________________________________________ ”

VII SPECIAL TOOLS ________________________________________________________________ ”

7

8-9

10

11

12

13

14

VIII MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING _______________________________ ” 15-16

IX

X

DISASSEMBLY OF THE ENGINE ___________________________________________________ ” 17

Camshaft gear extraction ................................................................................................................................................ 17

Crankshaft gear extraction .............................................................................................................................................. 17

Flywheel extraction .......................................................................................................................................................... 17

Oil pressure register valve extraction ............................................................................................................................. 17

CHECKS AND OVERHAUL ______________________________________________________ Page 18

Camshaft ........................................................................................................................................................................ 24

Connecting rods ............................................................................................................................................................. 22

Crankshaft ....................................................................................................................................................................... 23

Cylinder heads ................................................................................................................................................................ 18

Cylinders ......................................................................................................................................................................... 20

Governor lever and spring .............................................................................................................................................. 25

Oil pump checking .......................................................................................................................................................... 25

Oil seal rings ................................................................................................................................................................... 24

Piston rings - Pistons - Piston pins ................................................................................................................................ 21

Rocker arms ................................................................................................................................................................... 20

Tappet checking .............................................................................................................................................................. 24

Valves - Guides - Seats ................................................................................................................................................... 18

Valves and springs ......................................................................................................................................................... 20

4

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

INDEX

XI

XII

INJECTION EQUIPMENT ________________________________________________________ Page 26

Checking injection pump ................................................................................................................................................ 26

Fuel circuit ....................................................................................................................................................................... 26

Injection pump ................................................................................................................................................................ 26

Injection pump assembly ............................................................................................................................................... 27

Injection pump setting .................................................................................................................................................... 26

Injector checking and setting .......................................................................................................................................... 28

Injectors ........................................................................................................................................................................... 28

Testing air tightness ....................................................................................................................................................... 28

ELECTRICAL EQUIPMENT ______________________________________________________ Page 29

Alternator checking (stator) ............................................................................................................................................. 30

Circuit checking ............................................................................................................................................................... 29

Electric starting with motor and alternator for battery re-charging ................................................................................. 29

Method of use .................................................................................................................................................................. 30

Wire checking .................................................................................................................................................................. 30

XIII ENGINE ASSEMBLY ___________________________________________________________ Page 32

Camshaft preparation ..................................................................................................................................................... 32

Checking injector protrusion .......................................................................................................................................... 38

Checking start of injection .............................................................................................................................................. 41

Checking T.D.C. .............................................................................................................................................................. 40

Checking valve head face depth ..................................................................................................................................... 38

Connecting rod-crankshaft coupling .............................................................................................................................. 36

Crankshaft preparation ................................................................................................................................................... 33

Cylinder height adjustement .......................................................................................................................................... 38

Cylinder mounting ........................................................................................................................................................... 37

Feeding pump assembly ................................................................................................................................................ 36

Fitting cylinder heads ...................................................................................................................................................... 39

Fitting of oil seal rings ..................................................................................................................................................... 35

Injection pump fitting ....................................................................................................................................................... 40

Injection pump tie rod connection .................................................................................................................................. 40

Oil pump assembly ......................................................................................................................................................... 35

Piston ring fitting ............................................................................................................................................................. 37

Piston ring working position ........................................................................................................................................... 37

Piston-connection rod couplings .................................................................................................................................... 36

Preparation of crankcase ................................................................................................................................................ 32

Protective cap fitting ........................................................................................................................................................ 37

Timing cover assembly ................................................................................................................................................... 34

Upper crankcase preparation ......................................................................................................................................... 33

Valve clearance ............................................................................................................................................................... 39

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

5

INDEX

XIV ENGINE TESTING _____________________________________________________________ Page 42

Checking for oil leaks ..................................................................................................................................................... 42

Checking oil pressure .................................................................................................................................................... 42

Speed adjustment ........................................................................................................................................................... 42

Testing engine on brake ................................................................................................................................................. 43

XV STORAGE ___________________________________________________________________ Page 44

How to prepare the engine for operation ........................................................................................................................ 44

Permanent protection (over 6 months) ........................................................................................................................... 44

Storage ............................................................................................................................................................................ 44

Temporary protection (1/6 months) ................................................................................................................................ 44

XVI QUICK REFERENCE CHARTS ____________________________________________________ Page 45

Adjustments .................................................................................................................................................................... 45

Couplings ........................................................................................................................................................................ 45

End floats ........................................................................................................................................................................ 45

Standard screw tightening torques ................................................................................................................................. 46

Tightening torques .......................................................................................................................................................... 46

6

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

TROUBLE SHOOTING I

POSSIBLE CAUSES AND TROUBLE SHOOTING

The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before removing or replacing any part.

TROUBLE

POSSIBLE CAUSE

Clogged pipes

Clogged fuel filter

Air inside fuel circuit

Clogged tank breather hole

Faulty fuel pump

Injector jammed

Jammed injection pump delivery valve

Wrong injector setting

Excessive plunger blow-by

Jammed injection pump delivery control

Wrong injection pump setting

Oil level too high

Jammed pressure relief valve

Worn oil pump

Air inside oil suction pipe

Faulty pressure gauge or switch

Clogged oil suction pipe

Battery discharged

Wrong or inefficient cable connection

Defective ignition switch

Defective starter motor

Clogged air filter

Excessive idle operation

Incomplete running-in

Engine overloaded

Advanced injection

Delayed injection

Incorrect governor linkage adjustment

Broken or loose governor spring

Idle speed too low

Worn or jammed piston rings

Worn or scored cylinders

Worn valve guides

Jammed valves

Worn bearings

Governor linkage not free to slide

Drive shaft not free to slide

Damaged cylinder head gasket

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

7

II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS

SAFETY AND WARNING DECALS

DANGER CAUTION

Failure to comply with the instructions could result in damage to persons and property

Failure to comply with the instructions could lead to technical damage to the machine and/or system

SAFETY INSTRUCTIONS

Lombardini Engines are built to supply their performances in a safe and long-lasting way. To obtain these results, it is essential for users to comply with the servicing instructions given in the relative manual along with the safety recommendations listed below.

The engine has been made according to a machine manufacturer's specifications and all actions required to meet the essential safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit. All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined by Lombardini which thus declines all liability for any accidents deriving from such operations.

The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine operation in particular, along with the relative routine maintenance work.

The user must read these instructions carefully and become familiar with the operations described. Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of the machine.

The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and the deriving dangers. This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the latter case, must only be carried out by persons specifically trained by Lombardini and who work in compliance with the existing documentation.

Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal of seals, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve Lombardini from all and every liability for deriving accidents or for failure to comply with the laws in merit.

On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous objects, also considering the movements made by the operator. Pull-starting with a free cord (thus excluding selfwinding starting only), is not permitted even in an emergency.

Make sure that the machine is stable to prevent the risk of overturning.

Become familiar with how to adjust the rotation speed and stop the engine.

Never start the engine in a closed place or where there is insufficient ventilation. Combustion creates carbon monoxide, an odourless and highly poisonous gas. Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death.

COMPILER TECO/ATI

8

REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS II

The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is dust that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been certified for the machine.

To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.

Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation.

Fuel is inflammable. The tank must only be filled when the engine is off. Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil. Make sure that no soundproofing panels made of porous material are soaked in fuel or oil. Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil.

Fully tighten the tank plug each time after refuelling. Do not fill the tank right to the top but leave an adequate space for the fuel to expand.

Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place.

Do not smoke or use naked flames when refuelling.

The engine must be started in compliance with the specific instructions in the operation manual of the engine and/or machine itself. Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).

Before starting, remove any tools that were used to service the engine and/or machine. Make sure that all guards have been refitted.

During operation, the surface of the engine can become dangerously hot. Avoid touching the exhaust system in particular.

Before proceeding with any operation on the engine, stop it and allow it to cool. Never carry out any operation whilst the engine is running.

The coolant fluid circuit is under pressure. Never carry out any inspections until the engine has cooled and even in this case, only open the radiator plug or expansion chamber with the utmost caution, wearing protective garments and goggles. If there is an electric fan, do not approach the engine whilst it is still hot as the fan could also start operating when the engine is at a standstill. Only clean the coolant system when the engine is at a standstill.

When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to safeguard the environment. The spongy filtering material in oil-cooled air filters must not be soaked in oil. The reservoir of the separator pre-filter must not be filled with oil.

The oil must be drained whilst the engine is hot (oil T ~ 80°C). Particular care is required to prevent burns. Do not allow the oil to come into contact with the skin.

Make sure that the drained oil, the oil filter and the oil it contains are disposed of in the correct way in order to safeguard the environment.

Pay attention to the temperature of the oil filter when the filter itself is replaced.

Only check, top up and change the coolant fluid when the engine is off and cold. Take care to prevent fluids containing nitrites from being mixed with others that do not contain these substances since "Nitrosamine", dangerous for the health, can form. The coolant fluid is polluting and must therefore be disposed of in the correct way to safeguard the environment.

During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect and insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter motor from being energized.

Only check belt tension when the engine is off.

Only use the eyebolts installed by Lombardini to move the engine. These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should be used.

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

9

III MODEL NUMBER AND IDENTIFICATION

MODEL NUMBER

Nr. Cylinders

Displacement (cc)

Diesel

LOMBARDINI

Engine group number

ENGINE IDENTIFICATION

R.P.M.

Customer's code

Approval code

Engine Serial Number

10

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

CHARACTERISTICS

ENGINE TYPE

*

**

Number of cylinders

Bore

Stroke

Swept volume

Compression ratio

N.

m m m m cm³

Power kW (HP)

N 80/1269/CEE-ISO 1585

NB ISO 3046 - 1 IFN

NA ISO 3046 - 1 ICXN

@ 3000 RPM

@ 3600 RPM

@ 3000 RPM

@ 3600 RPM

@ 3000 RPM

@ 3600 RPM

Max. torque *

Fuel consumption **

Oil consumption

Capacity of standard oil sump

Recommended battery 12V

Dry weight

Combustion air volume

Cooling air volume

Max.permissible driving shaft axial: continuous (instantaneous)

Flywheel site: continuous (instantaneous)

N m g/kW.h

g/kW.h

lt

Ah -A kg m³/h m³/h kg.

Max. inclination Power take off site: continuous (instantaneous)

Lateral: continuous (instantaneous)

Referred to N power

Consumption at max torque

TECHNICAL DATA

12 LD 477-2

[email protected]

236

0,8

3

66-300

78

90

950

100(350)

25°(35°)

25°(40°)

25°(40°)

2

90

75

954

19:1

15(20,5)

17(23)

14(19)

15,7(21,4)

12,9(17,6)

14,5(19,8)

IV

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

11

V CHARACTERISTICS

CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES

12 LD 477-2

N (80/1269/EEC - ISO 1585)

NB (ISO 3046 - 1 IFN)

AUTOMOTIVE RATING

: Intermittent operation with variable speed and variable load.

RATING WITH NO OWERLOAD CAPABILITY:

continuos ligth duty operation with constant speed and variable load.

NA (ISO 3046 - 1 ICXN) CONTINUOS RATING WITH OVERLOAD CAPABILITY:

continuos heavy duty with constant speed and constant load.

Mt-N Torque

at

N

power.

C

Specific fuel consumption at

N

power.

U1:

U2:

Standard utilization range of engines rated at 3000 rpm

Standard utilization range of engines rated at 3600 rpm

The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of

20°C and 1 bar.

Max. power tolerance is 5%.

Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C.

Note:

Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.

12

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

OVERALL DIMENSIONS VI

Note: Dimensions in mm

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

13

VII SPECIAL TOOLS

TOOL CODE DESCRIPTION

00365R0010

Extractor

00365R0940

Injection advance control tool

00365R0020

Flywheel extractor

00365R0040

Oil seal insertion tool

00365R0260

Oil seal protection cone

00365R0210

Injection pump spanner

00365R0450

Valve guide gauge Ø 7 mm (0.27 inch.)

00365R0850

Valve guide grinder Ø 7 mm (0.27 inch.)

00365R0540

Tool for valve seat

00365R0500

00365R0510

Cutter Ø 38 mm (1.50 inch.)

Cutter Ø 40 mm (1.57 inch.)

00365R0430

Injector test bench

14

COMPILER TECO/ATI

00365R0100

Bearing extractor

00365R0770

00365R0880

Cylinder collar Ø 80=85 mm (3.15=3.35 inch.)

Valve extractor

REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system

VIII

MANUTENANCE

OPERATION

COMPONENT

8

INTERVAL (HOURS)

50 200 300 500 2500 5000

CLEANING

CHECK

OIL-BATH AIR CLEANER

HEAD AND CYLINDER FINS

FUEL TANK

INJECTOR

AIR CLEANER OIL

LEVEL OIL SUMP

BATTERY FLUID

VALVE/ROCKER ARM CLEARANCE

INJECTOR SETTING

(*)

(*)

REPLACEMENT

OIL

AIR CLEANER

SUMP

EXTERNAL OIL FILTER CARTRIDGE

FUEL FILTER CARTRIDGE

DRY AIR CLEANER CARTRIDGE

(**)(***)

OVERALL

INSPECTION

PARTIAL

COMPLETE

(x)

(xx)

(*)

(**)

(***)

(x)

(xx)

First replacement

Under severe working conditions, clean daily.

Under extremely dusty conditions, change every 4-5 hours.

See recommended oil type.

The partial overhaul includes the following operations: valve and seat lapping, injector and injection pump overhaul, injector projection check, fuel injection spark advance check, check of the harmful area between head and piston, camshaft and crankshaft end float check, tightening of bolts.

The general overhaul includes - in addition to all partial overhaul - the following procedures: cylinder and piston replacement, seat, guide and valve refacing, crankshaft replacement or grinding, bench bearing and connecting rod replacement.

The maintenance operations listed above refer to an engine operating in normal conditions (temperature, degree of humidity, dust in the working environment). They may vary significantly according to the type of use.

To avoid explosions or fire outbreaks, do not smoke or use naked flames during the operations.

Fuel vapours are highly toxic. Only carry out the operations outdoors or in a well ventilated place.

Keep your face well away from the plug to prevent harmful vapours from being inhaled. Dispose of fuel in the correct way and do not litter as it is highly polluting.

FUEL

When refuelling, it is advisable to use a funnel to prevent fuel from spilling out. The fuel should also be filtered to prevent dust or dirt from entering the tank.

Use the same type of diesel fuel as used in cars. Use of other types of fuel could damage the engine. The cetane rating of the fuel must be higher than 45 to prevent difficult starting. Do not use dirty diesel fuel or mixtures of diesel fuel and water since this would cause serious engine faults.

The capacity of the standard tank is: lt. 7.0

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

15

VIII MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed.

Use a suitable oil in order to protect the engine.

The lubrication oil influences the performances and life of the engine in an incredible way.

The risk of piston seizure, jammed piston rings and rapid wear of the cylinder liner, the bearings and all moving parts increases if oil whose characteristics differ from the recommended type is used, or if the oil is not regularly changed. All this notably reduces engine life.

Oil viscosity must suit the ambient temperature in which the engine operates.

Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil is inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible.

Appropriate protective gloves etc should be wore during this operation.

Old oil is highly polluting and must be disposed of in the correct way. Do not litter.

RECOMMENDED OIL

GRADE

AGIP SINT 2000 5W40 specification API SJ/CF ACEA A3-96 B3-

96 MIL-L-46152 D/E.

ESSO ULTRA 10W40 specification API SJ/CF ACEA A3-96 MIL-L-

46152 D/E.

In countries where AGIP and ESSO products are not available, use API SJ/CF oil for gasoline-fuelled engines or oil that complies with military specification MIL-L-46152 D/E.

OIL SUPPLY ( liters )

Standard oil sump filter included

ACEA SEQUENCES

A = Gasoline (Petrol)

B = Light Diesel fuels

E = Heavy Diesel fuels

Required levels :

A1-96

A2-96

A3-96

B1-96

B2-96

B3-96

E1-96

E2-96

E3-96

3.0 l.

-

40

-

35

-

30

-

25

-

20

-

15

-

10

SAE 10W

-

5 0

+

5

+

10

+

15

+

20

+

25

+

30

+

35

+

40

+

45

+

50

SAE 20W

SAE 30

SAE 40

SAE 10W-30

SAE 10W-40

SAE 10W-60

SAE 15W-40 base minerale

SAE 15W-40 base semi-sintetica

SAE 20W-60 base semi-sintetica

SAE 5W-30 base sintetica

SAE 5W-40 base sintetica

SAE 0W-30 base sintetica

DIESEL

BENZINA - ESSENCE - PETROL

BENZIN - GASOLINA

API CF CE CD CC CB CA SA SB SC SD SE SF SG SH

SJ

D- 5

228.3

D- 4

CCMC G- 2

CCMC G- 3

CCMC PD - 1 / PD - 2

CCMC D- 2

CCMC D- 3

MIL - L - 2104 D

MIL - L - 2104 E

MIL - L -46152 C

MIL - L- 46152 D/E

MB 226.1

MB 227.1

MB 228.1

VW 500.00

VW 501.01

VW 505.00

VOLVO VDS

G- 4

G- 5

MB 226.5

MB 227.5

MAN QC 13-017

16

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

1

2

3

DISASSEMBLY OF THE ENGINE IX

During repair operations, when using compressed air, wear eye protection.

DISASSEMBLY AND REASSEMBLY

Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and operating instructions. Always use original LOMBARDINI spare parts for repair operations.

Flywheel extraction

Use extractor cod.

00365R0020

, as shown in figure 1.

During the demounting phases, pay particular attention to prevent the flywheel from dropping as this could seriously injure the operator.

Wear protective goggles when removing the flywheel ring.

IMPORTANT: Do not tap the end of the extractor when removing the flywheel.

Crankshaft gear extraction

Use extractor cod.

00365R0010

and cod.

00365R0100

(fig. 2).

Camshaft gear extraction

Use extractor cod.

00365R0010

(fig. 3).

Oil pressure register valve extraction

Use extractor cod.

00365R0880

(fig. 4).

4

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

17

5

IX CHECKS AND OVERHAUL

Cylinder heads

Details of fig. 5:

1. Cylinder head - 2. Pipe - 3. O-Ring - 4. Rockerarms - 5. Rockers -

6. Cotters - 7. Plates - 8. Springs - 9. Guides - 10. Seats - 11. Valves

- 12. Tappets - 13. Camshaft.

The heads are of aluminium with inserted guides and valve seats in cast iron. Make sure there are no cracks or imperfections. Should it be so, replace according to the instructions given in the spare parts catalogue.

Never remove head while still hot in order to avoid deformation.

6

Valves - Guides - Seats

Clean the valves with a wire brush and renew them if the valve heads are deformed, cracked or worn.

Check clearance between valve and guide with a micrometer on stem B (fig. 7) and with a go/no go gauge as shown in fig. 6 (tool cod.

00365R0450

).

Change the guide if the maximum gauge diameter passes through it, as it has passed the maximum permissible wear.

After having fitted the new guide, check exact diameter using the

“go” end of the gauge and if necessary grind it to the dimensions indicated in the table using the adjustable grinder (tool cod.

00365R0850

).

Engine

12LD477-2

Guide

Inlet

Outlet

Ø Guide mm

7,000 ÷ 7,010

go

Ø Gauge mm no go

7,000 7,079

7

Fitting of new guides always requires grinding of the valve seats

(see page 19).

Valve guides with an external diameter increased by

0.10 mm

are available.

If the inlet clearance between valve and guide is lower than

0.08

mm

and the outlet clearance is lower than,

0.10 mm

, the wear on

B

is less than

0.03 mm

and

A

is more than

0.05 mm

, recondition the valve by grinding face

P

to

45°

(fig. 7).

As a result of prolonged engine operation, the hammering of the valves on their seats at high temperature causes the face of the seats to harden and hand grinding is made difficult. It is thus necessary to remove the hardened surface with a

45°

cutter mounted on a valve seat grinding tool (fig. 8). Final fitting can then be carried out manually with the cutters listed below.

Cut dimensions for valve seats

Engine

12LD477-2

A x B

40 x 12 mm

Inlet

Ø guide

7 mm

A x B

38 x 12 mm

Outlet

Ø guide

7 mm

8

18

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

9

10

11

CHECKS AND OVERHAUL X

Cutting of the valve seats involves the widening of the valve seat face

P

with a consequent reduction of seal of the valve itself, fig. 9

If face

P

is more than

2 mm

wide, invert cutter and lower level

Q

of the seat, fig. 10, so as to restore the

P

level to the value of:

Fitting mm

0,7 ÷ 1,2

Max. wear mm

2

Final lapping of the valve on the seat must be carried out by coating the seat with a fire grinding paste and rotating the valve backwards and forwards with a slight pressure until a perfect finish to the surface is obtained (fig. 11).

Make sure the face of the valve head in relation to the face of the cylinder head is:

Fitting mm

0,9 ÷ 1,1

Max. wear mm

1,8

If the distance is less, the valve will strike the piston.

If the distance is more than

1.8 mm

the valve seat rings need to be changed. Fitting of new valves or seats always requires grinding.

Valve seats with an external diameter increased by

0.2 mm

, are available.

After grinding, wash valve and seat carefully with petrol or paraffin to eliminate any residual grinding paste or cuttings.

To check the worthiness of the seal between valve and seat, after grinding has taken place, proceed as follows:

1. Fit valve on head with spring, plates and cotters (see fig. 5).

2. Invert head and pour a few drops of diesel or oil round the outside of the valve head.

3. Blow compressed air into the inlet of the cylinder head, taking care to seal the edges so that the air does not escape (fig. 12).

Should air bubbles form between the seat and the valve, remove the valve and regrind the seat.

The fit can also be checked by pushing the valve upwards and letting it fall freely down onto its seat. If the resulting bounce is considerable and uniform, also when the valve is rotated, it means that the fit is good. If not, continue grinding until the conditions described above are achieved.

12

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

19

X CHECKS AND OVERHAUL

14,6 kg

25 kg

Valves and springs

In order to check the springs for possible failure measure the lengths under load as shown in figure 13.

The permissible tolerance for loads and lengths is ± 10%. If the figures measured do not fall within these values, the springs must be renewed.

13

14

15

Rocker arms

Make sure that the facing surfaces between rocker and pin are not scored and show no signs of seizure. If such marks are encountered, renew rocker and pin. Rocker / pin clearance (fig.14):

Fitting mm

0,030 ÷ 0,056

Rocker axial play (fig.14):

Max. wear mm

0,15

0,10 ÷ 0,50

Cylinders

Air cooled with cylinder barrels in special cast iron with integral liners.

Use a dial gauge to check internal diameters (C-D) at three different heights (fig.15).

Maximum permitted taper (A-B) and ovality (C-D) is 0.06mm.

Diameter of cylinders (fig.15):

12LD477-2

Ø 90 ÷ 90,015

If the diameter of the cylinder does not exceed said values or if there are slight surface scores on the cylinder, it will be sufficient to change the piston rings.

Do not manually hone the cylinder bore surfaces with emery cloth or other means.

The cross-hatch pattern should be at an angle of 90°÷120°; lines should be uniform and clear in both directions (fig. 16).

Average roughness must range between 0.5 mm 1 µm.

The cylinder surface which comes into contact with piston rings should be machined with the plateau method.

If the taper and ovality of the cylinder exceed the values indicated, then the cylinder and piston must be renewed.

16

20

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

17

18

19

CHECKS AND OVERHAUL X

Piston rings - Pistons - Piston pins

Check the wear of piston rings by fitting them into the cylinder through the lower end and measuring the end gap (fig.17). The values should be:

Piston ring

Compression

Oil scrapper

Fitting mm

0,30 ÷ 0,50

0,25 ÷ 0,50

Max. wear mm

0,80

0,80

Check that the rings move freely in the grooves and check the ring/ groove clearance using a feeler gauge (fig.18).

If the clearance exceeds the values shown in the table, renew the piston and the piston rings.

Piston ring

1st Compression

2nd- 3rd Compression

4th Oil scrapper

Max. wear mm

A = 0,22

B -C= 0,18

D = 0,16

Piston rings must always be renewed after dismantling the piston.

Piston diameter check: The diameter of the piston must be measured at approximately 18 mm from the base (fig.19).

Engine

12LD477-2

Diameter mm

89,919 ÷ 89,930

Check the clearance between cylinder and piston, if it is greater than 0.120 mm both cylinder and piston must be replaced.

Assembly clearance between piston pin and piston in millimetres:

Fitting mm

0,001 ÷ 0,010

Max. wear mm

0,060

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

21

20

X CHECKS AND OVERHAUL

Connecting rods

On the small end there is a groove (A, fig. 20) for the lubrication of the gudgeon pin. The small end and the gudgeon pin are coupled without a bush in between.

Assembly clearance between connecting rod small end and piston pin in millimetres:

Engine

12LD477-2

Ø Piston pin mm

21,997 ÷ 22,002

Assy.clearance

mm

0,023 ÷ 0,038

Max wear mm

0,070

If it is necessary to replace a complete connecting rod with bushes and bolts, make sure its weight is:

Engine

12LD477-2

Weight

gr. 570 ± 10

21

Check parallelism between connecting rod axies (fig. 21) as follows:

1. Insert the gudgeon pin into the small end bush and a calibrated pin into the big end (with bearing fitted).

2. Place the ends of the pin on 2 prisms set out on a checking bench.

3. Check with a comparator gauge that the discrepancy in the readings at the two ends of the gudgeon pin is not more than

0.05 mm

. Should the distortion exceed this value (max

0.10

mm

), reset connecting rod as follows:

Place connecting rod stem on checking bench and apply a calibrated pressure to the convex side of the stem (fig. 22).

22

22

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

23

24

CHECKS AND OVERHAUL X

Crankshaft

Whenever the engine is dismantled, particularly for the replacement of cylinders and pistons due to wear caused by the aspiration of dust, it is good practice to check the condition of the crankshaft.

1. Remove the plugs “A” from the oil passages (fig.23).

2. Use an appropriately shaped steel punch to clean the inside of the oil passages and the collection traps. If the deposits are particularly resistant, immerse the whole crankshaft in petrol or paraffin before proceeding with the operations.

3. When the oil passages and traps have been throughly cleaned, close the openings with new plugs (fig.24).

Checking crankshaft dimensions

Once the crankshaft has been thoroughly cleaned, use a micrometer to check the wear and ovality of the main journals and crank journals across two sections at right angles to each other

(fig.25).

If wear exceeds 0.08 mm (fig.26) grind the crankshaft to the dimensions shown in the table:

Dimensions

A

B

STD mm

45,005

÷

45,015

44,994

÷

45,010

-0,25 mm

44,755

÷

44,765

44,744

÷

44,760

-0,50 mm

44,505

÷

44,515

44,494

÷

44,510

Undersize bearing bushes are already available at the necessary sizes without requiring any adjustment by boring.

25

Main bearing bushes with increased external diameters are also available. Table indicates the crankcase boring values.

Bearing

Standard

+ 1 mm

Ø of brush housingmm

47,965 ÷ 47,985

48,965 ÷ 48,985

During grinding take care not to remove the shim adjustment material from the main journal thrust face to avoid changing the crankshaft end float; also ensure that the grinding wheel radii are as specified in figure 26 so as not to create crack initiation sections on the crankshaft.

26

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

23

27

X CHECKS AND OVERHAUL

exhaust inlet

Camshaft

Check cams and support pins for wear or scores.

Check amount of wear by measuring points

A

and

B

shown in fig.

27 and 28 and comparing to the figures of the tables hereunder:

Distribution cam dimensions (fig. 27).

Engine

12LD477-2

Measurement

A-B

Fitting mm

29,95 ÷ 30,00

Max. wear

mm

29,70

28

Injection cam dimensions (fig. 28)

Engine

12LD477-2

Measurement

A

Fitting mm

28,39÷ 28,43

Max. wear

mm

28,30

The coupling clearance between pins and respective housings should be:

Fitting mm

0,015 ÷ 0,048

Max. wear mm

0,100

Renew the camshaft if the cams or journals show wear in excess of 0.1mm.

Oil seal rings

Make sure the oil seals have not hardened round the internal contact edge with the crankshaft and that they do not show signs of cracks or wear. If they do, replace them with new ones of the same size.

Then re-fitting the oil seal, use protective cone cod.

00365R0260.

Fit said cone over the ends of the crankshaft to avoid damage to the ring itself.

Tappet checking

Make sure the tappet surfaces are not worn, lined or present signs of seizure. If so, replace.

Tappet and seat check in mm (fig. 29).

Measurement

Tappet

Tappet seat

Fitting mm

11,98 ÷ 11,99

12,00 ÷ 12,018

Max .assy.clearance mm

0,10

29

24

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

30

31

32

CHECKS AND OVERHAUL X

Governor lever and spring

Check that the shoes (

S

, fig. 30) are level and that the springs have not lost their elasticity. Renew any excessively worn parts after consulting the spare parts catalogue.

Supplement and governor spring dimensions (fig. 30):

Spring

Supplement (H)

Governor (N)

Lenght mm

16,9 ÷ 17,4

53

Lenght under load mm

35

69,2

Load kg

0,3

2,5

Nr of windings

18,5

13

Oil pump checking

The pump is of the lobed rotor type driven by the camshaft.

Dismantle pump and check rotors.

Check lobes and centers and if they are worn, replace rotors.

Check the amount of pump wear, measure rotor

A

and rotor

B

(see fig. 31), and compare to the following table:

C

D

E

F

Measurement Dimensions mm

29,745 ÷ 29,770

40,551 ÷ 40,576

30,030 ÷ 30,60

17,920 ÷ 17,940

Max. wear mm

29,700

40,45

30,10

17,89

If wear exceed these figures, replace complete pump.

The coupling clearance between oil pump external rotor and basement housing is:

Fitting mm

0,094 ÷ 0,144

Max. wear mm

0,294

The axial clearance of the rotors (fig. 32) should be between:

Fitting mm

0,010 ÷ 0,050

Max. wear mm

0,100

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

25

33

34

XI INJECTION EQUIPMENT

Fuel circuit

Feeding is carried out by a diaphram pump actuated by a camshaft eccentric coupled to a cap.

See assembly on page 36 and consult spare parts catalogue for replacement.

Details of fig. 33:

1.Tank - 2.Diesel filter - 3.Feeding pump - 4.Injection pump -

5.Injection pipes - 6.Injectors - 7.Diesel discharge pipe.

Injection pump

The injection pump is of the single casing type with two, constant stroke, separate pumping elements. Details of fig. 34.

1.Pump casing - 2.Pumping element - 3.Rack bar - 4.Eccentric

dowel - 5.Adjusting bushing - 6.Spring - 7.Lower plate - 8.Tappet -

9.Upper plate - 10.Locking pin - 11.13.18.Gaskets - 12.Diesel intake connection - 14.Diesel exhaust screw - 15.Delivery valve -16.O-ring -

17.Valve spring - 19.Delivery connection.

Checking injection pump

Before dismantling injection pump check pressure seal of the pumping unit, cylinder and valve as follows:

1. Connect a pressure gauge graded up to

600 kg/cm²

(fig. 35) to the diesel delivery pipe.

2. Set the rack bar in a half way position.

3. Rotate flywheel showly until the pumping element has completed a compression stroke.

If the test is carried out on the bench, take care that the pumping element does not strike the delivery valve while pumping.

4. Take the pressure gauge reading. If the reading is less than

300 kg/cm²

, the complete pumping unit must be replaced.

During the test, the reading on the gauge will show a progressive pressure increase to a maximum value and will then fall suddenly and stop at a lower pressure.

Replace valve if the fall in pressure exceeds

50 kg/cm²

and continues to fall slowly.

Injection pump setting

Register eccentric dowel to the maximum capacity of the pumping elements (

q

, fig. 39).

35

26

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

INJECTION EQUIPMENT XI

The quantity of diesel is in relation to 1000 deliveries with the rack bar at

8 mm

from the stop position.

Engine

12LD477-2

Ø Pumping element mm

6

cc valve

15

Valve Ø mm

4

Capacity cc

24 ÷ 26

Pump

RPM

1500

36

37

38

Injection pump assembly

After having dismantled the injection pump it should be reassembled in the following manner:

1. Insert cylinders into pump casing with diesel inlet opposite to feeding inlet connection (fig. 36). This position is necessary due to two eccentric dowels on the pump casing.

Make sure the supporting faces of the cylinders and pumps are free of dirt.

2. Fix cylinders by inserting valves and temporarily tightening the delivery connections to stop the pumping elements from coming out. (fig. 37).

3. Insert rack bar and lock in a half way position (fig. 38). Make sure the bar moves freely on the guides. Resistance and drag will cause the engine to run unevenly.

4. Marks

b

cut on the bar must coincide with marks toothed quadrants. Marks

c a

of the on toothed quadrants must coincide with marks

d

on the flanges of the piston (fig. 39).

5. Insert piston into cylinder with groove turned towards the eccentric dowel on the pump casing.

6. Complete assembly of pump.

IMPORTANT:

The roller tappets (No 8 fig. 34) and the lower plates are not interchangeable as they determine the timing of the pumping elements.

When replacing parts make sure that: a. the distance between the injection cam in bottom dead centre position (PMI) and the pump supporting surface is

82.6

to

83 mm

as stated on the plate.

b. the piston stroke from the bottom dead centre position (PMI) of the injection cam to delivery commencement is

2.0

to

2.1 mm

.

7. Check pressure seal again, as described in paragraph

"Checking injection pump" page 26, to make sure the replaced parts are working properly.

39

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

27

40

XI INJECTION EQUIPMENT

Testing air tightness

Feed pressurized air at 6 kg/cm² into the fuel sullpy union and completely immerse the pump in oil or diesel fuel for about 20 ÷ 30 seconds (fig.40); check that no air bubbles are released.

N.B.: Tightness can be checked by compressing the springs to

52.8 ÷ 54.4 mm, which corresponds to the bottom dead centre working position of the pump.

Injectors (fig. 41)

1.Body - 2.Nozzle - 3.Ring nut - 4.Plate - 5.Rod - 6.Spring -

7.Adjustment shim.

41

42

43

28

COMPILER TECO/ATI

Injector checking and setting

1. Clean out nozzle holes with a thin piece of wire (fig. 42) of the same size as that of the nozzle holes indicated on the table:

Engine

12LD477-2

Ø holes mm

0,25

2. Set up injector on a test bench (tool cod.

00365R0430

).

3. Unscrew injector lock coupling (No 3 fig. 41) or nozzle ring nut and insert adjustment shim (7, fig. 41) until the pressure indicated in the table hereunder is reached on the pressure gauge while pumping.

Engine

12LD477-2

Setting kg/cm 2

225 ÷ 235

4. Tighten the nozzle ring nut (No 3 fig. 41) at:

5 kgm (49 Nm)

5. When setting is complete, while still at the test bench, run pumping elements a few times and check the amount of diesel that passes through the upper leak-off of the injector (fig. 43).

REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

44

ELECTRICAL EQUIPMENT XII

Electric starting with motor and alternator for battery re-charging

Characteristics

Starter motor:

anticlockwise rotation.

12V - 1.5 HP (1.1 kW)

Flywheel alternator:

For re-charging

12V/280W

batteries giving 17A charge at

3000

RPM

.

Regulator:

Electronic with controlled diodes and preset for battery re-charging pilot light connection.

12V-24A

Optional external alternator with belt control:

F

or re-charging

12V/200W

batteries giving

15.5A

charge at

6000

RPM

with

12V/26A

voltage adjustor.

Battery:

12V; 80 to 90 Ah

To check starting system circuit see figures 47.

Circuit checking

1. Make sure the connections between regulator and alternator are correct and in good condition.

2. Detach from the terminal on the starter motor, the red wire coming from the alternator, and insert a direct current ammeter with a

20 Amp

range between said free terminal and the detached wire.

3. Connect a direct current voltmeter with a minimum range of

15

Volts

(fig. 44), to the battery terminals.

4. Insert starter key and start up a few times at no load or insert a lamp load of

80

to

100 W

at the ends of the battery to keep the battery voltage under

13 Volts.

5. Run the engine up to the maximum of

3000 RPM

. The charging current reading on the ammeter should be about:

17A

with

12V/280W

alternator

For intermediate values see fig. 46.

6. Disconnect lamp load and keep engine running at A/m revs. for some time.

The battery voltage will increase progressively until it reaches the setting limit of the regulator which is about

14.5 V.

Simultaneously, the charging current will drop to about

2A

. This will occur very quickly if the battery is charged and slowly if it is discharged.

7. If the charging current cuts out or is lower than the values given above, replace governor. If the performance does not improve after this replacement, the trouble must be locked for in the alternator.

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

29

45

XII ELECTRICAL EQUIPMENT

Insulation

Alternator checking (stator)

Disconnect alternator cables from the regulator and check continuity between the windings with an Ohmmeter.

Also check that there is good insulation between cables and earth (fig. 45). In the event of an open circuit, replace the stator. If the stator is in good working order but the values of the alternator charge are lower than those stated, the rotor is demagnetised and the entire alternator must be replaced.

Continuity

46

Wire checking

Examine condition of wires bearing the following in mind:

1. With one of the yellow wires open circuited, the alternator will not supply current.

2. With both yellow wires open circuited, the alternator will not supply current at all.

3. With one or both wires earthed, the rotor will demagnitize very quickly and the coils of the stator will burn out.

4. With red wire open circuited, the alternator will not supply current.

5. With red wire earthed the alternator will not supply current, the connection wires and warning circuit will burn out and the battery will discharge completely.

6. Avoid sparks between cables, as the alternator could burn out.

7. With an imperfect earth between the negative battery terminal and regulator casing, the charging current is irregular and the regulator could be damaged.

8. If the battery connections are inverted, the alternator and regulator will burn immediately.

47

Method of use

By turning the starter key to the first position, the battery charging circuit is started off, and thus:

1. With engine stationary the key must be kept on the off position.

If it is left on the first position, the oil warning light could burn out, the battery could discharge and the regulator could be damaged.

2. With engine running turn key to first position. If it is left in the off position, the oil warning light and battery charging functions are excluded.

The voltage regulator will be damaged beyond repair, if it is run with the battery cables disconnected or with unactivated batteries.

30

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

48

ELECTRICAL EQUIPMENT XII

Diagram of electric starting wiring system

with flywheel alternator

(fig. 47).

1.Battery - 2.Regulator - 3.Alternator - 4.Starter motor - 5.Pressure

gauge - 6.Oil pressure warning light - 7.Starter key - 8.Battery

charging light.

Diagram of electric starting wiring system

with external alternator

(fig. 48).

1.Battery - 2.Regulator - 3.Alternator - 4.Starter motor - 5.Pressure

gauge - 6.Oil pressure warning light - 7.Starter key - 8.Battery

charging light.

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

31

49

50

51

XII ENGINE ASSEMBLY

Notice: These instructions are valid for engines up-dated prior to the publication of this manual. Any modifications must be checked on the technical circulars.

Before assembling the engine carefully clean all parts and dry them with compressed air. Lubricate moving parts to prevent seizing when starting up. Replace the gaskets with new ones each time the engine is assembled.

Use torque wrenches to ensure that the correct tightening torques are applied.

Preparation of crankcase

Clean support faces and remove seal residue and dirt with a copper plate or a fine emery stone to avoid damage to the contact surfaces (fig. 49).

Lower crankcase (fig. 50)

1. Insert plugs (A) into relative seats.

2. Screw in oil filter cartridge connection (B). The connection should protude 11 to 13 mm. from the crankcase.

3. Insert complete oil pressure register valve into its seat (C).

Make sure the seat of the valve ball in the casing is free of dirt or scores which could jeopardize the pressure seal.

4. Insert cylinder studs and centering pins.

Camshaft preparation

To prepare the camshaft unit (fig. 51) proceed as follows:

1. Insert shim adjustment washer (No 3) and governor plate

(No 4) on camshaft.

2. Fit snap ring (No 5) and tab (No 7) into respective housings.

3. Heat gear (No 6) complete with masses and insert onto camshaft making sure it rests against the locking snap ring.

4. Insert governor plate locking ring (No 2).

The speed governor is of the centrifugal mass type directly onto the ends of the camshaft gear (fig. 52).

s p l i n e d

Masses (

A

), pushed outwards by the centrifugal force, shift mobile plate (

P

) axially. Said plate actions lever (

R

) connected to injection pump rack bar (

E

) by means of tie rod (

T

).

A spring (

N

) placed under tension by the accelerator (

C

), contrasts the action of the centrifugal force of the governor.

The balance between the two forces keeps the revolutions practically constant when load is changed.

For pre-load adjustment of the speed governor see paragraph on page 40 "Injection pump tie rod connection".

52

32

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

ENGINE ASSEMBLY XIII

Crankshaft preparation

The insertion of the main distribution gear onto the crankshaft must be carried out while hot. Heat by means of dry heating or an oil bath at 70/80 °C (fig. 53).

53

54

Upper crankcase preparation

1. Insert accelerator internal lever onto crankcase taking care not to damage the oil seal O-Ring.

2. Fit interchangeable tappets into housings on crankcase.

3. Camshaft assembly (fig. 54): in order to assemble the shaft correctly, the cams must be introduced, without applying force, along the grooves inside the crankcase.

4. Mount governor lever and insert lever fulcrum pin taking care not to damage the oil seal rings (fig. 55). The lever should be able to effect the complete stroke without strain.

Insert spring between governor lever and accelerator.

5. Insert main bearings into respective housings and spread with oil slightly.

The three main bearings are identical and interchangeable.

6. Fit rubber gaskets and O-Rings between crankcases taking care to insert same properly into respective grooves so as to prevent oil leaks between the contact surfaces (fig. 56).

It is advisable to spread a bit of rubber adhesive round the edges of the rubber gasket for better seal.

55

56

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MODEL N°

50907

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REVISION

00

DATE

01.08.2003

ENDORSED

33

57

XIII ENGINE ASSEMBLY

7. Place crankshaft on previously housed shells making sure the timing references found on the gears coincide (fig. 57).

8. Insert oil seal rings on the drive side of the crankshaft (fig. 58).

A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems.

Use genuine oil retainers with the LOMBARDINI.

9. Mount lower crankcase complete with studs, centering pins and bearings.

10.Take care to insert the centering pins between crankcases into their respective housings without using force.

11.Tighten crankcase screws, to starting from the centre and alternating towards the outside at:

kgm 1,3 (Nm 12,8)

58

59

Timing cover assembly

Before mounting the timing cover check that between the gear shims and the crankcase surface (fig. 59) there is a maxi clearance of:

0,10 mm

The axial clearance is measured at the timing cover gaskets and must be between:

0,10 ÷ 0,20 mm

If the axial clearance of the crankshaft becomes excessive after a long working period, add adjustment shims to the engine shaft and camshaft gear until the clearance returns to normal values (fig. 60).

0.2 and 0.3 mm shims are available.

60

34

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MODEL N°

50907

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REVISION

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DATE

01.08.2003

ENDORSED

61

62

63

ENGINE ASSEMBLY XIII

Fitting of oil seal rings

To introduce oil seal ring, flywheel side, use an ordinary cylindrical plug of appropriate size as shown in fig. 61.

A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems.

Use genuine oil retainers with the LOMBARDINI.

The oil seal rings are to be fitted with the arrow pointing in the same direction of the crankshaft rotation.

Final insertion of the oil seal ring, drive side, requires the use of special tool code

00365R0040

(fig. 62).

Oil pump assembly

For rotor checks see page 25.

After tightening crankcase, mount oil pump external rotor with the notch facing inwards (fig. 63).

Make sure the O-Ring on the oil pump cover is in perfect condition.

Tighten screws gradually to a pressure of:

kgm 1 (Nm 9,8)

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MODEL N°

50907

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08-03

REVISION

00

DATE

01.08.2003

ENDORSED

35

64

XIII ENGINE ASSEMBLY

Feeding pump assembly

1. Insert fuel feeding pump cap into its housing and make sure it moves freely. The length of the cap is :

34 ÷ 34,2 mm

2. Fit gasket (0.5 mm and 0.2 mm thick).

3. With fuel pump control cams in a rest position the cap should protude from the gasket surface (fig. 64) for:

1,7 ÷ 2,1 mm

4. With fuel feeding pump control cams at bottom dead centre position mount feeding pump and action manually. There should still be a small suction stroke (fig. 65).

If said checks are not carried out, the fuel feeding pump diaphram could be damaged due to the excessive stroke to which it will be subjected.

65

Piston-connection rod couplings

The piston is coupled to the connecting rod by means of slight hand pressure on the gudgeon pin without heating the piston.

The clearance between the small end and the gudgeon pin is:

0.023

to

0.038 mm

and between gudgeon pin and piston:

0.002

to

0.008 mm.

The lubrication groove (A, fig. 66) on the small end must be turned towards the engine rotation direction (injection pump side).

66

67

36

COMPILER TECO/ATI

Connecting rod-crankshaft coupling

After insertion of the bearings into the big end, attach connecting rods to crank pins, bearing in mind that an arrow, on the pistons, indicates the rotation direction of the engine (fig. 66).

The combustion chamber, which is eccentric with respect to the axis, should be turned to the nozzle side.

Mount connecting rod caps with reference numbers corresponding to those on the rod (fig. 67). The coupling clearance between big end bearing and pins is:

0.020 to 0.072 mm

. Tighten up connecting rod bolts to:

kgm 3,8 ÷ 4 (37,3 ÷ 39,3 Nm)

REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

68

ENGINE ASSEMBLY XIII

Piston ring fitting

Fit rings onto pistons in the following order (fig. 68):

1. Chromed compression seal ring.

2. Torsional compression seal ring (with internal notch turned upwards).

3. Expander oil scraper ring.

Piston ring working position

Before mounting cylinders, rotate rings 120° opposite to each (fig.

69) other with the ends of the 1st compression ring in line with the gudgeon pin axis.

69

Protective cap fitting

To prevent the entrance of dust and water which could block the cylinder studs to the upper crankcase, insert protective caps on the studs themselves (fig. 70).

To facilitate cap mounting, oil stud roots.

Insert on crankcase, under the rocker shaft pipes, plates for the lubrication of the camshaft.

70

Cylinder mounting

The lower end of the cylinder is chamfered for piston ring insertion

(fig. 71).

The operation can be carried out easily by using a standard piston ring compression tool (tool

00365R0770

).

71

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50907

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08-03

REVISION

00

DATE

01.08.2003

ENDORSED

37

72

XIII ENGINE ASSEMBLY

Cylinder height adjustement

Between the top face of the cylinder and the piston at top dead center, there must be a clearance of:

0,25 ÷ 0,35 mm

In order to carry out this operation correctly, make the check with the cylinder pressed well down on its crankcase (fig. 72).

The clearance is adjusted by means of shims inserted between the lower face of the cylinder and crankcase (fig. 73).

Shim dimensions:

0.1

to

0.2 mm

73

Checking valve head face depth

When replacing valves check that the clearance from the top of the head to the face (fig. 74) is of:

Fitting mm

0,9 ÷ 1,1

For different values see on pages 18-19.

Max. wear mm

1,8

74

Checking injector protrusion

Before mounting the heads on the cylinders, insert injectors in their housings and after having secured them temporarily, check protusion of nozzles from head surface (fig. 75).

Protusion

S

should be:

2,25 ÷ 2,75 mm

75

38

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MODEL N°

50907

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08-03

REVISION

00

DATE

01.08.2003

ENDORSED

ENGINE ASSEMBLY XIII

Adjustment is effected by inserting copper washers between the injector and injector supporting faces on the heads (fig. 76). Washer thickness

1 mm

.

76

Fitting cylinder heads

Insert oil seal O-rings on rocker arm housing and fit the cylinder head in place. Insert 0.5 mm copper gaskets between the surfaces.

(fig. 77).

Make sure the oil seal rings are housed properly in the heads to avoid oil leaks.

77

Align heads using a manifold or a metallic bar as shown in fig. 78.

Tighten down cylinder head nuts uniformly (fig. 78) increasing 1 kgm at every turn until a pressure is reached of:

5 kgm (49 Nm)

78

Valve clearance

The clearance between valves and rockers with the engine cold (fig.

79) is:

0,15 mm intake/exhaust

The operation must be carried out with the pistons at their top dead center compression position.

79

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MODEL N°

50907

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08-03

REVISION

00

DATE

01.08.2003

ENDORSED

39

80

XIII ENGINE ASSEMBLY

Injection pump fitting

Fit injection pump into timing case inserting adjusting shim between supporting flange and crankcase (fig. 80).

To facilitate the insertion of the pump, rotate the flywheel so as to bring the actuating cam to rest position and set the rack bar in a half way position.

To facilitate tightening of pump nuts on the cylinder side, use the special key (tool od.

00365R0210

) illustrated in fig. 81.

81

82

Injection pump tie rod connection

- The injection pump tie rod length, measured from the connecting centre of the rack bar to the centre of the ball joint must be

mm 118 ±1

complete turn.

Careful operation will avoid uneven running, starting difficulties and power losses.

- Connect tie rod to governor lever, engaging the ball joint to 90°

(fig. 82), and to the injection pump rack bar and then insert split pin.

Checking T.D.C.

With pistons in respective top dead center compression position check that the arrows on the air conveyor coincide with top dead center position indications on the flywheel (fig. 83).

If the flywheel has to be replaced, transfer and punch the above mentioned indications on the new one.

83

40

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MODEL N°

50907

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08-03

REVISION

00

DATE

01.08.2003

ENDORSED

84

85

86

ENGINE ASSEMBLY XIII

Checking start of injection

1. Connect fuel tank to injection pump.

2. Bring accelerator lever to max. position and piston, flywheel side, at compression beginning (cylinder No 1)

All operations are to be carried out with the rack bar in working position to annul the delay caused by the notch on the pumping element of the injection pump.

3. Fit the special tool, p.n.

00365R0940

, to the delivery valve holder

(flywheel side) as shown in figure 84.

4. Insert a band (fig. 85) to ease the tension of the spring.

5. Turn the flywheel slowly until the column of diesel fuel inside the special tool starts to move. This indicates the start of static injection.

At this moment injection pimp delivery starts (fig. 86) and the top dead centre reference on the air conveyor must coincide with the

IP

mark punched cm the flywheel (fig. 87).

If the

IP

mark falls short of the notch on the air conveyor, injection is too fast. The injection pimp must be disassembled and shims must be added between the pump flange and the crank-case.

If the

IP

mark falls after the T.D.C. reference notch, injection is too slaw and the above operation is to be inverted.

Bear in mind that every

0.1 mm

shim under the pimp corresponds to a

2.5 mm

rotation of the flywheel.

Repeat operation on second pumping element.

Should the flywheel need to be replaced, the top dead center compression position of the pistons is to be determined as per page 40 and the start of injection according to the following table:

I.P.

26°

=

53,5 mm

Ø flywheel

236 mm

87

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DATE

01.08.2003

ENDORSED

41

88

XIV ENGINE TESTING

Speed adjustment

1. With engine hot set minimum speed at

1000 RPM

(fig. 88) and maximum to idle (fig. 89) at:

3150 RPM

3750 RPM

for engines at 3000 rpm for engines at 3600 rpm

2. Then stop the engine.

3. Remove injectors, clean nozzle holes carefully, check setting and re-fit.

4. Adjust clearance between valves and rockers, while engine is hot, to:

0,15 mm intake/exhaust

5. Re-fit rocker covers and sealing gaskets.

89

90

Checking oil pressure

1. Remove union from rocker oil hole and fit a pressure gauge graded from

0

to

8 kg/cm²

(fig. 90).

2. Start engine and run up to

3000 RPM.

Wait for the oil temperature to reach 70 to 80°C.

3. With engine idling at

3000 RPM

the pressure gauge needle should be slightly over half way corresponding to a pressure of

3

to

4 kg/cm².

Said pressure will stabilize at

2

to

3 kg/cm²

when engine runs at full load and the oil temperature exceeds 70 to 80°C.

4. Reduce revs to minimum. The pressure should not fall to under

1 kg/cm²

with the oil temperature exceeding

80°C.

Checking for oil leaks

1. Remove exhaust gas collection pipe from suction manifold and close with a plug (fig. 91).

2. Start engine and run for a few minutes. The pressure which forms inside the crankcase bring out any oil leaks.

3. Re-fit gas collection pipe to suction manifold.

91

42

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MODEL N°

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08-03

REVISION

00

DATE

01.08.2003

ENDORSED

92

93

94

ENGINE TESTING XIV

Testing engine on brake

After having placed the engine on the brake (fig. 92), proceed with the following operations:

1. Check oil level (fig. 93).

2. Start engine and run at minimum speed.

3. Check oil pressure on pressure gauge (fig. 90).

4. Run engine in before testing it at full power.

Running-in table

Time (min)

5

15

30

30

30

5

RPM

2000

3000/3600

3000/3600

3000/3600

3000/3600

3000/3600

Engine power curves are reported at page 12.

Load

0

0

30%

50%

70%

100%

In order to check that the setting is correct, without tools, accelerate the engine a few times with no load and check the exhaust fumes.

Delivery of diesel fuel is correctly calibrated when the exhaust gas is slightly coloured by smoke; change the adjustment if necessary by turning the adjustment screw

(fig. 94).

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REVISION

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DATE

01.08.2003

ENDORSED

43

95

96

XV STORAGE

Storage

Prepare engines as follows for storage over 30 days

Temporary protection (1/6 months)

Let engine run at idling speed in no-load conditions for 15 minutes.

Fill crankcase with protection oil MIL-1-644-P9 and let engine run at 3/4 full speed for 5/10 minutes.

When engine is warm empty oil pan and fill with standard new oil (fig. 95)

Remove fuel tube and empty the tank

Remove fuel filter, replace cartridge if dirty and refit (fig. 96).

Carefully clean cylinder fins, heads and fan (fig. 97).

Seal all openings with tape.

Remove injectors, pour a spoonful of oil type SAE 30 into the cylinders (fig. 98) and rotate manualy to distribute the oil. Refit injectors.

Spray oil type SAE 10W into exhaust and intake manifolds, rocker arms, valves, tappet etc. Grease all unpainted parts.

Loosen belt

Wrap the engine in a plastic film.

Store in a dry place, if possible not directly on the soil and far from high voltage electric lines.

Permanent protection (over 6 months)

The following is recommended apart from the above instructions:

For the lubrication and injection system as well as for moving parts use rustproof oil type MIL-L-21260 P10 grade 2, SAE 30

(Ex. ESSO RUST - BAN 623 - AGIP, RUSTIA C. SAE 30) Let the engine run with rustproof oil and drain any excess.

Coat external unpainted surfaces with antirust type MIL-C-

16173D - grade 3 /Ex. ESSO RUST BAN 398 - AGIP, RUSTIA

100/F).

How to prepare the engine for operation

Clean engine outside

Remove protections and covers

Remove antirust with an appropriate solvent or degreaser.

Remove injector, fill with standard oil, turn crankshaft by a few revolutions, remove oil pan and drain the protective oil.

97

98

44

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MODEL N°

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REVISION

00

DATE

01.08.2003

ENDORSED

Couplings

Camshaft journal and housing in timing cover

Camshaft journal and housing in crankcase

End gap of compression rings

End gap of oil scraper rings

Connecting rod and wrist pin

Rockers and shaft

Main journals and bearings bushes

Oil pump drive gear spindle and housing in crankcase

External oil pump rotor and housing in engine crankcase

Pistons and wrist pin

Big end bearing and crankpin

Valve guide and stem: inlet

Valve guide and stem: exhaust

QUICK REFERENCE CHARTS XVI

Spiel (mm)

0,017÷ 0,047

0,015÷ 0,048

0,30 ÷ 0,50

0,25 ÷ 0,40

0,023 ÷ 0,038

0,030 ÷ 0,056

0,010 ÷ 0,060

0,030 ÷ 0,065

0,094 ÷ 0,144

0,002 ÷ 0,008

0,020 ÷ 0,072

0,030 ÷ 0,050

0,045 ÷ 0,065

Grezen (mm)

0,1

0,1

0,8

0,7

0,07

0,15

0,15

0,115

0,294

0,05

0,17

0,1

0,1

Adjustments

Valves

Valve depth from cylinder head

Dead space between cylinder face and piston

Protrusion of injector

MIN (mm)

0,15

0,9 ÷ 1,1

0,25

2,25

MAX (mm)

0,15

1,8

0,35

2,75

MIN (mm)

0,10

0,10

0,01

MAX (mm)

0,20

0,20

0,05

COMPILER TECO/ATI REG. CODE

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MODEL N°

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REVISION

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DATE

01.08.2003

ENDORSED

45

XVI QUICK REFERENCE CHARTS

Tightening torques

Crankcase

Connecting rod

Bolt on power take off end

Timing cover

Oil sump

Injectors

Injection pump

Oil pump cover

Cylinder head

Flywheel

kgm

1,3

3,8 ÷ 4,0

25

1

1,3

2,3

2,3

0,6

5

28

(Nm)

(12,8)

(37,3 ÷ 39,3)

(245,5)

(9,8)

(12,8)

(22,6)

(22,6)

(5,9)

(49)

(274,9)

Diameter x pitch

mm

4 x 0,70

5 x 0,80

6 x 1,00

7 x 1,00

8 x 1,25

9 x 1,25

10 x 1,50

13 x 1,75

14 x 2,00

16 x 2,00

18 x 2,50

20 x 2,50

22 x 2,50

24 x 3,00

Standard screw tightening torques

Denomination

8.8

= 8.8

89

135

205

257

358

435

557

19,8

29,6

38

52,5

Nm

3,6

7

12

R

≥≥≥≥≥

800 N/mm 2

9,09

13,80

21,00

26,30

36,60

44,40

56,90

kgm

0,37

0,72

1,23

2,02

3,02

3,88

5,36

R10

= R10 = 10.9

125

190

289

362

504

611

784

27,8

41,6

53,4

73,8

Nm

5,1

9,9

17

R

≥≥≥≥≥

1000 N/mm 2

12,80

19,40

29,50

37,00

51,50

62,40

80,00

kgm

0,52

1,01

1,73

2,84

4,25

5,45

7,54

R12

= R12 = 12.9

150

228

347

435

605

734

940

Nm

6

11,9

20,4

33

50

64.2

88.7

R

≥≥≥≥≥

1200 N/mm 2

15,30

23,30

35,40

44,40

61,80

74,90

96,00

kgm

0,62

1,22

2,08

3,40

5,10

6,55

9,05

46

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08-03

REVISION

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DATE

01.08.2003

ENDORSED

NOTE

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

47

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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 vorbehält alle Rechte, diese Angabe jederzeit verändern.

La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación.

48

COMPILER TECO/ATI REG. CODE

1-5302-625

MODEL N°

50907

DATE OF ISSUE

08-03

REVISION

00

DATE

01.08.2003

ENDORSED

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