LOMBARDINI CHD LDW 1503, CHD LDW 2004, CHD LDW 2004/T Engine Workshop Manual

WORK SHOP

MANUAL

CHD series engines, p.no 1-5302.345

LDW 1503

CHD

LDW 2004

CHD

LDW 2004/T

CHD

3rd edition

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1-5302-345

MODELLO N°

50534

SERVICE

DATA EMISSIONE

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DATA

REVISIONE

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30-09-1996

VISTO

1

INTRODUCTION

This manual contains very important information for the repair of LOMBARDINI water-cooled indirect injection Diesel engines type LDW 1503, LDW 2004 and LDW

2004/T: updated August 01, 1996.

II

III

I

INDEX

MODEL NUMBER AND ENGINE IDENTIFICATION

CHARACTERISTICS

MAINTENANCE-RECOMMENDED OIL TYPE-REFILLING

IV TROUBLE SHOOTING

V OVERALL DIMENSIONS

VI DISASSEMBLY/REASSEMBLY

VII TURBOCHARGER

VIII LUBRICATION SYSTEM

IX COOLING SYSTEM

X FUEL SYSTEM

XI ELECTRIC EQUIPMENT

XII SETTINGS

XIII STORAGE

XIV TECHNICAL DATA

XV TORQUE SPECIFICATIONS

XVI SPECIAL TOOLS

GENERAL ALPHABETICAL INDEX

" 38

" 40

" 47

" 52

" 54

" 56

" 57

" 59

" 61

Page 3

" 4

" 5

" 6

" 7

" 10

" 33

" 35

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MODEL NUMBER AND IDENTIFICATION I

MODEL NUMBER ENGINE IDENTIFICATION

No of cylinders

Displacement (multiplied by 10)

Water cooled

Diesel

LOMBARDINI

Engine Serial Number

Customer's Code

Approval Code

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3

II CHARACTERISTICS

CHARACTERISTICS POWER, TORQUE AND SPECIFIC CONSUMPTION CURVES

and variable load.

speed and constant load.

The above power values refer to an engine fitted with an air cleaner and standard muffler; after run-in and at the environmental conditions of 20°C and 1 bar.

Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m altitude and by 2% every 5°C above 25°C.

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MAINTENANCE - RECOMMENDED OIL TYPE - RECOMMENDED ANTIFREEZE - REFILLING

III

MAINTENANCE

INTERVAL (HOURS)

OPERATION COMPONENT

10 50 125 250 500 1000 2500 5000

CLEANING

OIL-BATH AIR CLEANER (*)

FUEL TANK

INJECTORS

RADIATOR FINS

OIL PICK-UP STRAINER

AIR CLEANER OIL

LEVEL CRANKCASE

BATTERY FLUID

(°°°)

C H E C K

REPLACEMENT

RADIATOR FINS

ALTERNATOR BELT TENSION

VALVE AND ROCKER ARM CLEARAN.

INJECTOR CALIBRATION

DRY AIR CLEANER

OIL

ANTIFREEZE

AIR CLEANER (*) (**)

CRANKCASE (**)

(°)

OIL FILTER CARTRIDGE

FUEL FILTER CARTRIDGE

DRY AIR CLEANER CARTRIDGE (°°)

ALTERNATOR BELT

OVERHAUL PARTIAL (***)

INSPECTION COMPLETE

*

First replacement

Under special working conditions clean daily

Under extremely dusty conditions clean every 4-5 hours.

*** See recommended oil type

**** Includes checking cylinders, piston rings, guides, springs, grinding valve seats, scaling heads and cylinders as

well as checking injection pump and injectors.

(°) Every two years or after 1000 hours of operation.

(°°) When clogging indicator shows the need for replacement.

RECOMMENDED OIL TYPE

RECOMMENDED ANTIFREEZE

CAPACITIES (Liters)

AGIP DIESEL SIGMA S SAE 30-40 specification MIL-L-2104 C ESSOLUBE D3, specification MIL-L-2104 D and UNIFARM specification MIL-L-2104 C.

In countries where AGIP and ESSO products are not available use diesel engine oil API SERVICE CD or similar type complying with the military specification

MIL-L-2104 and MIL-L-2104 D.

Suggested oil grades

SAE 10W

SAE 20W/20

AGIP ANTIFREEZE. Antifreeze and protective fluid to be mixed with water.

The cooling mixture freezing point depends upon the concentration of the product in water: at -15°C concentration is 30%, at -20°C,-

25°C, -30°C and -35°C, it is

35%,40%,45% and 50% respectively.

In any case a 50% mixture is always recommended for general purposes.

Standard oil sump

LDW 2004 LDW 2004

LDW 1503 LDW 2004/T LDW 2004/T

with dyn.bal. no dyn.balan.

with filter with filter

max. level

min. level

4.4

2.3

Cooling system

5.3

3.6

6.4

3.6

LDW LDW 2004

1503 LDAW 2004/T

with expansion 7.5

tank

8.5

SAE 30

no expansion

tank

6.5

7.5

SAE 40

°C

-20 -10 0

°F

-13 -4 5 14 23 32 41

+10 +20 +30

50 59 68 77

86

SAE 5W/30

SAE 10W/40

SAE 15W/30

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5

IV TROUBLE SHOOTING

POSSIBLE CAUSES AND TROUBLE SHOOTING

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

TROUBLE

POSSIBLE CAUSE

6

Clogged pipings

Clogged fuel filter

Air inside fuel circuit

Clogged tank breather

Faulty feed pump

Stuck injector

Stuck injection pump valve

Wrong injector setting

Excessive plunger blow-by

Sticking injection pump rack

Wrong injection pump setting

Too high oil level

Stuck pressure relief valve

Worn oil pump

Air inside oil suction pipe

Faulty pressure gauge or switch

Clogged oil suction pipe

Burnt preheating glow plug fuse

Defective glow plug control box

Battery dis-charged

Wrong or inefficient cable connection

Defective starter swich

Defective starter

Clogged air filter

Excessive idle operation

Incomplete running-in

Engine overloaded

Advanced injection

Retarded injection

Incorrect governor linkage adjustment

Broken or loose governor spring

Too low idle-speed

Worn-out or stuck piston rings

Worn-out cylinders

Worn-out valve guides

Sticking valves

Worn-out bearings

Governor linkage not freely operating

Crankshaft not turning freely

Damaged cylinder head gasket

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OVERALL DIMENSIONS V

OVERALL DIMENSIONS LDW 1503

Note : Dimensions shown in mm

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7

V OVERALL DIMENSIONS

OVERALL DIMENSIONS 2004

Note : Dimensions shown in mm

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OVERALL DIMENSIONS V

OVERALL DIMENSIONS 1204/T

Note : Dimensions shown in mm

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9

VI DISASSEMBY AND REASSEMBLY

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.

Oil-bath air cleaner (optional)

Check gaskets and replace if necessary.

Check that flange welds are free of porosity or defective spots.

Carefully clean bowl and filtering element with Diesel fuel and dry with compressed air.

Top up engine oil to the mark (see below).

When refitting tighten nuts to 24.5 Nm

See page 5 for periodic cleaning and oil replacement.

Oil-bath air cleaner components

1 Bowl

2 Outer seal ring

3 Filtering element

4 Inner seal ring

5 Gasket

6 Cover

7 Cap clamp

8 Cap

9 Centrifugal pre-filter

10 Centrifugal pre-filter clamp

11 Oil level mark

Note: Centrifugal pre-filter 9 is fitted upon request.

Dry air cleaner (optional)

A = Fitting to accomodate clogging indicator

See page 5 for maintenance details and cartridge replacement.

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DISASSEMBLY AND REASSEMLY VI

2 Nut

3 Filter element

4 Body

5 Cap

6 Vacuator valve

Air filter restriction switch

Components:

1 Reset button

2 Connection

Note: There are two types: one for an aspirated engine and one for a supercharged engine.

Setting for aspirated engine (LDW 1503,LDW 2004)= 600/

650 mm column of water.

Setting for supercharged engine (LDW 2004/T= 370/420 mm column of water.

Intake manifold

The sealing surface should be clean, smooth and free of any scoring.

Replace gasket A.

Tighten nuts to 25 Nm.

Exhaust manifold

Check that the sealing surface is smooth and that the inside is free of carbon deposits.

Replace gasket A.

Tighten nuts to 25 N m.

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11

VI DISASSEMBLY AND REASSEMBLY

"V" belt

The "V" belt is of the Pirelli

Sectoflex AV 10D type.

Outside length 990 mm

Tension adjustment:

Adjustments are made by means of scew 1; stretch belt so that a

100 Nm load located half-way between the two pulleys causes a

10/15mm flexure.

Cooling fan

Take off the fan and check that all blades are not damaged; if any are damaged, replace the entire fan.

See page 56 for cooling air volume.

Driving pulley

This pulley drives the alternator and the water pump. It also represents the second engine p.t.o. which allows 100% power

(axial) for the models LDW 1503 and 70% of the power for models

LDW 2004 and 2004/T.

Bolt 1 can be loosened by turning clockwise. When refitting tighten this bolt to 350 Nm.

12

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"Ringfeder" Rings on LDW 2004, LDW 2004/T

From the second p.t.o. of the engines LDW 2004 and LDW 2004/T it is possible to take off 3/4 of the power.

If you want to take off all the power it is necessary to mount the

Ringfeder rings on the driving shaft spigot.

1 Appropriate pulley

2 Screw M6x1

3 Ringfeder ring

4 Screw M16x1.5

5 Driving shaft spigot

6 Shoulder ring

7 Inner Ringfeder ring

8 Fixing flange

MODELLO N°

50534

DATA EMISSIONE

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VISTO

12

DISASSEMBLY AND REASSEMBLE VI

"Ringfeder" rings, disassembly

Refer to figures 11 and 12. Clean and oil with engine oil the parts involved in assembly. Insert the shoulder ring 6, outer ringfeder ring and inner ringfeder ring into the pulley 1. Oil the screws 2 especially at the base of the head. Lightly tighten flange 8 by means of the screws 2 in the sequence: after tightening the first screw, the second one will be the opposite one, after tightening the third screw the fourth one will be the opposite one, etc. Fit the assembled pulley onto the driving shaft spigot. Tighten screw 4 to 352 Nm.

Tighten screws 2 in three phases.

1 Phase: 4/6 Nm

2 Phase: 12 Nm

3 Phase: check the tightening torque of the screws in the sequence they were tightened in.

Tank (optional)

Remove fuel line and loosen clamp screws.

Completely empty the tank and check that no impurities are found inside.

Check that cap breather hole is not clogged.

13

Flywheel

Remove the bolts which attach the flywheel to the engine shaft; when refitting tighten to 140 Nm after checking that the locating pin is in its seat.

To remove the starter ring gear, it is recommended to cut it into several portions with an iron hacksaw and then use a chisel; to replace starter ring gear slowly heat to 300°C for 15/20 minutes.

Drive the gear onto the flywheel checking that it perfectly rests against the shoulder. Let it cool down slowly.

14

Rocker arm cover

Components

1 - Breather cap

2 - Oil fill cap

3 - Gasket

A small filtering element is located inside cap 1 with the purpose of separating oil from the venting vapors; check filtering element state and clean if necessary.

Replace gasket 3.

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VI DISASSEMBLY AND REASSEMBLY

Valve/rocker arm clearance

Setting should be performed when the engine is cold.

Bring each cylinder piston to top dead center on the compression stroke and set clearance A at 0.15 mm for both the intake and exhaust valve.

16 17

18 19

Rocker arm assemly

Loosen the screws which fasten the assembly to the head; when refitting tighten to 50 Nm.

The journal has a bore inside for lubrication purposes but is closed by two plugs at the ends. Check journal and rocker arm bushings for wear.

Remove the two end plugs and carefully clean the bore inside; when refitting apply a drop of Loctite 270 onto the threads.

Dimension (mm):

A = 14,032/14,050 with bushing fitted to the rocker arm and reamed

B = 13,982/14,000

(A-B) = 0,03/0,07 (A-B) limit value = 0,14

Cylinder head

Do not remove when hot to avoid deformation.

Check cylinder head plane using a metal straight edge and thickness gauge; if warpage exceeds 0.10 mm, level off by removing a maximum 0.20 mm.

See fig. 52,53 and 54 for cylinder head tightening.

20

21

14

Valve removal

Components:

1 - Valve

2 - Lower spring seat

3 - Valve guide seal (for intake only)

4 - Spring

5 - Spring cap

6 - Cotters

To remove the cotters firmly press down as shown in the figure.

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DISASSEMBLY AND REASSEMBLY

Valve spring

Measure free length with a gauge.

Free length A = 52 mm.

VI

23

24

Valve material

Exhaust valve A :Valve stem and valve head are made of two different materials.

2 Welded portion

3 Chromium-plated portion

4 Portion made of X 45 Cr Si 8 UNI 3992

5 Portion made of X 70 Cr Mn Ni N 216 UNI 3992

D = 35,30/35,50 mm

Intake valve B

Material: X 45 Cr Si 8 UNI 3992

1 Chromium-plated portion

C = 40,30/40,50 mm

Valve guides and cylinder head

Intake and exhaust valve guides are both made of gray cast iron with pearlitic and phosphoric matirx.

Dimensions (mm)

A = 38,00

C = 12,020/12,038

D = 12,048/12,058

Valve guides with outside diameter D increased by 0.5 mm are available; in such case valve guide bore C should also be increased by 0.5

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Valve guide insertion

Press guides considering the A and B distances from the lower head plane g or, alternatively, the E and F values.

Dimensions (mm):

A,B = 36,8/37,2

C = 7,020/7,035

D = 6,985/7,000

E = 10,5/11,0

F = 6,5/7,0

Clearance (mm)

(C-D) = 0,020/0,065 (C-D) limit value = 0,130

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VI

DISASSEMBLY AND REASSEMBLY

Oil seal in the valve guide, disassembly

To prevent the seal 1 warping when mountig the valve guide 3 put it into the tool 2 part no. 7107-1460-047 and proceed as shown in the figure, making sure the seal 1 reaches its stop.

27 28

Valve seats and bore

Dimensions (mm):

A = 41.5000/41.520

B = 41.575/41.590

C = 36.500/36.520

D = 36.575/36.590

a

= 44.53' / 45° a

1 = 59.53' / 60°

Press valve seats into the bore and cut as a function of a and

a

1

29

30

32

16

Valve recess and sealing surfaces

After cutting, cap valve seats with fine lapping compound.

S = Sealing surface width on exhaust side

S1 = Sealing surface width on intake side

D = Valve recess with reference to the head plane

Dimensions ( mm)

Tipo motore S S1 D

LDW 1503

LDW 2004 1.27/1.55 1.20/1.60 0.75/1.00

LDW 200/T

S and S1 worn limit = 2.00 mm

D worn limit = 1.3 mm

31

Precombustion chamber

To remove the precombustion chamber tap with a punch on the injector housing side. Replace it because it might undergo warpage during removal.

Introduce precombustion chamber by making dowel 1 match with notch 2.

Press uniformily.

The clearance allowance between the precombustion chamber and its bore on the cylinder head is equal to 0.05 mm.

Using a depth gauge check that the precombustion chamber plane protrusion does not exceed 0.04 and does not receed over 0.02

mm from the head plane level.

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36

38 39

35

37

DISASSEMBLY AND REASSEMBLY VI

Tappet

Dimensions (mm):

A = 24.50/24/56

B = 24.46/24.48

(A-B) = 0.02/0.06 (A-B) limit value = 0.10

Nota: If tappet is worn out along diameter B replace it. No oversize tappets are available. If tappet/camshaft surface is worn replace

Injection pump follower

Introduce the follower into its housing and manually turn screw 3 until it matches with notch 2.

Before locking screw 3 check that the follower is allowed to freely move in the vertical position using your finger.

Space 1 should be introduced into the pushrod with the flat surface facing upwards

Note: Screws 3 are of the same length except for the one on the distribution side inside the shorter stop cover, take care not to replace it with one of the longer ones.

Cylinders

Reset dial gauge with a calibrated ring. Check diameter size D at 1,

2 and 3; repeat the same operation at the same places after turning the dial gauge by 90°. Check for wear in the X area where piston rings are located.

Dimensions (mm):

LDW 1503

LDW 2004 D = 88.00/88.01 wear limit = 88.100

LDW 2004/T

The above diameter sizes refer to class A cylinders which match with pistons of the same class (See page 18 fig. 44,45).

To check clearance with the matching piston measure the diameter size at Z along the axis which runs at right angles to the driving shaft.

Cylinders, class

The references of the classes of pistons (A,B,C,R) are given inside the piston, fig. 45, whereas those of the cylinders are at the position shown by E.

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41

VI

DISASSEMBLY AND REASSEMBLY

Cylinder roughness

The inclination of the cross-hatched marks left by machining should range between 115°-!40°; they should be uniform and clearly visible in both directions.

Average roughness should range between 0.5 and 1 m

m .

The cylinder surface which comes into contact with the piston rings should be machine honed with the plateau system.

Warning: Manual grinding of the cylinder inner surface using an emery cloth is not allowed.

42

44

43

45

Piston

Remove circlips and piston pin.

Remove piston rings and clean grooves.

Measure diameter Q at the A distance from the bottom of the skirt

(A = 12 mm)

In case of diameter wear exceeding 0.05 mm of the minimum given value replace piston and rings.

Nota : The oversizes are 0.50 and 1.00 mm. The LDW 2004/T piston differs from that of the LDW 2004 in its cooling sprayer passage niche and an insert in the slot of the first ring.

Piston classes and logo

Depending on their diameter size pistons are subdivided into class

A,B,C or R; such reference letters are stamped inside the piston together with the logo.

Note: The class R piston rings are oversized with respect to those of class A, B and C.

Dimensions (mm)

Engine Class Cylinder Ø Piston Ø Clearance

LDW 1503 A 88.00/88.01 87.96/87.967

LDW 2004 B 88.01/88.02 87.97/87.977 0.033/0.050

LDW 2004/T C 88.02/88.03 87.98/87.987

R 88.10/88.11 88.06/88.067

Piston availability

Pistons with standard diameter value are available only in class A and R.

Oversize pistons of 0.50 and 1.00 are supplied in the A class only.

Piston weight

Weigh the pistons when replacing them in order to avoid unbalance.

The difference in weight should not exceed 6 g.

46

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DISASSEMBLY AND REASSEMBLY

Piston rings - End gaps (mm)

Place piston rings into the cylinder and measure end gap A.

1st ring A = 0.30/0.50

2nd ring A = 0.30/0.50

3rd ring A = 0.25/0.50

VI

47

Piston rings - Clearance between grooves (mm)

For LDW 1503 and LDW 2004

A = 0.09/0.12

B = 0.06/0.10

C = 0.05/0.08

For LDW 2004/T

A = ---

B = 0.07/0.10

C = 0.05/0.08

48

49

50

Piston rings - Fitting sequence

A = 1st (chromium - plate, internal tapered, torsional) ring *

B = 2nd (internal tapered, torsional) ring

C = 3rd (chromium-plated oil control ring

* The first ring in the LDW 2004/T engine is different, it has a trapezoidal cross-section.

Note: In case an inscription is visible on the segment surface fit that surface upwards.

Piston - Refitting

Connect piston to connecting rod after lubricating piston pin and introducing it by exerting pressure with your thumb.

Position the two piston pin ciclips and check that they are well inside their seats. Using a ring compressor introduce the piston into the cylinder with combustion chamber facing the injection pump side.

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VI DISASSEMBLY AND REASSEMBLY

Piston position and clearance

To obtain a clearance of 0.67/0.90 mm measure protrusion A of all pistons from the cylinder plane and consider the A value of the most protruding piston (see below).

Perform this measurement along the engine axis.

53

54

Cylinder head gasket

At B the gasket shows small semi-circular notches indicating thickness. Choose the most suitable gasket considering that each A value in the table corresponds to no notch, one notch and two notches on the gasket.

A No.of notches Resulting clearance

mm m m

0.60/0.83

0.67/0.90

0.84/0.98

0.99/1.10

0.67/0.84

Note: The notches shown above protrude from the cylinder head plane; you can thus determine the gasket thickness before taking down the head.

Cylinder head tightening

Use a torque wrench (fitted with tool for angular tightening).

The head should not be re-tightened after engine testing.

It is recommended to replace the screws depending on their stretching caused by their tightening.

The length of the screws is 126.40/126.60 mm, if they have stretched by 2 mm replace them.

55

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57

58

DISASSEMBLY AND REASSEMBLY VI

Cylinder head tightening steps

A = For LDW 1503

B = For 2004, 2004/T

Following the number sequence shown in the figure bolts shuld be tightened in four susequent steps with the following torque values:

1st step = 40 Nm

2nd step = 70 Nm

3rd step = 100 Nm

4th steps = Rotate wrench by 180° (in two steps 90°+90°)

Connecting rod

Remove oil pan and oil pump suction pipe.

Dsconnect the connecting rod from the engine shaft and perform the following checks:

When refitting both centering notches A and B should be located on the same side.

Tghten the connecting rod big end bolts to 70 Nm.

Connecting rod weights

Weigh connecting rods before replacing them in order to avoid unbalance.

The difference in weight should not exceed 10 g.

Connecting rod, piston and piston pin can also be weighed in a preassembled state but the difference in weigt should not exceed 14 g.

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61

VI DISASSEMBLY AND REASSEMBLY

Connecting rod and piston pin

Dimensions mm

A = 144.98/145.02

B = 28.02/28.03 (with reamed bushing in place)

C = 50.035/50.066 (with shell bearings in place and tightened to 70

Nm).

D = 27.995/28.000

E = 62.3 E (per LDW 2004/T) = 65.8

(B-A) = 0.02/0.03 (B-A) limite = 0.06

Note: The connecting rod big end shell bearings are supplied in either standard or with this value decreased by 0.25 and 0.50

mm respectively.

Connecting rod alignment

Use a surface plate gauge or a dial gauge as shown in the figure.

Checked for axis alignment; axial mis-alignment A = 0.02 mm; maximum limit 0.05 mm.

Moderate warpage may be corrected by gradually working with a press.

62 63

64

65

Piston cooling sprayer

This is assembled on turbo engines LDW 2004/T.

Blow on it with compressed air and check that there are no impurities inside.

Reassemble it back into place making sure you maintain axis alignment A of the spray with respect to axis B shown in the fugure.

Anyway the correct position is ensured by the fixing screw.

a

= 3° a

1 = 28°

D = 28 mm.

Connecting rod/piston assemlies

The three connecting rod/piston assemblies should be fitted back into their original cylinders. Mark them with references to avoid mistake.

Note: The custom at LOMBARDINI is to consider the cylinder on the flywheel side as the first cylinder.

66

22

67

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DATA EMISSIONE

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DATA

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VISTO

DISASSEMBLY AND REASSEMBLY VI

Center main bearings

Center main bearing caps are marked with 1 point, 2 points or 3 points.

The same reference marks are given on the crankcase.

Match caps with the same points and on the same side; comunque fare riferimento alle due tacche di centraggio dei semicuscinetti della bronzina che si devono trovare dallo stesso lato.

68

Front and rear main bearing caps

When refitting rear main bearing cap 1, replace lateral rubber gaskets 2 considering that A and B should protrude 0.5/1.0 mm from the crankase; cut any excess portion.

Follow the same procedure for the front main bearing cap.

To introduce the bearing caps into the crankcase place two plates C and D measuring 0.1 mm in thickness between the surfaces.

Tighten bolts to 120 Nm.

69

70

71 72

To check clearance between main bearings and journals

Use "Perfect Circle Plastigage" A and position it with a few drops of oil at the center of the half bearing; tighten bolts to 12o Nm.

Determine clearance by measuring the squeezed portion of the plastigage with the indexed scale supplied.

For clearance between main journals, connecting rod big end journals and the corresponding bearings see page 26 fig 84.

Note: When replacing bearings make sure that the lower half is kept separate from the upper one.

Thrust bearings

Apply some grease to make sure that the halves remain in their seats.

Halves should be fitted with grooves A as shown in the figure.

Thrust bearing thickness = 2.31/2.36 mm; oversize halves with thickness increased by 0.1 and 0.2 mm are available as spares.

73

74

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75

VI DISASSEMBLY AND REASSEMBLY

76

Thrust bearing, oversizes

Dimensions (mm)

A*

Standard 27.77/27.92

C

28.00/28.05

B**

1st Oversize

2nd Oversize

27.97/28.12

28.20/28.25

28.07/28.22

28.30/28.35

0.08/0.28

3rd Oversize 28.17/28.32 28.40/28.45

* A of fig. 77

** B of fig. 78

Grinding B according to the above table, following half-rings can be assembled:

1st Oversize. Half-rings 1 and 2, on both the support sides +0.10

mm.

2 nd Oversize. Half-rings 1 and 2 , on one support side +0.10 mm

and on the other side +0.20 mm.

3 rd Oversize. Half-rings 1 and 2, on both the support sides +0.20

mm.

Crankshaft end play

After tightening main bearings measure the end play A between the crankshaft shoulder on the flywheel side and main bearing halves.

A = 0.08/0.28 mm

B = 28.00/28.05 mm

If the end play does not fall within the given values check B and possibly fit the oversize thrust bearings.

77

79

24

78

Crankshaft front and rear oil seal

The front oil seal A is located in the oil pump cover while the rear oil seal ring B, is positioned in the flange on the flywheel side.

Replace seals if warped, hardened or damaged.

In case of replacement:

· Carefully clean the seat.

·

Soak the seal in engine oil for approximately half an hour.

·

Fill the inside with grease and lubricate and sealing lip with thick oil.

·

Drive the seal into its seal exerting a uniform pressure over the entire front area.

Note:The crankshaft, to avoid its wear, is hardened in the ring working areas. The rings in this case are made of red siliconic material.

Engines of recent production have rings in "Viton" material and are brown coloured.

In this case crankshaft are not hardened in this area.

As a consequence red rings cannot be assembled at the place of brown rings; these last however can be assembled on both crankshafts.

Warning: in case of room temperature below -35°C seals could become damaged.

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DATA EMISSIONE

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DATA

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VISTO

DISASSEMBLY AND REASSEMBLY VI

Crankshaft timing gear

The following steps are required to remove timing gear A.

To remove use a bearing puller.

To refit first heat it up to 180°-200°C and then drive it in position.

80

81

Crankshaft lubrication ducts

Dip crankshaft into a petroleum bath.

Remove plugs and clean ducts A, B and C with a pointed tool.

Finally blow with compressed air.

Re-place plugs using a calking tool and check for sealing.

Checking main journals and crank pins

Use an outside micrometer gauge.

82

Main journal and connecting rod big end journal diameter

Dimensions (mm)

A = 57.980/58.000

B = 49.989/50.000

The crakshaft is made of spheroidal graphite cast iron hardened at the level of the oil seal rings 1 and 2. Hardness 55 hrc, hardening depth 0.5/1.5 mm.

83

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30-09-1996

VISTO

25

84

85

VI DISASSEMBLY AND REASSEMBLY

Main bearing and connecting rod big bearing inside diameter

Dimensions (mm)

E = 50.035/50.066

F = 58.041/58.091

The above dimensions refer to tightened berings.

Clearance between bearings and corresponding journals ( mm ).

(E-B) = 0.035

¸

0.077

(E-B) worn limit = 0.150

(F-A) = 0.041

¸

0.111

(F-A) worn limit = 0.200

See fig. 71 and 72 for checking procedures.

Note:Both main bearing and connecting rod big end bearings are available with inside diameter measuring 0.25 and 0.50 mm.

less than standard.

Crankshaft for LDW 2004, LDW 2004/T

The main bearing and connecting rod big end bearing inside diameter is the same as for model LDW 1503.

In addition, the crankshaft comes with seat for the control gear of the counter-rotating shaft dynamic balancer.

Components:

1 Control gear for counter-rotating shafts

2 Seat for the control gear of counter-rotating shafts

Dimensions (mm):

A = 132.00/132.03 B = 132.07/132.09

To replace the gear heat it up to 180°/200°C.

Locate it into its seat so that the timing reference marks on the teeth are found on the flyweel side.

86

Dynamic balancer (on request) - Adjustment of clearance between teeth D and ring gear A

Follow figures 86 and 87.

Screw the screw B into support C taking care to centre the hole in the mass of the gear D to lock it.

Fit the mass assembly under the crankcase so that the tooth with reference E goes between the teeth with references F.

Fix the mass assembly with the four M10 screws to the crankcase, provisionally tightening it to 40 Nm.

By making the driving shaft turn, check the clearance between the ring gear A and the gear of mass D; set a comparator with the feeler on one tooth of the timing system control gear G; by turning the driving shaft a little way check the clearance which must be 0.026/

0.067.

If the clearance measured does not come within the values given, repeat the operation placing the 0.05 mm shims provided for adjustment between the support C and the crankcase.

When mounting the balancer, lubricate the bushings with Molikote then couple the two masses, taking into account the references H and I.

Permanently fix the support C to the crankcase by tightening the screws to 50 Nm plus one turn of the wrench clockwise through 45°.

The four screws will have to be mounted with a few drops of Loctite

242.

87

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MODELLO N°

50534

DATA EMISSIONE

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DATA

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VISTO

DISASSEMBLY AND REASSEMBLY VI

Front cover

To remove front cover 1 bring the 1st cylinder to the top dead center, remove throttle cover 2 and release spring 3.

When refiting replace gasket 4 and 5; tighten front cover 1 to 25

Nm.

88

89

90

91

I dler gear and hub

Components:

1 Idle wheel

3 Thrust washer

5 Oil seal ring

Dimensions (mm):

A = 36.00/36.02

2 Hub

4 Fitting

6 Bushing lubrication hole

B = 35.959/35.975

C = 1.95/2.05

D = 0.96/1.00

Clearance (mm):

(A-B) = 0.025/0.061 (A-B) worn limit = 0.120

End play = 0.10/0.30 limit = 0.6

Note: Unscew fitting 4 clockwise and when refitting it to 200 Nm.

Speed governor

Components:

1 Gear

2 Bell

3 Counterweights

4 Adjusting screw

5 Throttle control rod

6 Governor spring

7 Control yoke for injection pump

delivery rod

8 Injection pump delivery rod

9 Yoke 7 adjustement eccentric

10 Bushing

11 Lever

12 Bolt

Yoke 7 is pre-set through screw 4 and eccentric 9. Do not unscrew,

(see below).

When refitting camshat gear 1 tighten bolt 12 to 80 Nm.

92

93

94

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Dimensions for injection pump delivery control yoke adjustement

A = 10.8 C = 13.4 D = 88

Components:

4 Adjusting screw

7 Control yoke for injection pump delivery rod

10 Bushing

11 Lever

13 Reference and mounting plane for support 14

14 Lever Support

Note: If, when adjusting, screw 4 is unintentionally loosened adjust yoke 7 considering the dimensions A, C and D.

In case of replacement lever 11 is supplied complete with preset yoke 7.

DATA EMISSIONE

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27

95

VI DISASSEMBLY AND REASSEMBLY

Speed governor counterweights and springs

Counterweights 3 inside the camshaft gear come in two dimensions: for engines in the 2200 to 3000 rpm setting range and engines in the 1500 to 1800 rpm setting range.

For settings other than the standard one (3000 rpm) different springs 6 are used.

96

Frame with idling speed governor spring

Engines for applications requiring a certain power capacity at low speeds are fitted with the frame 5 complete with the idling speed spring which allows satsifying the above described requirements without the engine tending to stop.

Components:

1 Adapter

2 Top speed adjustment.

3 Idling speed adjustment

4 Camshaft gear and speed governor

5 Frame for idling speed spring

6 Rocker arm with speed governor springs.

Spring for extra fuel supply at starting

The device is operated automatically: when the engine is stopped spring 1 acts on the injection pump control lever 2 providing maximum fuel delivery until the governor starts operating.

97

28

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DATA

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VISTO

DISASSEMBLY AND REASSEMBLY VI

Camshaft

Camshaft removal

To remove camshaft first remove valve tappets 1, injection pump follower 2, bearing stop plate 3 and fuel pump control rod 5.

Note: To remove follower 2 loosen screw 4 by three or four turns.

98

Checking camshaft bushing internal diameter

Use a bore gauge.

If the diameter size does not correspond to the given value remove the bushings using the special tool (fig. 102 and 103) and replace.

99

Camshaft journals and bushings in model LDW 1503

Dimensions (mm):

A = 43.000/43.025

B = 42.94/42.96

C = 42.000/42.025

D = 41.94/41.96

Clearance (mm):

(A-B) = 0.04/0.085 worn limit 0.16

(C-D) = " " " " "

Note: A and C values refer to driven in and bored bushings.

100

101

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Camshaft journals and bushings in models LDW 2004, LDW

2004/T

Dimensions:

A = 44.000/44.025

B = 43.94/43.96

C = 43.000/43.025

D = 42.94/42.96

E = 42.000/42.025

F = 41.94/41.96

Clearance (mm)

(A-B) = 0.040/0.085 worn limit 0.16

(C-D) = 0.040/0.085 worn limit 0.16

(E-F) = 0.040/0.085 worn limit 0.16

DATA EMISSIONE

DATA

REVISIONE

02

31-12-1989

30-09-1996

VISTO

29

VI DISASSEMBLY AND REASSEMBLY

Camshaft bushing replacement

Tool part No.7104-1460-021

Components:

1 Mandrel

2 Centering bushing

3 Bushing diam. 44 mm

4 Bushing diam. 43 mm

5 Bushing diam. 42 mm

Note: Before driving in the bushing, position it in such a way that the lubricating hole maiches with the hole in the crankcase.

102

103

Intake, exhaust and injecton cam height for model LDW 1503

Dimensions (mm)

A = 36.058/36.12 S = 35.62/35.68 I = 33.85/33.90

A,S and I have a worn limit of 0.4

A1 =1st cylinder intake cam

S1 = 1st cylinder exhaust cam

I1 = 1st cylinder injection cam

A2 = 2nd cylinder intake cam

S2 =2nd cylinder exhaust cam

I2 = 2nd cylinder injection cam

A3 = 3rd cylinder intake cam

S3 = 3rd cylinder exhaust cam

I3 = 3rd cylinder injection cam

104

105

Intake, exhaust and injection cam height for models LDW 2004,

LDW 2004/T

Dimensions LDW 2004

A = 36.058/36.12 S = 35.62/35.68 I = 33.85/33.90

Dimensions LDW 2004/T

A = 35.54/35.60 S = 35.24/ 35.30 I = 33.85/ 33.90

A1 = 1st cylinder intake cam A3 = 3rd cylinder intake cam

S1 = 1st cylinder exhaust cam S3 = 3rd cylinder exhaust cam

I1 = 1st cylinder injection cam I3 = 3rd cylinder injection cam

A2 = 2nd cylinder intake cam A4 = 4th cylinder intake cam

S2 = 2nd cylinder exhaust cam S4 = 4th cylinder exhaust cam

I2 = 2nd cylinder injection cam I4 = 4th cylinder injection cam

Camshaft timing

Fit idler gear B by making timing mark 2 coincide with timing mark

1 on the camshaft control gear A and mark 3 with 4 on the timing gear C.

106

30

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DATA

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VISTO

DISASSEMBLY AND REASSEMBLY VI

Valve timing without considering timing marks

Locate piston 1 (on flywheel) at the top dead center. Position two small rods A of the same length onto the tappets.

Rotate camshaft stopping when cylinder 1 tappets are in overlap position (intake open exhaust closed).

Using the straight edge B check that rods A are at the same length.

Engage idler gear with camshaft and timing gear.

107

Valve timing check

Check valve timing at the crankshaft.

The values shown are checked at the flywheel circumference (with flywheel diameter of 290 each degree corresponds to 2.53 mm).

Set valve clearance at 0.65-0.70 mm (after checking reset the value to 0.15 mm).

Set dial gauge on intake valve to a zero value; by rotating the crankshaft according to its direction of rotation you can measure a

(intake valve opening advance referred to top dead center S) and b

(intake valve closing delay referred to bottom dead center I).

Follow the same procedure for exhaust valves checking g (exhaust valve opening advance )and d ( exhaust valve closing delay).

108

109

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Timing angles for checking puposes

(valve clearance = 2 mm)

= 14° after S (corresponding to 35 mm on the flywheel)

= 6° after I (corresponding to 15 mm on the flywheel)

= 17° before I (corresponding to 43 mm on the flywheel)

= 15° before S (corresponding to 38 mm on the flywheel)

Timing angles for operating purposes

(valve clearance 0.15 mm)

= 14° before S (corresponding to 35 mm on the flywheel)

= 34° after I (corresponding to 85 mm on the flywheel)

= 46° before I (corresponding to115 mm on the flywheel)

= 14° after S (corresponding to 35 mm on the flywheel)

Timing angles for checking purposes LDW 2004/T

(valve clearance 2 mm)

= 15° after S (corresponding to 38 mm on the flywheel)

= 21° after I (corresponding to 52 mm on the flywheel)

= 31° before I (corresponding to 77 mm on the flywheel)

= 13° before S (corresponding to 32 mm on the flywheel)

Timing angles for operating purposes LDW 2004/T (valve clearance 0.15 mm)

= 12° before S (corresponding to 30 mm on the flywheel)

= 48° after I (corresponding to 120 mm on the flywheel)

= 58° before I (corresponding to 145 mm on the flywheel)

= 14° after S (corresponding to 35 mm on the flywheel)

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

31

VI DISASSEMBLY AND REASSEMBLY

Camshaft end play

Check camshaft end play after removing the cylinder head, the injection and the fuel pumps from the engine. Check that plate 1 is tightened.

Position the dial gauge on the camshaft front surface; push and pull the camshaft.

Maximum end play should be o.oo8 mm (ball bearing end play).

110

Hydraulic pump p.t.o.

A = 3rd p.t.o. with hydraulic pump Gr 2.

B = 4th p.t.o. with hydraulic pump Gr 1

Hydraulic pumps of either GR 1 or GR 2 type can be fitted, even simultaneously, on the erd and 4th p.t.o. provided the resulting power does not exceed 12.27 kW which equals a torque of 40 Nm.

The gear ratio between engine r.p.m. and 3rd and 4th p.t.o. is 1:1.

111

GR 1 and GR 2 hydraulic pump 3rd p.t.o.

1 O-R

2 O-R

3 Center ring

4 Circlip

5 Thrust washer

6 GR 2 hydraulic pump flange

7 GR 1 hydraulic pump flange

8 Bushing

9 Trust washer

10 GR 2 hydraulic pump drive gear

11 GR 1 hydraulic pump drive gear

12 Control gear

112

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VISTO

113

114

115

TURBOCHARGER VII

Turbocharger

It is installed on the engine in two versions: with air intake on the flywheel side and with air intake on the fan side.

To control the supercharge air pressure, screw the pressure gauge into the M8 holes A and B both for the version with air intake on flywheel side (fig. 113) and for air intake on fan side (fig.114)

Turbocharger components

1 Flexible hose

2 Actuator

3 Collar

4 Turbine body

5 Snap ring

6 Compressor volute

7 Thickness

8 Nut

9 Lock nut

10 Shaft with turbine

11 Segment

12 Flame shield

13 Bearing

14 Snap ring

15 Thickness

16 Segment

17 Oil deflector

18 Thrust block sleeve

19 O-ring

20 Thrust block bearing

21 Thrust block ring

22 Bearing

23 Snap ring

24 Snap ring

25 Bearing support

Turbocharger Testing

Get a pressure gauge with scale from zero to 2 bar, connect it according to fig, 113 and 114.

Start up the engine, warm it up for a few minutes, then take it to

3000 rpm at the power NB.

The supercharge air pressure value to be measured is 89/93 KPa

(0.89/0.93 bar).

If the setting pressure does not come within the required value it is necessary to adjust the stroke of the valve control rod C

(Wastegate), see below.

116

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33

117

VII TURBOCHARGER

Checking actuator setting - "Waste gate" valve control rod stroke adjustment

This test must be done with the engine stationary.

Disconnect pipe 7 from the compressor side.

Using a T coupling, connect up with a pressure gauge 4 (scale from zero to 2 bar) and with the compressed air mains pipe complete with reduction unit 5.

The mains air pressure must be 1.5/2.0 bar. Make a hole B diameter

1.5 mm in the pressure gauge pipe where part of the air will escape which has the purpose of stabilizing the pressure in the pressure gauge.

Use the reduction unit 5 to send air to the actuator so as to make terminal 2 of A move forward (A = 1 mm).

Position a comparator 6 so that the feeler rests on the terminal 2.

The pressure read on the pressure gauge must be 830/890 mm Hg

(1.11/1.19 bar). If the pressure is lower than the given value, proceed as follows.

Unscrew the lock nut 1.

Remove the split pin 9 and disconnect the rod 8. Keeping the rod stationary, screw the terminal 2 to reach the setting pressure. While the terminal is rotating the rod must undergo no twisting.

34

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VISTO

LUBRICATION SYSTEM VIII

LUBRICATION SYSTEM LAYOUT

118

Components:

1) Oil fill cap

2) Rocker arm shaft

3) Oil filter

4) Main journal

5) Connecting rod journal

6) oil dipstick

7) Drain plug

8) Breather

9) Camshaft

10) Oil pressure switch

11) Oil pump

12) Crankshaft

13) Oil pressure adjusting valve

14) Oil pick-up screen

15) Turbocharger, only on LDW 2004/T.

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MODELLO N°

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DATA

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35

VIII LUBRICATION SYSTEM

119

120

Oil pump

Components:

1 Suction port

2 Delivery port

4 Gasket

5 External rotor

3 Oil pressure adjusting Valve port 6 Internal rotor

7 Key

The oil pump is driven by the crankshaft via key 7. Rotor 6 is locked in the circumferential but not in the axial direction. This allows the shaft to move axially while rotors 5 and 6 are prevented from damaging the pump sealing surfaces.

Oil pump capacity = 24.5 litres/min. at a pressure of 4.5/4.75 bar

(engine speed 3000 rpm, oil temperature 38/42°C).

Oil pump rotor clearance

Measure clearance A between the teeth located along the axis of the keyway (as shown in the figure); its value is 0.150 mm; worn limit clearance 0.280 mm.

121

122

Oil pressure adjusting valve

Components:

1 Valve

2 Spring

3 Gasket

4 Plug

Dimensions (mm):

A = 45.5/46.0

Blow compressed air into the valve seat and carefully clean all components; using a caliper measure the length of spring A.

123

124

125

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1-5302-345 oil filter cartridge

Components:

1 Gasket

2 Plate

3 Gasket

4 Blade

5 Filtering material

6 By-pass valve

Specifications:

Max. working pressure = 7 bar

Max. explosion pressure = 20 bar

Low temperature limit = -35°C

By-pass valve setting = 2.1/2.8 bar

Total filtering surface = 2000 cm2

Degree of filtration = 15 m m

MODELLO N°

DATA EMISSIONE

REVISIONE

02

50534 31-12-1989

DATA

30-09-1996

VISTO

LUBRICATION SYSTEM VIII

Oil pressure check

On completing assembly, fill with engine oil and fuel; connect a 10 bar pressure gauge to the pressure switch fitting.

Start the engine and check pressure as a function of the oil temperature (see below).

126

Oil pressure curve for LDW 1503

.Fig. 127 - The curve is obtained at the oil filter level constant engine speed of 850 rpm in no-load conditions.

Fig. 128 - The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power.

127 128

Oil pressure curve for LDW 2004

.Fig. 129 - The curve is obtained at the oil filter level constant engine epeed of 850 rpm in no-load conditions.

Fig. 130 - The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power.

129

130

Oil pressure curve for LDW 2004/T

.Fig. 131 - The curve is obtained at the oil filter level constant engine epeed of 850 rpm in no-load conditions.

Fig. 132 - The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power.

131

132

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MODELLO N°

50534

Note:

The max lubrication oil temperature must be lower than the sum: ambient temperature + 95°C.

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

37

IX COOLING SYSTEM

COOLING SYSTEM

133

Components:

1) Coolant fill cap

2) Expansion tank

3) Cylinder block

4) Circulating pump

5) Coolant temperature warning lamp

6) Thermostat

7) Fan

8) Radiator

9) Heat exchanger, only on LDW 2004/T.

38

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DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

COOLING SYSTEM IX

Expansion tank and cap

The expansion tank is separated from the radiator and is fitted with a coolant fill cap. The cap comes with vacuum valve 1 and pressure relief valve 2.

The pressure relief valve opens at a pressure of 0.7 bar.

134

Checking for cooling system leaks

Remove the cap from the expansion tank and check coolant level.

Replace the cap with one fitted with portable hand air pump coupling as shown in the figure.

Compress air at a pressure of 1 bar for approximately 2 minutes.

Check that no leaks occur.

Note: In normal conditions clean radiator fins every 250 hours. In adverse conditions, clean as necessary.

Replace coolant as specified on page 5.

135

136

137

Coolant circulating pump

Impeller 3 and hub 5 are fitted to the shaft by press fit.

To remove the impeller, screw the M 18x1.5 bolt into bore 2.

To remove that shaft take 4 which locks the bearing to the pump body.

A seal is located on the shaft between the bearing and the impeller.

In case of worn-out seal, coolant leaks from hole 1.

LDW 1503 and LDW2004:

The ratio between the pump and engine rpm = 1:1.2

Pump delivery at 3000 rpm is 70 liters/min.

LDW 2004/T:

The ratio between the pump and engine rpm = 1:1.5

Pump delivery at 3000 rpm is 116 liters/min.

Thermostat

1 - Air valve

Specifications:

Opening temperature: 77°/81°C

Max. stroke at 94°C = 7.5 mm

Coolant flow rate with thermostat and valve in closed position = 15

Liters/h.

138

139

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1-5302-345

MODELLO N°

50534

DATA EMISSIONE

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DATA

REVISIONE

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30-09-1996

VISTO

39

X FUEL SYSTEM

140

141

142

Fuel feeding/injection circuit

Components:

1 - Tank

2 - Fuel feeding pump

3 - Fuel filter

4 - Fuel feeding tube

5 - Return tube

6 - Injection pump

7 - High pressure tube

8 - Injector

9 - Injector return tube

10 - Solenoid valve

Fuel filter

Components:

1 - Drain screw

2 - Cover

3 - Seal

4 - Fitting

5 - Cartridge

Cartridge specifications

Filtering paper:

Filtering area:

Filtering degree:

5000 cm2

2/3 m

Max. working pressure: 4 bar

See page 5 for maintenance details.

Fuel feeding pump

Components:

1 - Feeding pump

2 - Push rod

3 - Seal ring

The fuel feeding pump is of the diaphragm type operated by a camshaft eccentric through a push rod.

If features an external lever for manual operation.

Characteristics:

When the control eccentric rotates at 1500 rpm minimum delivery is

64 l/h while self-regulation pressure is 5/6 m water column.

Fuel feeding pump drive rod protrusion

Push rod 2 shows a protrusion A of 1.5/1.9 mm from the crankcase plane. Check this value with eccentric 1 at the lowest point.

Push rod length = 32.5/32.7 mm.

Check push rod length and replace push rod if size is inadequate.

143

40

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144

FUEL SYSTEM X

Injection pump

The injection pump of a simplified Q type has been designed by

LOMBARDINI for installation on engines of the CHD series: LDW

1503, LDW 2004, LDW 2004/T.

The injection system includes three or four separate pumps each of which feeds a cylinder.

Located on the crankcase at the level of the corresponding cylinder, pumps are directly operated by the camshaft. All high pressure tubes A feature the same shape and dimensions.

Note:The diameter of the pumping element of the injection pump of the LDW 2004/T engine is larger, see Fig. 157.

Injection pump disassembly

Release the spring from the cap and remove the plunger.

Two pins keep the upper cap connected to the pump body; pry with a tool between the pump body and the cap.

145

Injection pump components

1 Delivery union

2 Spacer

3 Spring

4 Gasket

5 Delivery valve

6 Gasket

7 Cap

8 Spring

9 Upper cap

10 Plunger

11 Lever

12 Pin

13 Body

A Fuel feed union

B Fuel dischrge union

C Pump flange

D Barrel

E Fuel control helix

Note: Union A and B, flange C and barrel D form an integral part of the pump body.

146

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X

FUEL SYSTEM

How to reassemble injection pump components

Fit the plunger with helix E directed towards the discharge union B; if it is erroneously fitted with spiral facing the fuel feed union A the injection pump will not operate (thus the possibility of the engine overspeeding is completely ruled out); complete reassembly following fig. 146 and 147.

Tighten delivery union to 35 Nm.

147

Injection pump non-return valve

The discharge union is fitted with a non-return valve A; this valve improves injection by bleeding the air inside the fuel and stops the engine immediately after the stop device is operated.

148

Injection pump control rod

Control rod 1, operated by the throttle and controlled by the speed governor, controls the injection pump. Ring nut 2 keeps rod 1 in the required position by means of groove 3.

Note: Do not unscrew ring nut 2 before removing rod 1.

149

151

42

150

How to remove injection pump feeding tubes

Cut the nylon tube at A.

Remove the portion left inside the union using pliers. Deform the nylon tube without damaging the union seals as shown in the figure.

Warning:

Cutting the pipe in the opposite direction to the arrow A

(horizontally) damages the pump coupling with consequent leakage of fuel.

152

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DATA

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VISTO

FUEL SYSTEM X

How to reassemble injection pump feeding tubes

1 Pliers for 6 mm diam. tubes - Part No. 7104-1460-022

2 Pliers for 8 mm diam. tubes - Part No. 7104-1460-023

Feeding and discharge tubes are made of nylon; they fit into the injection pump unions by exerting pressure and using special pliers and a plastic hammer.

153

154

155

156

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MODELLO N°

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Instrument for equalizing injection pump delivery - Part No.

7104-1460-090

Components:

1 Tank

2 Test tube

3 Support

4 Handle

5 Injection pump discharge tube cut-off valve

6 Injection pump intake tube-off valve

A Tube for connection to injection pump intake union

B Tube for connection to injection pump discharge union

·

Remove feed tubes from all injection pumps and fit the

instrument tubes making sure that each pump has its own intake and discharge tubes; with reference for figures 155 and

156 connect the instrument A with the engine A and the instrument B with the engine B.

Proceed in a similar manner with the other pumps.

·

Open valves 5 and 6 of each tube and completely fill with clean

Diesel fuel.

·

Start the engine and carry out the test at 2000 rpm in no-load

conditions; the maximum equalization error between the test

tubes should not exceed 2 cm³ /1 min.

Injection pump delivery equalization.

Once instrument with Part No.7104-1460-020 has been connected and filled with fuel, locate it at least 20 cm. above the injection pump level. Bring the engine to 2000 rpm in no-load conditions.

Cut off fuel supply from the engine by turning handle 4 Fig 155.

Then check test tube levels. If a level is lower than the others reduce delivery of the corresponding pump. Bearing in mind that the pump flange screw bores are slot-shaped do as follows: loosen the screws fixing the pump to the crankcase by 1/4 turn.

With drift and hammer tap so that the pump body is allowed to slightly rotate. Delivery increases by turning clockwise and decreases by turning counterclockwise. Tighten screws to 25 Nm.

Any time an injection pump is replaced delivery equalization should be performed.

Note: A reference notch is located between the pump flange and its mounting on the crankcase. If one or more pumps are disassembled and reassembled do as follows:

·

Leave the shims for injection timing setting under each pump

unchanged.

·

Each pump should be reassembled in its own housing. Align the

delivery reference notches located on the pump flange with those

on the crankcase.

DATA EMISSIONE

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DATA

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43

X FUEL SYSTEM

157

158

Injection pump P. No. 6590-249 - Plunger and barrel assembly

Components:

1 Pump body 2 Barrel 3 Plunger

4 Retardation notch

Dimensions (mm):

A = 2.00/2.03 B = 1.50/1.53 C = 6.00

D = 26.00 E = 0.47/0.50

Note: Barrel 2 forms an integral part of the pump body 1. For this reason both the barrel and plunger 3 should not be replaced.

When checking static injection timing refer to retardation notch 4.

The new injection pump Part No. 6590-267 has a pumping element of the same size but has no retardation notch.

The injection pump Part No. 6590-251 mounted on the LDW

2004/T has a pumping element of diameter C of 7 mm and has no retardation notch.

Checking injection pump delivery

1 Delivery adjustment rod

2 Rod 1 stop position

3 Rod 1 max. delivery position

A = 18.5/19.5 mm (rod max. stroke) a = 66° (rod max. rotation)

Test data of injection pump P.No 6590-267 for LDW 1503, LDW

2004

Control rod

max. force

Newton

0.35

Rod stroke from Camshaft Delivery max. delivery rpm

point

mm rpm mm3/stroke

9

9

0

1500

500

150

30/40

25/35

56/66

Test data of injection pump P.No. 6590-251 for LDW 2004/T

Control rot

max. force

Newton

0.35

Rod stroke from Camshaft max.delivery

rpm

point

mm

9

9

0

Delivery

rpm mm3/stroke

1500

500

150

40/48

20/28

58/64

159

44

Checking low pressure injection timing

Fill the tank and connect it to the inlet pipe 4 of the injection pump fig. 161. Check that the level of fuel in the tank is at least 20 cm above the injection pump. If this is not possible, excite the solenoid valve by means of the starter key and operate the supply pump.

Disconnect the outlet pipe 3 fig. 161 and introduce a metal wire making it protrude by approximately 1 cm to check dripping.

Put all the injection pumps in the stop position by using the appropriate lever.

By turning the driving pulley in the direction of rotation of the engine (clockwise), take the 1st cylinder to the TDC of compression, go back by 1/4 of a turn, see below.

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MODELLO N°

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DATA EMISSIONE

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DATA

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30-09-1996

VISTO

160

161

15°

14°

13°

12°

11°

10°

9°

8°

7°

6°

5°

162

LDW 1503 LDW 2004 LDW 2004/T

(mm)

1.866

1.627

1.405

1.198

1.008

0.834

0.676

0.534

0.409

0.301

0.209

FUEL SYSTEM X

Fuel will be seen to come out of the outlet pipe 3 of the injection pump.

Slowly turn the pulley clockwise, taking care to stop as soon as fuel stops dripping: this is the static injection timing.

If the TDC reference of the pulley of the 1st cylinder D does not coincide with C (standard injection timing reference fig. 160) remove the injection pump and replace the pad with one of the right thickness, fig.161.

Proceed in the same manner with the other pumps, bearing in mind that TDC references of every cylinder are given on the pulley, fig.160.

Note: Changing the thickness B by 0.1 mm fig 163 (or the thickness of the seal of the old system) changes timing by approximately 1 degree.

Injection timing and top dead centre references of cylinders

LDW 1503, LDW 2004, LDW 2004/T (fig. 160)

A = TDC on timing system cover

B = Injection timing reference with respect to the TDC for adjustments under 2400 rpm,

a

= 10°/12°.

C = Injection timing reference (standard) with respect to the TDC for adjustments from 2400 to 3000 rpm, a

1 = 12°/14°; for LDW

2004/T from 2400 to 3000 rpm, a

= 7°, for adjustments under

2400 rpm, a = 3/5°

References on the pulley (fig 160)

D = TDC of the 1st cylinder LDW 1503, of the 1st and 4th cylinder

LDW 2004 and LDW 2004/T

E = TDC of the 2nd cylinder LDW 1503

F = TDC of the 3rd and 2nd cylinder LDW2004, LDW 2004/T

G = TDC of the 3rd cylinder LDW 1503.

Injection timing control in low pressure making reference to lowering the piston with respect to the TDC.

When it is not possible to access the pulley due to a lack of space inside the application, it is possible to cotnrol the injection timing by using the tool 1 Part No. 7107-1560-075 fig. 161 with the advantage of obtaining more exact values than the above described control.

Remove the rocker arm cap, intake manifold and mount tool 1 as in the figure.

Put all the injection pumps in the stop position by using the appropriate lever.

Take the piston to TDC; by operating lever 2, take the intake valve into contact with the piston and zero the comparator.

Turn the pulley anticlockwise by 1/4 of a turn, then again clockwise proceeding very slowly, observing the dripping of pipe 3 fig. 161 taking care to stop as soon as the fuel stops dripping.

This is the injection timing also according to what is described in fig.160.

By using the lever 2 check the lowering of the piston with respect to the TDC, making reference to the table on the left, note that the standard injection timing for the LDW 1503, LDW 2004 con a

=

13° corrisponds to lowering the piston 1.405 mm.

The table shows lowering the piston referring to the injection timings of the other cylinders, fig. 160.

To correct the injection timing replace the thickness of the pad inside the injection tappets, fig. 163 or the shim under the injection pump of the old system.

fig 164.

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MODELLO N°

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DATA EMISSIONE

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DATA

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30-09-1996

VISTO

45

163

165

X

FUEL SYSTEM

164

Injection timing correction by changing the pad thickness

The new system comprises a single seal A under the flange of the injection pump and moreover has the purpose of ensuring a seal against any oil leakage.

In addition to the thickness of the seal A the injection timing is determined by the thickness of the pad inside the injection tappet.

To remove the pad B use a rod with a sucker C or a magnet at its end.

The spare pads supplied have 8 different thicknesses (from 4.0 to

4.7 mm) and the value of the thickness is stamped on the bottom of the pad.

Injector

Whenever maintenance operations are carried out on the injector clean the seal ring and replace it if not in proper condition.

Introduce seal ring 1 into the injector housing with the sealing surface facing upwards (see figure).

See page 5 for maintenance intervals.

Fix injector to the head tightening to 70 Nm.

Injector setting

Connect injector to a hand pump and check that setting pressure is

140/150 bar; Make the required adjustments, if any, by changing the shim over the spring. Eleven different shims are available as spares with size from 1 to 2 mm.

When replacing the spring, setting should be performed at a 10 bar greater pressure(160 bar) to allow for bedding during operation.

Checke needle valve sealing by slowly moving the hand pump until approximately 120 bar per 10 seconds.

Replace nozzle in case of dripping.

166

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MODELLO N°

50534

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DATA

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VISTO

167

ELECTRIC SYSTEM

Alternator type Marelli AA 125 R 14V 45A

Characteristics:

Rated voltage = 14V

Rated current = 45A

Max. speed = 14000 giri/1'

Peak speed (max 15 min) = 15000 rpm

Bearing on control side = 6203.2z

Bearing on manifold side = 6201-2z/C3

Voltage regulator = RTT 119 AC

RH direction of rotation.

Note: Lube the two bearings with high temperature grease.

Tighten the nut 1 to 60 Nm.

The alternator has a W terminal for a speed indicator.

XI

Characteristic curves for alternator type Marelli AA 125 R 14V

45A

The curves have been detected with electronic voltage regulator after thermal stabilization at 25°C; test voltage 13.5 V.

P1 = Power in kW

I = Current in Ampere h = Alternator efficiency

Note: The alternator rpm is equal to to the rpm shown in the table multiplied by 1000.

Ratio between engine/alternator rpm = 1:1.8

168

Characteristic voltage curve for regulator type RTT 119 AC

The electronic voltage regulator is built into the alternator.

The curve changes depending on temperature.

A = Max. voltage curve

B = Min. voltage curve

169

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MODELLO N°

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DATA EMISSIONE

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DATA

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30-09-1996

VISTO

47

170

XI ELECTRIC SYSTEM

12V Electric wiring -Marelli 14V - 45A

1 Alternator

2 Starter Motor

3 Battery (See below for sizing details)

4 Glow Plugs

5 Thermistor (Glow Plug Controller Circuit)

6 Glow Plug Controller / Timer

7 Key Switch

8 System Fuse, 50A (LDW 1503), 80A (LDW 2004,2004/T).

9 Fuse (Accessory)- 5A

10 Fuel Valve

11 Glow Plug Indicator Lamp

12 Coolant High Temperature Lamp

13 Coolant High Temperature Switch (N.O.)

14 Oil Pressure (Low) Lamp

15 Oil Pressure Switch (N.C.)

16 Alternator Charging Lamp (Off if Charging)

17Diode

18 Air Filter High Restriction Indicator

19 Air Filter Restriction Switch (N.O.)

20 Low Fuel Level Lamp

21 Low Fuel Level Switch (N.O.)

A Accessory

B Off Position

C

On Position

D Starting Position

Note: This electric starting diagram holds for both 45A and 65A alternators.

Battery 3 is not supplied by LOMBARDINI.

Anyhow, for installation we recommend a battery for all the range of engines with the following particulars, see following table.

Engine Model

LDW 1503

LDW 2004

LDW 2004/T

Starter Rating

(Kw)

Normal Ambient

Extreme Ambient

Amp-Hours

@

20 hours

Rating

Conditions

Maxim.Battery

Amps

@

-18° C

Conditions

Amp-Hours

@

20 hours

Rating

Maxim.Battery

Amps

@

-18° C

2.2

3

2.2

3

2.2

3

88

110

88

110

88

110

330

450

330

540

330

540

110

143

110

143

110

143

450

570

450

570

450

570

48

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171

ELECTRIC SYSTEM

Alternator type Marelli AA 125 R 14V 65A

Characteristics:

Rated voltage = 14V

Rated current = 45A

Max. speed = 14000 giri/1'

Peak speed (max 15 min) = 15000 rpm

Bearing on control side = 6203.2z

Bearing on manifold side = 6201-2z/C3

Voltage regulator = RTT 119 AC

RH direction of rotation.

Note: Lube the two bearings with high temperature grease.

Serrare il dado 1 a 60 Nm.

The alternator has a W terminal for a speed indicator.

XI

Characteristic curves for alternator type Marelli AA 125 R 14V

65A

The curves have been detected with electronic voltage regulator after thermal stabilization at 25°C; test voltage 13.5 V.

P1 = Power in kW

I = Current in Ampere h = Alternator efficiency

Note: The alternator rpm is equal to the rpm shown in the table multiplied by 1000.

Ratio between engine/alternator rpm = 1:1.8

172

Characteristic voltage curve for regulator type RTT 119 AC

The electronic voltage regulator is built into the alternator.

The curve changes depending on temperature.

A = Max. voltage curve

B = Min. voltage curve

173

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49

XI ELECTRIC SYSTEM

Starting Motor

Bosch type EV 12V 2.2 Kw

RH direction of rotation.

Note: Apply to a Bosch service center for any tipe of repair.

174

Characteristic curves for starting motor type Bosch EV 12V 2.2

kW

The solid lines were obtained at a temperature of +20°C; the dotted lines were obtained at a temperature of -20°C.Battery type 110 Ah

450A.

U = Motor terminal voltage in Volt

n = Motor speed in rpm.

A =Absorbed current in Ampere

P =Power in kW

M = Torque in Nm

175

Key switch electrical layout

A = Accessory

B = Off position

C = On position

D = Starting position

176

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ELECTRIC SYSTEM

Pre-heating glow plug

Characteristics:

Nominal voltage = 12.5V

Current = 12/14A after 5 seconds

Sheath surface temperature = 850°C after 5 seconds

Components:

1 Sheath

2 Regulation filament

3 Heating filament

Installation torque 20 Nm.

XI

177

178

179

Glow plug controller relay with coolant temperature sensor

To avoid white smoke generation at cold start-up, post-heating is maintained for approximately 5 sec. after starting.

Transducer Heating time in seconds

Resistance Temp.fluid Pre-heating Post-

(ohm) °C

7000 -20 23.5/29.5

heating

2400

1000

460

0

+20

+40

+50

13.5/16.5

8.5/10.5

6.0/8.0

4/7 no heating

4/7

* Time the operator has available before starting up the starter motor.

Temperature sensor ( Thermistor)

The thermistor is located on the thermostat housing, adjacent to the high coolant temperature switch. The thermistor must be installed in the thermostat housing in the port located nearest to the cylinder head. (See the figure to the left)

Characteristic:

Working range = 30/50°C

Voltage = 6/24 V

Max. temperature = 150°c

Max. installation torque = 30 Nm.

180 181

182 183

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Coolant high temperature lamp switch

Characteristics:

Single-pole circuit, normally open

Supply voltage: 6/24V

Absorbed power: 3W

Circuit closing temperature: 107/113°C

When refitting tighten to 25 Nm.

Note: As an alternative to the thermostat, on request the thermistor for an electrical thermometer can be fitted with the following characteristics:

Power supply voltage = 6/24 V

Resistance: at 60°C = 600/470 W ; at 90°C = 215 W ; at 120°C

= 93/73 W .

DATA EMISSIONE

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51

XII SETTINGS

Settings

Idling speed setting in no-load conditions (standard)

After filling with oil, fuel and coolant, start the engine and warm up for 10 minutes.

Adjust idling speed at 850.950 rpm by turning screw 1 then tighten lock nut.

Note: Speed decreases when loosening scew 1 and increases when tightening it.

184

Full speed setting in no-load conditions (standard)

After setting idle speed turn screw 2 and set full speed in no-load conditions at 3200 rpm; then tighten lock nut.

When the engine reaches the pre-set power, full speed stabilizes at

3000 rpm.

Nota: Speed increases when loosening scew 2 and decreases when tightening it.

185

186

187

52

Standard injection pump delivery setting without torque dynamometer

Injection pump delivery setting should be performed with engine on a dynamometer; if not, setting will only be approximate.

In any case, do as follows:

Loosen delivery limiting device C by 5 turns.

Bring engine to max. rpm in no-load conditions i,e. 3200 rpm.

Tighten limiting device C until the engine rpm decreases.

Unscrew limiting device C by 1 1/2 turn.

Tighten lock nut.

Note:If the engine, at full load, generates too much smoke tighten

C; loosen C if no smoke is observed at the exhaust and if the engine cannot deliver its full power.

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Injection pump delivery limiting and torque adjusting device

Limiting device C has the function of limiting the injection pump maximum delivery

The same device acts as torque adjusting device since springs N act on lever L and thus oppose the resistance of spring M contained in the barrel.

The torque limiting device allows lever L to have a stroke H of 1.0/

1.1 mm: this increases the injection pump delivery while torque reaches its peak.

Note: In application for generating sets and motor welding units the torque adjusting device only acts as delivery limiting device without spring M and stroke H.

MODELLO N°

50534

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

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30-09-1996

VISTO

188

SETTINGS

XII

Injection pump delivery setting

1) Bring engine to idling speed

2) Unscrew delivery limiting device C ( see fig. 186)

3) Bring the engine to the power and rpm required by the

manufacturer of the device.

4) Check that fuel consumption falls withing the table specifications

(see below).

If consumption is not as indicated change balance conditions at

the torque dynamometer by varying the load and adjusting the

governor. Under stable engine conditions check consumption

again.

5) Tighten limiting device C until the engine rpm decreases.

Lock the limiting device by means of lock nut.

6) Check for torque increase at the given rpm if required.

7) Release brake completely and check at what speed the engine

becomes stable

Speed governor should comply with the requirements of the class

indicated by the manufacturer of the device.

8) Stop the engine.

9) Check valve clearance when engine has cooled down.

Standard settings

Power * Specific fuel consumption

Engine rpm time, seconds

Kw for 100 cc gr/Kw.h

LDW 1503 3000 24.56 43/46 280

LDW 2004 3000 32.72

32/34 270

LDW 2004/T 3000 42 26/27 265

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XIII SETTINGS

189

190

191

192

Fuel limiting device

(fig. 189 e 190)

When starting up the engine the fuel limiting device has the aim of preventing excessive smoke at the exhaust.

Use the delivery adjustment rod of the injection pumps 5 Fig.190 in a constant manner when ambient temperature is above 15°C.

As the temperature gradually falls, this device gradually lessens its action to then exclude it at zero degrees.

Fuel limiting device adjustment

(fig189 e 190)

·

Take the engine to the setting speed and power

·

Loosen the lock nut 2.

· Unscrew the screw 1 (to bring lever 4 close up to rod 5) until the engine speed tends to decrease.

· Screw the screw down by at most 1/2, 3/4 of a turn so as to distance lever 4 from rod 5 by 1.2/1.8 mm.

Screw down the lock nut 2.

·

When the temperature falls under zero degrees, lever A turns (pin

6 of the thermostat 3 comes back in) to go into position B

thereby allowing rod 5 to go into the supplement position.

Stop setting

·

Unscrew the screw 2

· Move rod 1 fully to the left.

· Screw down screw 2 to touch rod 1.

· Continue screwing screw 2 by 1/2 turn.

· Lock nut 3.

Note: In these conditions the injection pump delivery control limit stops cannot be damaged by violent impact caused by operation of any electro-stops that may be fitted.

54

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VISTO

193

194

195

STOCKAGE XIII

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.

· Remove fuel tube and empty the tank

·

Remove fuel filter, replace cartridge if dirty and refit.

·

Carefully clean cylinder fins, heads and fan.

· Seal all openings with tape.

· Remove injectors, pour a spoonful of oil type SAE 30 into the

cylinders 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

RUSTIA 100/F).

398 - AGIP,

·

Change the antifreeze liquid after two years.

How to prepare the engine for operation

· Clean engine outside

·

Remove protections and covers

·

Remove antirust by an appropriate solvent or degreaser.

· Remove the intake manifold, pour engine oil close to the valves, turn the driving shaft a few turns, then remove the pan and drain off the oil containing the protective element dissolved in it.

·

Check injectors, valve clearance, belt tension, head tightening,

oil filter and air cleaner for proper setting.

ENTE COMPILATORE TECO/ATL

COD. LIBRO

1-5302-345

MODELLO N°

50534

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

55

SPECIFICATIONS LDW 1503, LDW 2004, LDW 2004/T

Cylindres

Borte

Stroke

Displacement

TIPO MOTORE

Compression ratio

R.P.M.

N 80/1269/CEE-ISO 1585-DIN 70020

Power KW NB ISO 3046 - 1 IFN - DIN 6270

NA ISO 3046 - 1 ICXN - DIN 6270

LDW 1503 LDW 2004 LDW 2004/T

N.

mm mm

Cm³

3

88

85

1551

22:1

3000

26.4

24.6

22.2

4

88

85

2068

22:1

3000

35

33

29.6

4

88

85

2068

22:1

3000

44.1

42

37.8

Max. torque *

Max. torque 3rd + 4th p.t.o.

Specific fuel consumption **

Oil consumption ***

Dry weight

Combustion air volume at 3000 r.p.m.

Cooling air volume at 3000 r.p.m.

Nm @ RPM

Nm @ RPM gr/KW.h @ RPM

Kg/h

Kg l./min.

l./min.

Max. permissible driving shaft axial load in both directions

Max. 60 seconds

Max inclination

Firing Order

Lasting up to 30 seconds

Permanent

Kg.

a a a

95.4@2100

39.2@3000

268@2300

0.024

155

2326

95.830

300

35°

25°

****

1-3-2

128@2100

39.2@3000

260@2300

0.032

190

3100

128.330

300

35°

25°

****

1-3-4-2

165.7@2000

39.2@3000

256@2200

0.032

195

3900

180.000

300

35°

25°

****

1-3-4-2

* Referred to max. N power

** Referred to max. NB power

*** At NA power

**** Depending on the application

TORQUE SPECIFICATIONS

XV

Connecting rod

Diesel fuel union bolts

Flywheel housing

Preheating glow plug

Roker arm cover

Main bearing cap

Intake manifold

Exhaust manifold

Throttle cover

Oil pump cover

1P hydraulic pump flange cover

Oil pressure indicator

Camshaft gear

Injector

Starting motor

Front engine foot

Engine foot on bell

Oil pan

Feed pump stud bolts

Drive puly

Oil filter nipple

Injection pump union

Intermediate thrust block union

Injection pump union

Water recirculation unions

Engine mounting bracket

Rocker arm assembly

Tank bracket

Crankcase lubrication port plug

Water drain plug

Oil drain plug

Air bleed plug under oil sump

Head (see fig. 55 - 56 )

High pressure injection line

Air bleed tube under oil sump

Flywheel

MAIN TORQUE SPECIFICATIONS

Diam.and pitch Torque Sealant

mm Nm Loctite, type

10x1.5

70

14x1.5 40

10x1.5 50

12x1.25

8x1.25

12x1.25

8x1.25

8x1.25

20

20

120

25

25

6x1

6x1

6x1

12x1.5

10x1.5

10

10

10

35

80

24x2

10x1.5

70

45

16x1.5 196

10x1.5 40

8x1.25

25

8x1.25

16x1.5

UNF 3/4

12x1.5

-

352

-

35

22x1.5 150

12x1.5 25

14x1.5

-

12x1.75

50

10x1.5 50

8x1.25 30

14x1.25

-

14x1.5 40

14x1.5 50

14x1.5 40

12x1.25

12x1.5

12x1.25

24,5

35

140

270

270

270

270

554

554

270

ENTE COMPILATORE TECO/ATL

COD. LIBRO

1-5302-345

MODELLO N°

50534

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

57

XV TORQUE SPECIFICATIONS

STANDARD BOLT TORQUE SPECIFICATIONS

DESCRIPTION

Diameter per Pitch (mm)

4x0.70

5x0.80

6x1.00

7x1.00

8x1.25

9x1.25

10x1.50

12x1.75

14x2.00

16x2.00

18x2.50

20x2.50

22x2.50

24x3.00

135

205

257

358

435

557

R

³ 800

N/mm2

Nm Kgm

3.6

7

12

19.8

29.6

38

52.5

89

0.37

0.72

1.23

2.02

3.02

3.88

5.36

9.09

13.80

21.00

26.30

36.60

44.40

56.90

R

³

1000 N/mm2

Nm

Kgm

5.1

9.9

17

27.8

41.6

53.4

73.8

125

5.45

7,54

12.80

0.52

1.01

1.73

2.84

4.25

190

289

362

504

611

784

19.40

29.50

37.00

51.50

62.40

80.00

228

347

435

605

734

940

R

³ 1200

N/mm2

Nm Kgm

6 0.62

11.9 1.22

20.4 2.08

33 3.40

50 5.10

64.2 6.55

88.7 9.05

150 15.30

23.30

35.40

44.40

61.80

74.90

96.00

58

ENTE COMPILATORE TECO/ATL

COD. LIBRO

1-5302-345

MODELLO N°

50534

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

SPECIAL TOOLS

XVI

SPECIAL TOOLS

DESCIPTION

Part No.

Fuel delivery equalization tool. Allows the adjustment of individual unit injector fuel delivery.

7104-1460-090

Glass column for fuel delivery equalization tool.

7104-1460-072

Camshaft bushing replacement tool

Static timing tool

7104-1460-021

7271-1460-024

T.D.C. determination fixture.

7107-1460-75

Pliers for injection pump feeding tubes

1 For tube diam. 6 mm

2 For tube diam. 8 mm

1 7104-1460-022

2 7104-1460-023

ENTE COMPILATORE TECO/ATL

COD. LIBRO

1-5302-345

MODELLO N°

50534

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

59

NOTE

60

ENTE COMPILATORE TECO/ATL

COD. LIBRO

1-5302-345

MODELLO N°

50534

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

Air filter restriction switch pag.

11

Alternator type Marelli 47,49

Camshaft

Camshaft bushing replacement

29

30

Camshaft end play

Camshaft journals and bushings in model LDW 1503

32

29

Camshaft journals and bushing in models LDW 2004,LDW 2004/T 29

Camshaft removal 29

Camshaft timing

Center main bearings

Characteristics curves for alternator type Marelli

Characteristics curves for starting motor type Bosch

Checking camshaft bushing internal diameter

Checking dynamic balancer

Checking injection pump delivery

Checking main journals and crank pins

30

23

47, 49

50

29

26

44

25

Checking for cooling system leaks

Characteristics

Cooling system

Connecting rod

Connecting rod alignment

Connecting rod and piston pin

Connecting rod/piston assemblies

Connecting rod weight

Coolant circulating pump

Cooling fan

Crankshaft end play

Crankshaft for LDW 2004 and LDW 2004/T

Crankshaft front and rear oil seal

Crankshaft lubrication ducts

Crankshaft timing gear

Cylinder head

24

25

25

14

39

12

24

26

22

22

22

21

39

4

38

21

Cylinder class

Cylinder head gasket

Cylinder head tightening

Cylinder head tightening steps

Cylinder roughness

Cylinders

Dimensions for injection pump delivery control yoke adjstment

Dysassembly/Reassembly

Dry air cleaner

Driving pulley

Dry air cleaner components

Dynamic balancer

Electric system

Exhaust manifold

Expansion tank and cap

Flywheel

Front and rear main bearings

Front cover

Fuel feeding/injection circuit

Fuel feeding pump

Fuel feeding pump drive rod protrusion

Fuel filter

Fuel limiting device

Fuel system

Full speed setting in no-load conditions

Glow plug controller relay

GR! and GR" hydraulic pump 3rd p.t.o.

How to prepare the engine for operation

FHow to reassemble injection pump components

How to reassemble injection pump feeding tubes

How to remove injection pump feeding pump feeding tubes

Hydraulic pump p.t.o.

Idler gear and hub

Idling speed setting in no-load conditions

Index

Injection pump

IInjection pum components

Injection pump control rod

41

42

IInjection pump delivery equalization 43

Injection pump delivery limitimg and torque adjusting device pag. 52

Injection pump delivery setting with engine at the torque dynamo.

53

Injection pump non-return valve 42

27

52

2

41

47

11

39

13

10

12

11

27

18

17

27

10

17

20

20

21

42

43

42

32

52

51

32

55

40

40

54

40

23

27

40

40

GENERAL ALPHABETICAL INDEX

Injection pump follower

Injection pump disassemble

Injection timing check

Injection timing correction

Injection timing reference marks

Injector

Injector setting

Instrument for equalizing injection pump delivery

Intake, exhaust and inject.cam height for mod. LDW 1503 30

Intake,exhaust and injection cam height , models LDW 2004,2004/T 30

Intake manifold

Key switch electrical layout

11

50

Lubrication system

Main bearing and connecting rod big end bering inside diameter

Maintenance

Model number and engine identification

35

26

5

3

45

46

46

43

17

41

44

46

Oil-bath air cleaner

Oil-bath air cleaner components

Oil filter cartridge

Oil pressure adjusting valve

Oil pressure curve at idling speed

Oil pump

Oil pump rotor clearance

Overall dimensions

Permanent protection

Piston

Piston classes and logo

Piston position and clearance

Piston-Refiting

Piston rings - Clearance between grooves

Piston rings - Fitting sequence

Piston rings - End gaps

37

36

36

7, 8, 9

10

10

36

36

19

19

19

19

55

18

18

20

Pistons availability

Piston weight

Plunger and barrel assembly

Precombustion chamber

Preheating glow plug

Ring feder

Rocker arm cover

Rocker arm assembly

Settings

Speed governor

Speed governor counterweights and springs

Spring for extra fuel suppy at starting

Standard injection pump delivery setting without dynam. brake

Standard bolt torque specifications

Starting motor

Stop setting

Storage

Tank

Tappet

Technical data

Temperature sensor

Temporary protection

Test data of injection pump

Thrust bearings

Timing angles for checking purposes

Timing angles for operating puroses

To check clearance between main bearings and journals

Turbocharger

Torque specifications

Trouble shooting

Valve guide insertion

Valve guides and cylinder head

Valve matirial

Valve recess and sealing surface

Valve removal

Valve/rocker arm clearance

Valve seats and bore

Valve spring

Valve timing check

Valve timing without considering timing marks

"V"-belt

31

31

23

33, 34

57

6

15

15

51

55

55

23

55

13

17

56

16

15

31

31

12

15

16

14

14

52

58

50

54

52

27

28

38

51

12

13

14

18

18

44

16

ENTE COMPILATORE TECO/ATL

COD. LIBRO

1-5302-345

MODELLO N°

50534

DATA EMISSIONE

31-12-1989

DATA

REVISIONE

02

30-09-1996

VISTO

61

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: [email protected]

Internet: http://www.lombardinifim.it

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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.

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

ENTE COMPILATORE TECO/ATL

COD. LIBRO

1-5302-345

MODELLO N°

50534

DATA EMISSIONE

31-12-1989

REVISIONE

02

DATA

30-09-1996

VISTO

62