LOMBARDINI CHD 1503, CHD 1603, CHD 2004, CHD 2004/T, CHD 2204, CHD 2204/T Engine Workshop Manual
Below you will find brief information for Engine CHD 1503, Engine CHD 1603, Engine CHD 2004, Engine CHD 2004/T, Engine CHD 2204, Engine CHD 2204/T. This workshop manual will guide you through the process of assembly, disassembly, overhauling, replacement and tuning operations for your LOMBARDINI diesel engines. This includes information on the fluid cooling circuit and updates as of December 1st 2009. By following the instructions provided in this manual, you can ensure the proper and safe maintenance of your engines.
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WORKSHOP MANUAL
CHD series Engine
cod. 1-5302-345
CHD Engine Series
PREFACE
- Every attempt has been made to present within this service manual, accurate and up to date technical information.
However, development on the
LOMBARDINI series is continuous.
Therefore, the information within this manual is subject to change without notice and without obligation.
- The information contained within this service manual is the sole property of
LOMBARDINI.
As such, no reproduction or replication in whole or part is allowed without the express written permission of
LOMBARDINI.
Information presented within this manual assumes the following:
1 - The person or people performing service work on
LOMBARDINI series engines is properly trained and
equipped to safely and professionally perform the subject operation;
2 - The person or people performing service work on
LOMBARDINI series engines possesses adequate hand and
LOMBARDINI special tools to safely and professionally perform the subject service operation;
3 - The person or people performing service work on
LOMBARDINI series engines has read the pertinent
information regarding the subject service operations and fully understands the operation at hand.
- This manual was written by the manufacturer to provide technical and operating information to authorised LOMBARDINI
after-sales service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations.
- As well as employing good operating techniques and observing the right timing for operations, operators must read
the information very carefully and comply with it scrupulously.
- Time spent reading this information will help to prevent health and safety risks and financial damage.
Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the following table.
Drafting body
CUSE/ATLO
Document code
1-5302-345
Model
N°
50534
Edition
6°
Revision
5
Issue date
31-12-89
Review
date
01-12-2009
Endorsed
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
CHAPTER INDEX
-
This manual gives the main instructions on how to repair LOMBARDINI diesel engines
LDW 1503 - 1603 - 2004 -
2004/T - 2204 - 2204/T, fluid cooling circuit, updates as of December 1 st
2009.
INDEX
1 GENERAL REMARKS AND SAFETY INFORMATION .......................................................................... 9 - 11
General safety during operating phases ......................................................................................................................... 11
General Service manual notes .......................................................................................................................................... 9
Glossary and terminology ................................................................................................................................................. 9
Safety and environmental impact .................................................................................................................................... 11
Safety and warning decals .............................................................................................................................................. 10
Safety regulations ........................................................................................................................................................... 10
Warranty certificate ........................................................................................................................................................... 9
2 TECHNICAL INFORMATION ...............................................................................................................12 - 20
Approval data .................................................................................................................................................................. 14
Characteristics power, torque and specific fuel consumption curves .............................................................................. 20
Manufacturer and motor identification data ..................................................................................................................... 14
Overall dimensions .......................................................................................................................................................... 15
Performance diagrams .................................................................................................................................................... 20
Possible causes and trouble shooting ............................................................................................................................. 12
Table of likely anomalies and their symptoms ................................................................................................................. 12
Technical specifications ................................................................................................................................................... 18
3
4
MAINTENANCE - PRESCRIBED LUBRICANT - REFILLING ............................................................22 - 25
ACEA Regualtions - ACEA Sequences ........................................................................................................................... 23
API / MIL Sequences .................................................................................................................................................... 23
Aviation fuel ..................................................................................................................................................................... 25
Biodiesel fuel ................................................................................................................................................................... 25
Coolant ............................................................................................................................................................................ 25
Extraordinary maintenance ............................................................................................................................................. 22
Fuel recommendations .................................................................................................................................................... 25
Fuel type ......................................................................................................................................................................... 25
Fuels for low temperatures .............................................................................................................................................. 25
International specifications .............................................................................................................................................. 23
Lubricant ......................................................................................................................................................................... 23
Ordinary maintenance ..................................................................................................................................................... 22
Prescribed lubricant ........................................................................................................................................................ 24
Routine engine maintenance .......................................................................................................................................... 22
SAE Classification .......................................................................................................................................................... 23
DISASSEMBLY/REASSEMBLY ...........................................................................................................26 - 56
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-
Chapter index
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
7
8
6
5
Chapter index
-
TURBOCHARGER ...............................................................................................................................58 - 59
LUBRICATION SYSTEM ......................................................................................................................60 - 62
COOLING SYSTEM ..............................................................................................................................64 - 65
FUEL SYSTEM .....................................................................................................................................66 - 72
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-
Chapter index
9 ELECTRIC SYSTEM.............................................................................................................................73 - 82
10 SETTINGS ............................................................................................................................................83 - 84
11 ENGINE STORAGE .................................................................................................................................... 85
12 TORQUE SPECIFICATIONS AND USE OF SEALANT ......................................................................86 - 87
13 SPECIAL TOOLS ........................................................................................................................................ 88
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
GENERAL REMARKS AND SAFETY INFORMATION
1
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.
GENERAL SERVICE MANUAL NOTES
1 - Use only genuine Lombardini repair parts.
Failure to use genuine Lombardini parts could result in sub-standard performance and low longevity.
2 - All data presented are in metric format. That is,
GLOSSARY AND TERMINOLOGY
For clarity, here are the definitions of a number of terms used recurrently in the manual.
dimensions are presented in millimeters (mm), torque is presented in Newton-meters (Nm), weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) and pressure is presented in barometric units (bar).
- Cylinder number one: is the piston timing belt side
«viewed from the flywheel side of the engine».
- Rotation direction: anticlockwise «viewed from the flywheel side of the engine».
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1
General remarks and safety information
SAFETY AND WARNING DECALS
- Important remarks and features of the text are highlighted using symbols, which are explained below:
Caution – Warning
This indicates that it is necessary to take proper precautions to prevent any risk to the health and safety of individuals and avoid financial damage.
Danger – Attention
This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals.
Important
This indicates particularly important technical information that should not be ignored.
SAFETY REGULATIONS
•
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 self-winding 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.
• 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.
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
General remarks and safety information
1
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.
• 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.
GENERAL SAFETY DURING OPERATING PHASES
– The procedures contained in this manual have been tested and selected by the manufacturer’s technical experts, and hence are to be recognised as authorised operating methods.
– Some tools are normal workshop ones, while others are special tools designed by the Manufacturer of the engine.
– All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely.
– It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual.
– Holes must be lined up methodically and with the aid of suitable equipment. Do not use your fingers to carry out this operation to avoid the risk of amputation.
– Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.
– Do not use flammable liquids (petrol, diesel, etc.) to degrease or wash components. Use special products.
– Use the oils and greases recommended by the manufacturer.
Do not mix different brands or combine oils with different characteristics.
– Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.
– Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.
SAFETY AND ENVIRONMENTAL IMPACT
Every organisation has a duty to implement procedures to identify, assess and monitor the influence of its own activities
(products, services, etc.) on the environment.
Procedures for identifying the extent of the impact on the environment must consider the following factors:
- Liquid waste
- Waste management
- Soil contamination
- Atmospheric emissions
- Use of raw materials and natural resources
- Regulations and directives regarding environmental impact
In order to minimise the impact on the environment, the manufacturer now provides a number of indications to be followed by all persons handling the engine, for any reason, during its expected lifetime.
- All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place.
- Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution.
- When discontinuing use of the engine, select all components according to their chemical characteristics and dispose of them separately.
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22
TECHNICAL INFORMATION
POSSIBLE CAUSES AND TROUBLE SHOOTING
THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:
1) - The engine rpms suddenly increase and decrease
2) - A sudden and unusual noise is heard
3) - The colour of the exhaust fumes suddenly darkens
4) - The oil pressure indicator light turns on while running.
TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS
The following table contains the possible causes of some failures which may occur during operation.
Always perform these simple checks before removing or replacing any part.
TROUBLE
POSSIBLE CAUSE
ELECTRIC SYSTEM
Obstructed fuel line
Fuel filter clogged
Air or water leaks in fuel system
The tank cap vent hole is clogged
No fuel
Discharged battery
Cable connection uncertain or incorrect
Faulty starting switch
Faulty starting motor
Faulty glow plugs
Faulty glow plug control relay
Burnt fuse on preheating spark plugs
Clogged air filter
Excessive idle operation
Incomplete run-in
Overloaded engine
Incorrect adjustment governor linkage
Governor spring broken or unhooked
Low idle speed
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Rings worn or sticking
Worn cylinder
Worn main con rod-rocker arm bearings
Badly sealed intake valve
Damaged cylinder head gasket
Defective timing system
Bent rods
Faulty hydraulic tappets
High noise level
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
POSSIBLE CAUSE
Damaged injector
Injection pump valve damaged
Injector not adjusted
Faulty fuel feeding pump
Hardened pump control rod
Broken or loose supplementary startup spring
Worn or damaged pumping element
Incorrect tuning of injection components
(delivery balancing advance)
Cracked or broken precombustion chamber
Oil level too high
Oil level low
Oil pressure valve blocked or dirty
Worn oil pump
Oil sump suction line clogged
Faulty pressure gauge or pressure switch
Blocked draining pipe
Faulty spray nozzles (Turbo engines only).
Blocked draining pipe
Alternator fan belt loose or torn
Clogged radiator exchange surface
Insufficient coolant
COOLING CIRCUIT
Fault fan, radiator or radiator plug
Faulty thermostatic valve
Blockage inside the radiator or the coolant ducts
Coolant leaking from radiator, hoses, the crankcase or from the water pump
Faulty or worn water pump
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TROUBLE
Technical information
2
High noise level
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2
4
6
2
Technical information
MANUFACTURER AND MOTOR IDENTIFICATION DATA
B A D
The identification plate shown in the figure can be found directly on the engine.
It contains the following information:
A) Manufacturer’s identity
B) Engine type
C) Engine serial number
D) Maximum operating speed
E) Number of the customer version (form K)
F) Approval data
C F E
Approval data
The approval reference directives EC are on the engine plate.
Plate for EPA regulations placed on the recoil starter or the rockerarm cap.
1
3
5
7
It contains the following information:
1) Current year
2) Engine displacement
3) Rated power, measured in kW
4) EPA family ID
5) Injection timing
6) Injection opening preassure
7) Valve clearance
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OVERALL DIMENSIONS
B
A
C
D
LDW 1503-1603
P
Technical information
2
Q
E
K
J
L
R
F
G H
M
O
S
T
U
Z
Y
W
V
X
C1
A1
D1
B1
E1
Note : Dimensions shown in mm
A
B
C
D
E
468
235
233 max
231.3
425.2
F
G
H
J
K
208
175
147.5
250.2
154.2
L
M
N
O
P
DIMENSIONS mm
75
Q
215.7
220
240
R
S
81
348
310
171
T
U
250
187.5
V
W
X
Y
Z
70
356.4
191
283.3
164
A1
B1
C1
D1
E1
266
87
99.6
336
68
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2
Technical information
B
A
C
D
LDW 2004 - 2204
N
O
E
J
K
F G
H
L
M
Q
R
P
TAPPO SCARICO ACQUA
WATER DRAIN PLUG
TAPPO SCARICO OLIO
OIL DRAIN PLUG
W
Z
X
A1
V
U
S
T
Y
Note : Dimensions shown in mm
A
B
C
D
E
468
235
233
231.3
425.2
F
G
H
J
K
208
175
156.5
154.2
75
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L
M
N
O
P
DIMENSIONS mm
220
Q
240
171
R
S
350
187.5
356.3
215.7
81
T
U
191
283.3
V
W
X
Y
Z
164
366
133
99.6
436
A1
68
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
B
Technical information
2
LDW 2004/T - 2204/T
A
E
D
C
L
Q
P
S
R
F
G
M
O
N
H
J
K
T
V
Y
X
U
W
Z
A1
B1
Note : Dimensions shown in mm
C
D
A
B
E
166.7
195
153.5
160
348
H
J
F
G
K
350
210
386.1
164
190.5
N
O
L
M
P
DIMENSIONS mm
186.3
Q
366
R
235
233.1
68
133
468.1
S
T
U
168.7
452.5
208
X
Y
V
W
Z
224.8
156.5
373.2
133.5
220
A1
B1
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
210
310
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2
Technical information
TECHINICAL SPECIFICATIONS
ENGINE TYPE CHD
Cylindres
Bore
Stroke
Displacement
Compression ratio
R.P.M.
Power KW
Max. torque
*
N 80/1269/CEE-ISO 1585-DIN 70020
NB ISO 3046 - 1 IFN - DIN 6270
NA ISO 3046 - 1 ICXN - DIN 6270
Max. torque 3rd + 4th p.t.o.
Oil consumption
**
Dry weight
Combustion air volume at 3000 r.p.m.
Cooling air volume at 3000 r.p.m.
Max. permissible driving shaft axial load in both directions
Max. 60 seconds
Max inclination
Firing Order
Lasting up to 30 seconds
Permanent
*
**
Referred to max. N power
At NA power
*** Depending on the application
N.
mm mm
Cm³
Nm @ RPM
Nm @ RPM
Kg/h
Kg l/min m
3
/min
Kg
LDW 1503 LDW 2004
22.2
95.4
@ 2100
39.2
@ 3000
0.024
155
2326
3
88
85
1551
22:1
3000
26.4
24.6
108.3
300
35°
25°
***
1-3-2
29.6
128
@ 2100
39.2
@ 3000
0.032
190
3100
4
88
85
2068
22:1
3000
35
33.0
128
300
35°
25°
***
1-3-4-2
LDW 2004/T
37.8
165.7
@ 2000
39.2
@ 3000
0.04
195
3900
4
88
85
2068
22:1
3000
44.1
42.0
180
300
35°
25°
***
1-3-4-2
LDW 1503
LDW 2004/T
LDW 2004
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Technical information
2
ENGINE TYPE CHD PLUS
Cylindres
Bore
Stroke
Displacement
Compression ratio
R.P.M.
Power KW
Max. torque
*
N 80/1269/CEE-ISO 1585-DIN 70020
NB ISO 3046 - 1 IFN - DIN 6270
NA ISO 3046 - 1 ICXN - DIN 6270
Max. torque 3rd + 4th p.t.o.
Oil consumption
**
Dry weight
Combustion air volume at 3000 r.p.m.
Cooling air volume at 3000 r.p.m.
Max. permissible driving shaft axial load in both directions
Max inclination
Firing Order
Max. 60 seconds
Lasting up to 30 seconds
Permanent
N.
mm mm
Cm³
Nm @ RPM
Nm @ RPM kg/h kg l/min m
3
/min kg
LDW 1603 LDW 2204
25.4
113
@ 1600
39.2
@ 3000
0.019
156
2475
3
88
90.4
1649
22:1
3000
30.0
27.6
96
300
35°
25°
***
1-3-2
32.0
144
@ 2200
39.2
@ 3000
0.025
192
3300
4
88
90.4
2199
22:1
3000
38.0
34,5
128
300
35°
25°
***
1-3-4-2
LDW 2204/T
42.3
190
@ 1800
39.2
@ 3000
0.04
197
4200
4
88
90.4
2199
22:1
3000
49.2
47
180
300
35°
25°
***
1-3-4-2
*
**
Referred to max. N power
At NA power
*** Depending on the application
LDW 1603
LDW 2204/T
LDW 2204
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2
Technical information
PERFORMANCE DIAGRAMS
CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES
LDW 1503 LDW 1603
LDW 2004 LDW 2004/T
N (80/1269/CEE - ISO 1585) AUTOMOTIVE RATING: intermittent operation with variable speed and variable load.
NB (ISO 3046 - 1 IFN) RATING WITH NO OVERLOAD CAPABILITY: Continuous light duty operation with constand speed and variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOUS RATING WITH OVERLOAD CAPABILITY: continuous heavy duty with constant speed and constant load.
MN Torque curve (N curve) - MB (NB curve) - MA (NA curve) - C: Specific fuel consumption curve (NB curve)
Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m altitude and by 2% every 5°C above 25°C.
Engine power can be influenced by the type of coupling used with the cooling fan.
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Technical information
2
CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES
LDW 2204 LDW 2204/T
N (80/1269/CEE - ISO 1585) AUTOMOTIVE RATING: intermittent operation with variable speed and variable load.
NB (ISO 3046 - 1 IFN) RATING WITH NO OVERLOAD CAPABILITY: Continuous light duty operation with constand speed and variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOUS RATING WITH OVERLOAD CAPABILITY: continuous heavy duty with constant speed and constant load.
MN Torque curve (N curve) - MB (NB curve) - MA (NA curve).
C: Specific fuel consumption curve (NB curve)
Max. power tolerance is 5%.
Power decreases by approximately 1% every 100 m altitude and by 2% every 5°C above 25°C.
Engine power can be influenced by the type of coupling used with the cooling fan.
Important
Non-approval by Lombardini for any modifications releases the company from any damages incurred by the engine.
Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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3
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING
ROUTINE ENGINE MAINTENANCE
Caution – Warning
Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system.
AFTER THE FIRST 50 WORKING
HOURS
200
300
STANDARD OIL SUMP
ENHANCED OIL SUMP
EXTRAORDINARY MAINTENANCE
Engine oilreplacement. Oil filter replacement.
ORDINARY MAINTENANCE
OPERATION DESCRIPTION
LEVEL ENGINE LUBRICANT
COOLANT LEVEL
DRY AIR CLEANER
OIL BATH AIR CLEANER
RADIATOR EXCHANGE SURFACE
BELT FAN/ALTERNATOR STRETCH
(***)
(*)
SLEEVES
SETTING AND INjECTORS CLEANING
FUEL PIPES
RUBBER INTAKE HOSE (AIR FILTER – INTAKE
MANIFOLD)
INTERIOR RADIATOR CLEANING
ALTERNATOR AND STARTER MOTOR
ENGINE LUBRICANT
OIL FILTER
FUEL FILTER
ALTERNATOR FAN BELT
COOLANT LEVEL
PARTIAL OVERHAUL
TOTAL OVERHAUL
FUEL PIPES
RUBBER INTAKE HOSE (AIR FILTER – INTAKE
MANIFOLD)
SLEEVES
DRY AIR CLEANER EXTERNAL CARTRIDGE
DRY AIR CLEANER INTERNAL CARTRIDGE
(*)
(**)
(*) (°)
(*)
(*)
(**)
(**)
(**)
(**)
(**)
(***)
(***)
FREQUENCY x HOURS
10 200 300 600 1200 5000 10000
AFTER 6 CHECKS WITH CLEANING
AFTER 3 CHECKS WITH CLEANING
(*)
In case of low use: every year.
(**)
- In case of low use: every 2 years.
(***)
- The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates. The air filter must be cleaned and replaced more frequently in very dusty conditions.
(°) - If you are using oil of a quality lower than the prescribed one then you will have to replace it every 125 hours for the standard sump and every 150 hours for the enhanced sump.
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Maintenance - Recommended oil type - Refilling
LUBRICANT
SAE Classification
I n the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken into account.
The first number refers to the viscosity when the engine is cold (symbol W = winter), while the second considers viscosity with the engine at régime.
The criteria for choosing must consider, during winter, the lowest outside temperature to which the engine will be subject and the highest functioning temperature during summer.
Single-degree oils are normally used when the running temperature varies scarcely.
Multi-degree oil is less sensitive to temperature changes.
-
40
-
35
-
30
-
25
-
20
-
15
-
10
SAE 10W*
-
5 0
+
5
+
10
+
15
+
20
+
25
+
30
SAE 20W*
SAE 30*
SAE 40*
SAE 10W-30**
SAE 10W-40**
SAE 10W-60**
SAE 15W-40 **
SAE 15W-40 **
SAE 20W-60 **
SAE 5W-30 ***
SAE 5W-40 ***
SAE 0W-30 ***
+
35
+
40
+
45
+
50
SAE- Grade
* Mineral base
** Semi-synthetic base
*** Synthetic base
3
International specifications
They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.
A.P.I
MIL
: ( American Petroleum Institute )
: Engine oil U.S. military specifications released for logistic reasons
ACEA : European Automobile Manufacturers Association
Tables shown on this page are of useful reference when buying a kind of oil.
Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics.
Usually a specification showing a following letter or number is preferable to one with a preceding letter or number.
An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.
PETROL
A1 = Low-viscosity, for frictions reduction
A2 = Standard
A3 = High performances
ACEA Regualtions - ACEA Sequences
HEAVY DUTY DIESEL ENGINES
E1 = OBSOLETE
LIGHT DUTY DIESEL ENGINES
B1 = Low-viscosity, for frictions reduction
B2 = Standard
B3 =High performances (indirect injection)
B4 = High quality (direct injection)
E2 = Standard
E3 = Heavy conditions (Euro 1 - Euro 2 engines )
E4 = Heavy conditions (Euro 1 - Euro 2 - Euro 3 engines )
E5 =High performances in heavy conditions (Euro 1 - Euro 2 - Euro
3 engines )
API / MIL Sequences
DIESEL PETROL
API
CH-4 CG-4 CF-4 CF-2 CF CE CD CC SC SD SE SF SG SH SJ SL
MIL
L- 46152 D / E
CORRENTI - CURRENT OBSOLETI - OBSOLETE
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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3
Maintenance - Recommended oil type - Refilling
PRESCRIBED LUBRICANT
AGIP SINT 2000
TURBODIESEL
5W40
specifications
API CF - SH
ACEA B3-B4
MIL - L-2104 C/46152 D
In the countries where AGIP products are not available, use oil API CF/SH for Diesel engines or oil corresponding to the military specification MIL-L-2104 C/46152 D.
CHD ENGINES OIL CAPACITY
OIL VOLUME AT MAX LEVEL
(OIL FILTER INCLUDED)
OIL VOLUME AT MAX LEVEL
(WITHOUT OIL FILTER)
Sheet STD oil sump.
ENHANCED aluminium oil sump.
Sheet STD oil sump.
ENHANCED aluminium oil sump.
* With dynamic balancer
Litres
Litres
LDW 1503-1603
4.4
7.1
3.8
6.4
LDW 2004 - 2004/T
2204 - 2204/T
6.4 - 5.3*
9.5
5.7 - 4.5*
8.8
Important
If you are using oil of a quality lower than the prescribed one then you will have to replace it every 125 hours for the standard sump and every 150 hours for the enhanced sump.
Danger – Attention
- The engine may be damaged if operated with insufficient lube oil. It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion.
- Use proper lube oil preserve your engine. Good quality or poor quality of the lubricating oil has an affect on engine performance and life.
- If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking, and accelerated wear of the cylinder liner, bearing and other moving components increases significantly.
- Always use oil with the right viscosity for the ambient temperature in which your engine is being operated.
Danger – Attention
- The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.
- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.
- Do not disperse the oil in the ambient, as it has a high pollution power.
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Maintenance - Recommended oil type - Refilling
3
COOLANT
Danger – Attention
- The fluid coolant circuit is pressurized. Inspections must only be made when the engine has cooled and even in this case, the radiator or expansion chamber plug must be unscrewed with the utmost caution.
- If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the engine is at a standstill.
- Coolant fluid is polluting, it must therefore be disposed of in the correct way. Do not litter.
The anti-freeze protection liquid (AGIP ANTIFREEZE SPEZIAL) must be used mixed with water, preferably decalcified. The freezing point of the cooling mixture depends on the product concentration in water, it is therefore recommended to use a 50% diluted mixture which guarantees a certain degree of optimal protection. As well as lowering the freezing point, the permanent liquid also raises the boiling point.
Coolant refueling
ENGINE TYPE
LDW
1503 - 1603
LDW
2004 - 2204
LDW
2004/T - 2204/T
CAPACITY (Litres)
Without radiator
4.00
5.50
5.70
For information concerning the capacity of Lombardini radiators, please contact Lombardini directly.
The total volume for refilling the cooling liquid varies according to the type of engine and radiator.
FUEL RECOMMENDATIONS
Purchase diesel fuel in small quantities and store in clean, approved containers. Clean fuel prevents the diesel fuel injectors and pumps from clogging. Do not overfill the fuel tank.
Leave room for the fuel to expand. Immediately clean up any spillage during refueling.
Never store diesel fuel in galvanized containers; diesel fuel and the galvanized coating react chemically to each other, producing flaking that quickly clogs filters or causes fuel pump or injector failure.
High sulfur content in fuel may cause engine wear. In those countries where diesel has a high sufur content, its is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently. The regions in which diesel normally has a low sulfur content are Europe, North America, and Australia.
PRESCRIBED LUBRICANT
Fuel with low sulphur content
Fuel with high sulphur content
API CF4 - CG4
API CF
FUEL TYPE
For best results, use only clean, fresh, commercial-grade diesel fuel. Diesel fuels that satisfy the following specifications are suitable for use in this engine: ASTM D-975 - 1D or 2D, EN590, or equivalent.
FUELS FOR LOW TEMPERATURES
It is possible to run the engine at temperatures below 0°C using special winter fuels. These fuels reduce the formation of paraffin in diesel at low temperatures. If paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.
Fuel can be: - Summer up to
- Winter up to
- Alpine up to
- Arctic up to
0°C
-10°C
-20°C
-30°C
BIODIESEL FUEL
Fuels containing less than 20% methyl ester or B20, are suitable for use in this engine. Biodiesel fuels meeting the specification of BQ-9000 or equivalent are recommended. DO NOT use vegetable oil as a biofuel for this engine.
Any failures resulting from the use of fuels other than recommended will not be warranted.
EMISSION CONTROL INFORMATION
LOW SULFUR FUEL OR
ULTRA LOW SULFUR FUEL ONLY
AVIATION FUEL
Aviation fuels suitable for use in this engine include jP5, jP4, jP8 and, jET-A (if
5 percent oil is added).
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
EPA /CARB emission label must be attached near the fuel inlet.
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4
DISASSEMBLY/REASSEMBLY
RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING
Important
To locate specific topics, the reader should refer to the index.
– 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 proper repair operations.
– The operator must wash, clean and dry components and assemblies before installing them.
– The operator must make sure that the contact surfaces are intact, lubricate the coupling parts and protect those that are prone to oxidation.
– Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely.
– For safety and convenience, you are advised to place the engine on a special rotating stand for engine overhauls.
– Before proceeding with operations, make sure that appropriate safety conditions are in place, in order to safeguard the operator and any persons involved.
– In order to fix assemblies and/or components securely, the operator must tighten the fastening parts in a criss-cross or alternating pattern.
– Assemblies and/or components with a specific tightening torque must initially be fastened at a level lower than the assigned value, and then subsequently tightened to the final torque.
RECOMMENDATIONS FOR OVERHAULS AND TUNING
Important
To locate specific topics, the reader should refer to the index.
– Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely.
– The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine.
– Before carrying out any operation, clean the assemblies and/or components thoroughly and eliminate any deposits or residual material.
– Wash the components with special detergent and do not use steam or hot water.
– Do not use flammable products (petrol, diesel, etc.) to degrease or wash components. Use special products.
– Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them.
– Apply a layer of lubricant over all surfaces to protect them against oxidation.
– Check all components for intactness, wear and tear, seizure, cracks and/or faults to be sure that the engine is in good working condition.
– Some mechanical parts must be replaced en bloc, together with their coupled parts (e.g. valve guide/valve etc.) as specified in the spare parts catalogue.
Danger - Attention
During repair operations, when using compressed air, wear eye protection.
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
1
Disassembly / Reassembly
Oil-bath air cleaner
4
Danger – Attention
Never clean the filtering element 6 using solvents with a highly flash point. This could cause an explosion !
Caution – Warning
During repair operations, when using compressed air, wear eye protection.
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 25 Nm
See page 22 for periodic cleaning and oil replacement.
2
Oil-bath air cleaner components
1 Bowl
2 Outer seal ring
3 Lower 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
12 Upper filtering element (polyurethan sponge)
Note: Centrifugal pre-filter 9 is fitted upon request.
Dry air cleaner
Danger – Attention
Never clean the filtering element using solvents with a low flash point. This could cause an explosion !
A = Fitting to accomodate clogging indicator
See page 22 for periodic dry air cleaner check and replacement and the rubber intake hose (air filter - intake manifold).
3
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 27 -
4
Disassembly / Reassembly
5
7
1
2
3
9
4
6
8
1
2
3
A
4
5
4
B
Dry air components
1 Main cartridge
2 Safety cartridge
3 Axial cover
4 Vacuator valve
6
Rubber connecting hose to the air filter - manifold or compressor.
7 Air filter restriction switch
8 Mounting for clogging indicator
5 Cap complete with clamp 9 Fastener
Scavenging valve 4 must be positioned as in figure 4.
The cartridge can be cleaned by blowing compressed air breadthways outside and inside the cartridge, at a pressure not greater than 5 atmospheres, or in necessity case by knocking the front of the cartridge several times against a flat surface.
Use a lamp to check that the filter element is not damaged or inspect it against the light while slanted. In case of doubt, install a new cartridge.
Air filter clogging indicator
Important
The indicator has to be tightened to mounting 4, as shown in fig. 5 B. Due to space requirements, it can be assembled by using special fastener 3 (fig. A) and by creating a hole of
Ø14-15 mm in the rubber hose (see fig. 4).
1 Air filter restriction switch
2 Turbo adapter
3 Fastener
4 Mounting for clogging indicator
Note: There are two types: one for an aspirated engine and one for a supercharged engine.
Setting for aspirated engine(LDW 1503 - 1603 - 2004
-2204) = 635 mm column of water.
Setting for supercharged engine (LDW 2004/T - 2204/T)
= 380 mm column of water.
Intake manifold
The sealing surface should be clean, smooth and free of any strains and scoring.
When reassembly replace gasket
A.
Tighten the fastening screws to 25 Nm.
6
7
- 28 -
Exhaust manifold
Danger – Attention
Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns.
Verify that the seal surfaces are free of distortions and scratches and that the manifold is not broken in any way.
When refitting, replace gaskets B.
Tighten nuts to 25 Nm.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
8
9
Disassembly / Reassembly
4
"V" belt
Danger – Attention
Check the belt tension only when the engine is not running.
Tension adjustment:
Loosen alternator fixing bolts C.
Stretch belt so that a 100 Nm load located half-way between the two pulleys causes a 10÷15 mm flexure.
Pull strongly alternator externally and tighten fixing bolts C.
The final torque must be 40 Nm.
If you use the belt tension gauge type DENSO BTG-2, the correct value of tension must be from 20 to 25 kg.
Cooling fan
Danger – Attention
Before disassembling the cooling fan, isolate the positive battery cable to prevent accidental short-circuiting and, consequently, activation of the starter motor
Take off the fan and check that all blades are not damaged; if any are damaged, replace the entire fan.
Depending on the type of application the cooling fans can be suction or blower fans and can differ in diameter.
Driving pulley (2 a
P.T.O.)
The maximum torque that can be drawn from the second power take-off must be at maximum 70 Nm.
The driving pulley drives the alternator and the water pump and consequently the cooling fan.
Bolt D can be loosened by turning clockwise. When refitting lubricate the bolt with Molyslip and tighten it at 360 Nm.
10
Tank
Danger – Attention
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.
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.
11
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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4
Disassembly / Reassembly
12
13
14
Flywheel
Caution – Warning
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.
Remove the bolts which attach the flywheel to the crankshaft; 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 remove the starter rim, it is advisable to cut it into several parts with a hacksaw and to then use a chisel. To replace, slowly heat for
15-20 minutes to a temperature of 300°C max. Fit the rim into the flywheel housing. make sure that it rests evenly against the support of the housing itself. Allow it to slowly cool.
Rocker arm cover with vent into the air
Components:
1 - Decanting device
2 - Oil fill cap
3 - Gasket
Inside the decanting device 1 there is a small metal skein that separates the oil from the bled vapours; before reassembling it, clean it and verify its intactness.
Important
Every time the rocker arm cap is removed replace the gasket 3.
Rocker arm cover for engines with recirculating vent
Components:
1 - Recirculating vent system
2 - Oil refilling plug
3 - Rubber hose for the passage of the oil vapours
4 - Intake manifold
In the rocker arm cap we find most of the recirculating vent system 1.
This device is used to separate the oil vapours and to convey them, via a rubber hose 3, into the intake manifold 4.
The vapours are then recirculated inside the engine and not released into the air as they can be polluting.
A clogged up air filter and a consequent increase in suction vacuum could cause the oil to be sucked into the combustion chamber and the engine over-revving.
This is in any case avoided as the diaphragm valve 7 by winning the resistance of spring 6 - properly calibrated - closes duct 5 and stops the oil from reaching manifold 4 via hose 3.
15
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Disassembly / Reassembly
4
Rocker arm assemly
Loosen the screws which fasten the assembly to the head.
When refitting tighten to 50 Nm.
Inside the rocker arm pin flows the oil that lubricates the rocker arms and feeds the hydraulic tappets.
To clean the rocker-arm pin inside, remove the two tightening screws C at the ends (fig. 17).
When refitting apply a drop of Loctite 270 onto the threads.
16
To check the pin and the rocker-arm pin bearings for wear compare the measured values with the parameters in the table below.
Table of pin-rocker arm dimensions
Ref.
Dimensions
(mm)
Clearance
(mm)
Limit value (mm)
Ø A
*
Ø B
1 4 , 0 3 2 ÷ 1 4 , 0 5 0
1 3 , 9 8 9 ÷ 1 4 , 0 0 0
Ø A Ø B =
0 , 0 4 3 ÷ 0 , 0 5 0
0 .
0 1 4
*
With bushing fitted to the rocker arm and reamed.
17
Cylinder head
Caution – Warning
Do not demount when hot or the part could become deformed.
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 pictures 56÷59 (pages 39÷40) for cylinder head tightening.
18
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
20.
19 20
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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4
Disassembly / Reassembly
21
Valve spring - Check
Check the overall state of the valve springs.
Replace if damaged or if they have lost their original elasticity.
First of all, use a gauge to check that the free length matches the measurements given below.
A = 52 mm
Valve spring - check under load
Verify (with a dynamometer) that the length under load matches the nominal length.
If it is shorter than that quoted in figure 22, replace the spring.
22
23
EXHAUST VALVE
24
- 32 -
INTAKE VALVE
Valve material
Ref.
C aaaaa aaaaa
1
A
B
Dimensions
6 , 9 8 5 ÷ 7 , 0 0 m m
3 5 , 3 0 ÷ 3 5 , 5 0 m m
4 0 , 3 0 ÷ 4 0 , 5 0 m m
4 5 ° 3 0 ' ÷ 4 5 ° 4 5 '
6 0 ° 3 0 ' ÷ 6 0 ° 4 5 '
Valve guides and cylinder head
Intake and exhaust valve guides are both made of gray cast iron with pearlitic and phosphoric matirx.
Ref.
D
E
F
Dimensions (mm)
3 8 , 0 0
1 2 , 0 2 0 ÷ 1 2 , 0 3 8
1 2 , 0 4 8 ÷ 1 2 , 0 5 8
Valve guides with outside diameter F increased by 0.5 mm are available; in such case valve guide bore E should also be increased by 0.5.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
25
Disassembly / Reassembly
4
Valve guide insertion, after driving
Press guides considering the L distance from the head plane X.
Ref.
X
Y
L
A
Dimensions
(mm)
7 , 0 2 0 ÷ 7 , 0 3 5
7 , 0 2 0 ÷ 7 , 0 3 5
3 6 , 8 ÷ 3 7 , 2
6 , 9 8 5 ÷ 7 , 0 0
Ref.
Y A
X A
Clearance
(mm)
0 , 0 2 0 ÷ 0 , 0 5 0
Limit value
(mm)
0 , 1 0 0
Oil seal in the valves guides, (intake and exhaust)
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 27, making sure the seal 1 reaches its stop.
26 27
Valve seats and bore
aaaaa aaaaa
1
C
D
Ref.
A
B
Dimensions
4 1 , 5 0 0 ÷ 4 1 , 5 2 0 m m
4 1 , 5 7 5 ÷ 4 1 , 5 9 0 m m
3 6 , 5 0 0 ÷ 3 6 , 5 2 0 m m
3 6 , 5 7 5 ÷ 3 6 , 5 9 0
4 4 ° 5 3 ' ÷ 4 5 °
5 9 ° 5 3 ' ÷ 6 0 °
28
Valve recess and sealing surfaces
Ss* = Sealing surface width on exhaust side
Sa* = Sealing surface width on intake side
H = Valve recess with reference to the head plane
Ref.
S s *
S a *
H
Dimensions
(mm)
1 , 2 7 ÷ 1 , 5 5
1 , 2 0 ÷ 1 , 6 0
0 , 7 5 ÷ 1 , 0 0
Limit value
(mm)
2
1
,
,
0
3
0
0
29 30
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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4
Disassembly / Reassembly
31
33
32
34
Precombustion chamber
The precombustion chamber can be extracted from the head banging with a punch into the hole from the injector housing.
This procedure implies irreversible damages to the precombustion chamber which will have to be replaced. In the assembly stage line up the dowel 1 with the reference notch 2 located in the head.
Driving must be carried out evenly
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.
The precombustion chamber plugs of the CHD PLUS series engines have a different internal volume from the CHD series; therefore, they are not interchangeable.
Hydraulic tappet valve control
Ref.
A
B
Dimensions
(mm)
2 3 , 0 0 0 ÷ 2 3 , 0 2 1
2 2 , 9 6 0 ÷ 2 2 , 9 7 5
Clearance
(mm)
0 , 0 4 0 ÷ 0 , 0 4 6
Limit value
(mm)
0 , 1 0
Nota: If tappet is worn out along diameter B replace it.
No oversize tappets are available. If tappet/camshaft surface is worn - replace
Hydraulic diagram for feeding the tappets
1 Rocker-arm pin
2 Rocker arm
3 Push rod
4 Oil drainage
5 Hydraulic tappet
35
36
- 34 -
Hydraulic tappet components:
a) Tappet body
b) Plunger
c) Non-return valve
d) Spring
e) Push rod
f) Low-pressure chamber
g) High-pressure chamber
The hydraulic tappet is a device that enables elimination of clearance between timing system components and provides the following advantages:
- Reduces noise levels during operation.
- Reduces wear of the timing system components, thanks to there being no collisions at the opening with consequent breaking of the oil film.
- No maintenance.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
37
Disassembly / Reassembly
4
Hydraulic tappet operation
The operating principle of the hydraulic tappet is based on the incompressibility of the liquids and on controlled leakage.
Through push rod 1, the pressurised oil gets into the tappet in chamber A (low-pressure chamber), maintaining a constant flow of oil in the above chamber as well as in the high-pressure chamber B.
The oil can only enter chamber B through the non-return valve 2 and leave through the clearance between the plunger 3 and the tappet body 4 (controlled leakage).
Chamber B is refilled when the tappet is on the bottom of the cam base and spring 5 keeps plunger 3 pressed, thus eliminating the clearance in the entire valve-rocker arm-push rod-tappet-cam system.
The tappet body moves away from the plunger creating a slight vacuum in chamber B and causing the valve 2 to open, thus allowing the oil in chamber A to flow into chamber B, re-establishing the quantity of oil required for optimal running conditions.
Difficult operating conditions:
For correct functioning of the hydraulic tappets the pressure chamber of plunger 3 must always be filled with oil.
However, this is not possible in some conditions in that, when the engine is not running, oil leakages may cause partial emptying of the tappets. This situation will cause excessive clearance which will make itself apparent through an unusual ticking sound that is not to be confused with the normal ticking of the injectors.
1 - Starting from cold: the engine has not been used for some time and oil may have leaked out of the pressure chamber of the tappets. Moreover, lubricant flows with greater difficulty at low temperatures, and hence several seconds may go by before the tappets are once again supplied with oil.
2 - Engine very hot: at minimum speed, the oil pressure is low and tiny air bubbles may form inside it (more than 5% of its volume). This causes the lubricant to become compressible and the tappet is squeezed slightly creating clearance and, thus making a noise.
3 - Starting and stopping the engine repeatedly (very rare): in this situation the tappets may empty temporarily.
In all three cases the ticking should not last too long. If this is not the case, the problem is definitely due to a manufacturing fault, wear and tear or dirt, which can be drawn in by the oil and get between the non-return valve and its seat inside the plunger, thus compromising the functioning of the tappets. In this case the hydraulic tappets must be replaced.
Injection pump follower
Introduce the follower into its housing and manually turn screw 3 until it matches with notch 2.
Before locking screw 3 use your finger to check that the follower is allowed to move upwards freely.
Space 1 should be introduced into the pushrod with the flat surface facing upwards
Note: The screws 3a can be fitted without distinction in each cylinder.
Screw 3b however, which is shorter than the others, has to be fitted on the timing side of the cylinder (inside the stop lever cover).
38 39
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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4
Disassembly / Reassembly
40
42
43
45
- 36 -
41
44
46
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.
D ( m m )
8 8 , 0 0 ÷ 8 8 , 0 1 8 8 , 1 0 0
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.
Cylinder roughness
Important
Do not manually hone the cylinder bore surfaces with emery cloth or other means.
The inclination of the cross-hatched marks left by machining should range between 115°-140°; they should be uniform and clearly visible in both directions.
Average roughness should range between 0.5 and 1 mm.
The cylinder surface which comes into contact with the piston rings should be machine honed with the plateau system.
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 TURBO piston differs from that of the NATURALLY ASPIRATED
LDW in its cooling sprayer passage niche and an insert in the slot of the first ring.
Piston availability
The pistons oversized by 0.5 and 1.0 mm have the uprating reference on the crown, fig. 45-46.
Class
A
Ø Cylinder
Ø Piston Clearance
8 8 .
0 0 ÷ 8 8 .
0 1 8 7 .
9 6 0 ÷ 8 7 .
9 6 7 0 .
0 3 3 ÷ 0 .
0 5 0
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Disassembly / Reassembly
4
Piston weight
Weigh the pistons when replacing them in order to avoid unbalance.
The difference in weight should not exceed 6 g.
47
48
Piston rings - End gaps
Place piston rings into the cylinder and measure end gap
A.
1st ring
2nd ring
3rd ring
A
A
A
= 0 , 3 0
= 0 , 3 0
= 0 , 2 0
÷ 0 , 5 0 m m
÷ 0 , 5 0 m m
÷ 0 , 5 0 m m
Piston rings - Clearance between grooves
Ref.
A
B
C
NATURALLY ASPIRA-
TED LDW
0 , 0 7 ÷ 0 , 1 2 m m
0 , 0 2 ÷ 0 , 0 8 m m
0 , 0 5 ÷ 0 , 0 8 m m
LDW TURBO
A *
0 , 0 6 ÷ 0 , 9 5 m m
0 , 0 5 ÷ 0 , 0 8 m m
Piston rings - Fitting sequence
A* = 1st chrome plated compression ring *
B = 2nd tapered compression ring *
C = 3rd spiral spring oil scraper ring
* The first ring in the LDW TURBO engine is different from the
NATURALLY ASPIRATED version, it has a trapezoidal crosssection.
Assemble the segments with the TOP marking facing the piston crown
.
51
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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Disassembly / Reassembly
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 circlips 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.
52 53
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.
Perform this measurement along the engine axis.
54
55
Engine type
L D W 1 5 0 3 / 1 6 0 3
L D W 2 0 0 4
2 2 0 4
/
/
2 0
2 2
0 4
0 4
T
T
L D W 1 5 0 3 / 1 6 0 3
L D W 2 0 0 4
2 2 0 4
/
/
2 0
2 2
0 4
0 4
T
T
L D W 1 5 0 3 / 1 6 0 3
L D W 2 0 0 4
2 2 0 4
/
/
2 0
2 2
0 4
0 4
T
T
- 38 -
A (mm)
0 , 6 8 ÷ 0 , 8 3
0 , 6 8 ÷ 0 , 8 1
0 , 8 3 ÷ 0 , 9 8
0 , 8 1 ÷ 0 , 9 4
0 , 9 8 ÷ 1 , 1 0
0 , 9 4 ÷ 1 , 0 7
No.of notches
Cylinder head gasket
Caution – Warning
Remove the head gasket from its protective wrapping only when ready for fitting.
At B the gasket shows small semi-circular notches indicating thickness.
Choose the proper head gasket considering that for each value of A (maximum projection of the piston from the cylinder surface) there is a matching gasket among the three available (with no notch, one notch or two notches) to achieve a clearance volume between 0.66 and 0.90 mm.
In the LDW 1503 / 1603 engines the head gasket is made of fibre, while in the LDW 2004 / 2204-T / 2204 / 2204-T engines the head gasket is metal.
Resulting clearance (mm)
0 , 6 7 ÷ 0 , 8 2
0 , 7 2 ÷ 0 , 8 5
0 , 6 7 ÷ 0 , 8 2
0 , 6 9 ÷ 0 , 8 2
Note: The notches shown above protrude from the cylinder head plane; you can thus determine the gasket thickness before taking down the head.
0 , 6 7 ÷ 0 , 8 2
0 , 6 6 ÷ 0 , 7 9
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Disassembly / Reassembly
4
Cylinder head tightening for engines without hydraulic tappets
Use a torque wrench (fitted with tool for angular tightening).
It is recommended to replace the screws whenever the head is disassembled.
Important
The cylinder head must never be retightened.
It is advisable to lubricate the lower part of the screws with anti-seize of the type MOLYSLIP AS COMPOUND 40.
56
LDW 1503
1603
Cylinder head tightening steps
Following the number sequence shown in the figure 57 bolts should 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 = For bolts 10 R: Rotate wrench by 180° (in two steps 90°+90°)
For bolts 12 R (present only in the TURBO engines): perform a rotation of the key of 270° (in three steps, 90° + 90°+ 90°).
LDW 2004
2004/T
2204
2204/T
57
Assembling and tightening the cylinder head on engines with hydraulic tappets
Important
Before re-assembling the cylinder head the tappets must be removed from their housing and released.
58
This operation must be carried out using a pin 1.
Insert pin 1 inside the tappet and open the non-return valve.
The excess oil is released by turning the tappet upside down.
Rotate the crankshaft so as to position the pistons at half stroke for three-cylinder engines.
For four-cylinder engines, place the piston of cylinder number one at 150° after the top dead centre (in crossover stage).
Fit the head, insert the fastening screws and tighten them in the order shown in figure 57 and to their respective torques (see
“Cylinder Head Tightening Stage).
Reassemble the complete pin inserting the seats of the rocker-arms on their respective rods and screw up the fastening screws of the supports by hand.
Important
To avoid bending the push rods or damaging the tappets, the fastening screws of the rocker-arm pin supports must be tightened gradually before reaching the final torque.
This procedure will give time for the excess oil in the tappets to drain away.
Each time you start to tighten up the fastening screws of the supports, you can use the upper spring support cup of the valve spring as an indicator to know how far to screw them up.
The cup must never be compressed so much that it touches the valve stem oil sealing ring fitted on the guide.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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4
Disassembly / Reassembly
LDW 1503
1603
LDW 2004
2004/T
2204
2204/T
59
Tightening must be carried out as shown in figure 59.
Once the final torque 50 Nm is reached, wait thirty minutes before manually rotating the engine to verify that the pistons do not collide with the valves, if the engine turns freely start the engine normally, otherwise wait another 30 minutes before repeating the operation.
At first start-up the engine may run irregularly until all the air contained in the tappets has been drained.
60 61
Connecting rod
Important
When remounting the big-end bearings, remember to thoroughly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the first time.
Remove oil pan and oil pump suction pipe.
Disconnect the connecting rod from the engine shaft and perform the subsequent checks.
When refitting both centering notches A and B should be located on the same side.
Tighten the connecting rod big end bolts to 70 Nm.
Connecting rod weights
Connecting rod, piston and piston pin can also be weighed in a preassembled state but the difference in weigt should not exceed 14 g in order to avoid unbalance.
62 63
LDW
1503-2004-2004/T
LDW
1603-2204-2204/T
LDW
2004/T-2204/T
LDW
1503-1603
2004-2204
Connecting rod and piston pin
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.
Important
The fastening screws must be tightened by hand until the beginning of the tightening stage and then pre-tightened to
10÷15 Nm.
Final tightening is to 70 Nm.
64
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Ref.
E
G
C * *
D
A
F
B *
Dimensions
(mm)
1 4 4 , 9 8 ÷ 1 4 5 , 0 2
1 4 7 , 9 8 ÷ 1 4 8 , 0 2
2 8 , 0 2 ÷ 2 8 , 0 3
5 3 , 6 8 9 ÷ 5 3 , 7 0 8
2 7 , 9 9 5 ÷ 2 8 , 0 0 0
6 2 , 1 ÷ 6 2 , 3
6 5 , 6 ÷ 6 5 , 8
Disassembly / Reassembly
4
B
Ref.
D
Clearance (mm)
0 , 0 2 ÷ 0 , 0 3
Limit value (mm)
0 , 0 6
* With driven and bored bearing.
** With cap fitted and screws tightened to a torque of 70 Nm.
Connecting rod alignment
Use a surface plate and a dial gauge as shown in the figure 65.
Check the alignment of the axes using the wrist pin of the piston; deviation A = 0.02 mm; limit = 0.05 mm
Moderate warpage may be corrected by gradually working with a press.
65
66 67
Piston cooling sprayer
This is assembled on turbo engines LDW 2004/T -2204/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 figure 67.
Anyway the correct position is ensured by the fixing screw.
Ref.
aaaaa
D
Dimensions
3 °
2 8 °
2 8 m m
Connecting rod/piston assemblies
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.
68 69
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
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4
Disassembly / Reassembly
70
Center main bearings
The main bearing caps and the crankcase have reference holes marked on them (one, two or three).
Important
In the assembly stage make sure that the number of holes on the bearings matches those on the crankcase and that they are on the same side.
The main bearing, the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for
LDW1503, from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004/T.
Pre- and post-modification single parts are not interchangeable.
71 72
Main bearing caps timing side - flywheel side
When refitting rear flywheel side main bearing cap 1, replace the 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 timing side main bearing cap.
To introduce the supports complete with silicone rubber seals 2 into the crankcase place two plates C and D measuring 0.1 mm in thickness between the surfaces.
Tighten the screws to 120 Nm.
The main bearing, the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for
LDW1503, from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004/T.
Pre- and post-modification single parts are not interchangeable.
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
73 74
Disassembly / Reassembly
4
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 120 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 fig 79.
Important
When replacing bearings make sure that the lower half is kept separate from the upper one.
75
LDW
1503/2004
LDW
1603/2204
2004-T/2204-T
Thrust bearings
The main bearing, the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for
LDW1503, from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004/T.
Pre- and post-modification single parts are not interchangeable.
76
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4
Disassembly / Reassembly
Grease the shoulder half-rings so that they will remain in their seats during assembly.
Halves should be fitted with grooves A as shown in the figure
77-78.
Thrust bearing thickness = 2.31÷2.36 mm; oversize halves with thickness increased by 0.1 and 0.2 mm are available as spares.
77
79
78
Thrust bearing, oversizes
Grinding B according to the above table, following half-rings can be assembled:
1 st
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.
80
S t a n d a r d
1st Oversize
2nd Oversize
3rd Oversize
C
2 7 .
7 7 ÷ 2 7 .
9 2
2 7 .
9 7 ÷ 2 8 .
1 2
2 8 .
0 7 ÷ 2 8 .
2 2
2 8 .
1 7 ÷ 2 8 .
3 2
B
(fig. 82)
2 8 .
0 0 ÷ 2 8 .
0 5
2 8 .
2 0 ÷ 2 8 .
2 5
2 8 .
3 0 ÷ 2 8 .
3 5
2 8 .
4 0 ÷ 2 8 .
4 5
A
(fig. 81)
0 .
0 8 ÷ 0 .
2 8
81
- 44 -
82
Crankshaft end play
After tightening main bearings measure the end play A between the crankshaft shoulder on the flywheel side and main bearing halves.
Ref.
A
B
Clearance
(mm)
0 .
0 8 ÷ 0 .
2 8
2 8 .
0 0 ÷ 2 8 .
0 5
If the end play does not fall within the given values check B and possibly fit the oversize thrust bearings.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
83 84
Disassembly / Reassembly
4
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.
Warning: In case of room temperature below -35°C seals could become damaged.
Crankshaft timing gear
If gear A has to be replaced, use a bearing puller to remove it.
To reassemble it, you need to heat it up to a temperature of 180°
÷ 200°C and then fit it snugly.
85
Crankshaft lubrication ducts
Important
During repair operations, when using compressed air, wear eye protection.
Dip crankshaft into a bath (use a cleaning product).
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.
86
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4
Disassembly / Reassembly
Checking main journals and crank pins
Use an outside micrometer gauge.
The main bearing, the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for
LDW1503, from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004/T.
Pre- and post-modification single parts are not interchangeable.
87
88
Main journal and connecting rod big end journal diameter
Ref.
A
B
1 5 0
L D
3 / 2 0 0 4
W
/ 2 0 0 4 T
Dimensions (mm)
1 6 0
L D
3 / 2 2 0 4
W
/ 2 2 0 4 T
Pre-modification Post-modification Dimensions (mm)
5 7 , 9 8 0 ÷ 5 8 , 0 0 0 5 9 , 9 8 1 ÷ 6 0 , 0 0 0 5 9 , 9 8 1 ÷ 6 0 , 0 0 0
4 9 , 9 8 9 ÷ 5 0 , 0 0 0 4 9 , 9 8 4 ÷ 5 0 , 0 0 0 4 9 , 9 8 4 ÷ 5 0 , 0 0 0
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.
Main bearing and connecting rod big bearing inside diameter (mm)
See fig. 73 and 74 (page 43) 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.
89
- 46 -
Ref.
L D W
1 5 0 3 2 0 0 4 2 0
Dimensions
0 4 / T
Pre-modification Post-modification
E
F
5 8 , 0 4 1 ÷
Ref.
Clearance
5 8 , 0 9 1
Limit value
E B
0 , 0 3 5 ÷ 0 , 0 7 7 0 , 1 5 0
F A
0 , 0 4 1 ÷ 0 , 1 1 1 0 , 2 0 0
5 0 , 0 3 5 ÷ 5 0 , 0 6 6
5 9 , 0 4 ÷
Clearance
5 9 , 9 6 9
Limit value
0 , 0 3 5 ÷ 0 , 0 7 7 0 , 1 5 0
0 , 0 3 1 ÷ 0 , 0 9 6 0 , 2 0 0
L D W
1 6 0 3 2 2 0 4 2 2
Dimensions
0 4 / T
5 9 , 0 4 ÷
Clearance
5 9 , 9 6 9
Limit value
0 , 0 3 5 ÷ 0 , 0 7 7 0 , 1 5 0
0 , 0 3 1 ÷ 0 , 0 9 6 0 , 2 0 0
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
90
Disassembly / Reassembly
4
Crankshaft for engines with dynamic equalizer (only fourcylinder engines).
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
Ref.
Dimensions (mm)
L
M
1 3 2 .
0 0 ÷ 1 3 2 .
0 3
1 3 2 .
0 7 ÷ 1 3 2 .
0 9
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.
91
Dynamic balancer (on request) - Adjustment of clearance between teeth D and ring gear A
Follow figures 91 and 92.
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.
Remove screw
B.
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.
92
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4
Disassembly / Reassembly
93
95
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.
94
Idler gear and hub
Components:
1 Idle wheel
2 Hub
3 Thrust washer
4 Fitting
5 Oil seal ring
6 Bushing lubrication hole
Note: Unscrew fitting 4 clockwise and when refitting it to 150
Nm.
96
Clearance
(A-B) mm
0 , 0 2 5 ÷ 0 , 0 6 1
End play
(mm)
0 , 1 0 ÷ 0 , 3 0
Worn limit
(A-B) mm
0 , 1 2 0
Worn limit
(A-B) mm
0 , 6 0
Ref.
C
D
A
B
Dimensions
(mm)
3 6 , 0 0 ÷ 3 6 , 0 2
3 5 , 9 5 9 ÷ 3 5 , 9 7 5
1 , 9 5 ÷ 2 , 0 5
0 , 9 6 ÷ 1 , 0 0
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
97
99
98
Disassembly / Reassembly
4
Speed governor
Important
During reassembly, make sure the components are undamaged and verify they work properly.
Malfunctioning of the speed governor can cause serious damage to the engine and to people in the vicinity of it.
Components:
1 Gear
2 Bell
3 Counterweights
4 Bolt
5 Throttle control rod
6 Governor spring
7 Injection pump delivery rod
8 Yoke 9 adjustement eccentric
9 Control yoke for injection pump delivery rod
10 Bushing
11 Lever
12 Adjusting screw.
Yoke 9 is pre-set through screw 12 and eccentric 8.
Do not unscrew.
When refitting camshat gear 1 tighten bolt 4 to 100 Nm.
Dimensions for injection pump delivery control yoke adjustement
Components:
9 Control yoke for injection pump delivery rod
10 Bushing
11 Lever
12 Adjusting screw
13 Reference and mounting plane for support 14
14 Lever Support
Ref.
A
C
D
Dimensions (mm)
1 0 , 8 m m
1 3 , 4 m m
8 8 m m
Note: If, when adjusting, screw 12 is unintentionally loosened adjust yoke 9 considering the dimensions A, C and D.
In case of replacement lever preset yoke 9.
11 is supplied complete with
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4
Disassembly / Reassembly
100
Camshaft gear - Speed governor counter weights
Components:
1 Camshaft gear
2 Governor weights
3 Governor weight support
4 Governor weight pin
The governor weights 2 are housed inside the camshaft gear 1.
The weights 2 can be of two types: light or heavy, depending on the speed rate and the type of application.
Heavy weights for engines set to run at low rpm (1500 - 1800 rpm and agricultural applications), light weights for engines set to run at high rpm (2200 - 3000 rpm).
Speed governor counter springs
Besides the weights used according to the speed rate and application type, different types of springs with different features are used as well.
Components:
1 Camshaft gear
6 Speed governor springs
101
102
103
- 50 -
Components:
1 Limiting device / torque gearing device
2 Maximum rpm adjustment screw
3 Minimum rpm adjustment screw
4 Camshaft gear
5 Governor weight
6 Speed governor spring
For engines used on generating sets it is preferable to fit a single spring 6 to act against the heavy governor weights to avoid hunting with variations in the load and to achieve a more constant frequency over time.
Frame with idling speed governor spring
Engines for applications requiring a certain power capacity at low speeds are fitted with the frame 2 complete with the idling speed spring which allows satsifying the above described requirements without the engine tending to stop.
Components:
1 Rocker arm with speed governor springs.
2 Frame for idling speed spring
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Disassembly / Reassembly
4
Summary tables of the governor equipment according to the speed variation.
rpm
1 5 0 0
1 5 0 0
1 8 0 0
1 8 0 0
2 0 0 0
2 2 0 0 2 9 0 0
2 8 0 0
3 0 0 0
* Idle frame
** Anti-hunting
L D W 1 5 0 3 1 6 0 3
Weight type N.Spring Spring serial number
Duty
1 5 6 5 5 3 7 0
Duty
2 5 6 5 5 1 5 4 / 5 6 5 5 1 5 6 * *
Duty
Duty
Light
1
2
2
5 6 5 5 3 7 0
5 6 5 5 1 5 4 * *
5 6 5 5 1 3 5
Light
2 5 6 5 5 1 3 5
Duty
2 5 6 5 5 4 0 5
Light
2 5 6 5 5 1 2 9 / 5 6 5 5 1 3 5
rpm
1 5 0 0
1 5 0 0
1 8 0 0
1 8 0 0
2 0 0 0
2 2 0 0
2 5 0 0
2 8 0 0
3 0 0 0
* Idle frame
** Anti-hunting
L D W 2 0 0 4 2 2 0 4 2 0 0 4 / T 2 2 0 4 / T
Weight type
N.Spring Spring serial number
Duty
1 5 6 5 5 3 7 0
Duty
2
5 6 5 5 1 5 4 / 5 6 5 5 1 5 6
* *
Duty
1 5 6 5 5 3 7 0
Duty
2
Light
Light
Duty
Duty
Light
2
2
2
2
2
5 6 5 5 1 5 4
* *
5 6 5 5 1 3 5
5 6 5 5 1 2 9 / 5 6 5 5 1 3 5
5 6 5 5 1 2 9 *
5 6 5 5 4 0 5
5 6 5 5 1 2 9 / 5 6 5 5 1 3 5
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.
104
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.
105
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 51 -
4
Disassembly / Reassembly
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 (pic. 109 and 110) and replace.
106
107
108
109
- 52 -
110
Camshaft journals and bushings in model LDW 1503
Ref.
Dimensions
(mm)
Clearance
(mm)
(A-B) (C-D)
Worn limit
(mm)
(A-B) (C-D)
C
D
A
B
4 3 .
0 0 0 ÷ 4 3 .
0 2 5
4 2 .
9 4 0 ÷ 4 2 .
9 6 0
4 2 .
0 0 0 ÷ 4 2 .
0 2 5
4 1 .
9 4 0 ÷ 4 1 .
9 6 0
0 .
0 4 0 ÷ 0 .
0 8 5 0 , 1 6
Note: A and C values refer to driven in and bored bushings.
Camshaft journals and bushings in models LDW 2004-2004/T
A
B
C
D
E
F
Ref.
Dimensions
(mm)
4 4 .
0 0 0 ÷ 4 4 .
0 2 5
4 3 .
9 4 0 ÷ 4 3 .
9 6 0
4 3 .
0 0 0 ÷ 4 3 .
0 2 5
4 2 .
9 4 0 ÷ 4 2 .
9 6 0
4 2 .
0 0 0 ÷ 4 2 .
0 2 5
4 1 .
9 4 0 ÷ 4 1 .
9 6 0
Clearance (mm)
(A-B) (C-D) (E-F)
0 .
0 4 0 ÷ 0 .
0 8 5
Worn limit (mm)
(A-B) (C-D) (E-F)
0 , 1 6
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
Important
Before driving in the bushing, position it in such a way that the lubricating hole maiches with the hole in the crankcase.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
111
A1 =1
A2 = 2 st
A3 = 3
cyl. intake cam nd rd
cyl. intake cam
cy intake cam
A4 = 4 th
cyl intake cam
Disassembly / Reassembly
4
Intake, exhaust and injecton cam height for model LDW
1503
A ( m m )
L D
L D
W
W
1 5 0 3
2 0 0 4
L D W 2 0 0 4 / T
Limit value
(mm)
3 6 .
0 5 8 ÷ 3 6 .
1 2 0
3 5 .
5 4 ÷ 3 5 .
6 0
S ( m m ) I ( m m )
3 5 .
6 2 ÷ 3 5 .
6 8 3 3 .
8 5 ÷ 3 3 .
9 0
3 5 .
2 4 ÷ 3 5 .
3 0 3 3 .
8 5 ÷ 3 3 .
9 0
0 , 4
S1 = 1
S2 =2 st
cyl exhaust cam nd
cyl exhaust cam
S3 = 3 rd
cyl exhaust cam
S4 = 4 th
cyl exhaust cam
I1 = 1
I2 = 2
I3 = 3 st nd rd
cyl injection cam
cyl injection cam
cyl injection cam
4 = 4 th
cyl injection cam
Intake, exhaust and injection cam height for models LDW
2004- 2004/T
A ( m m )
3 5 .
4 4 ÷ 3 5 .
5 0
S ( m m )
3 5 .
1 4 ÷ 3 5 .
2 0
I ( m m )
3 3 .
9 5 ÷ 3 4 .
0 0
112
A1 =1 st
A2 = 2
cyl. intake cam nd
A3 = 3 rd
A4 = 4 th
cyl intake cam
cyl intake cam
cyl intake cam
S1 = 1 st
S2 =2 nd
S3 = 3
S4 = 4
cyl. exhaust cam
cyl exhaust cam rd
cyl exhaust cam th
cyl exhaust cam
I1 = 1
I2 = 2
I3 = 3
I4 = 4 st
cyl. injection cam nd
cyl injection cam rd th
cyl injection cam
cyl injection cam
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 53 -
4
Disassembly / Reassembly
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.
113
114
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.
Mark the idler gear with camshaft and timing gear.
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
α
(intake valve opening advance referred to top dead center S) and
β
(intake valve closing delay referred to bottom dead center I).
Follow the same procedure for exhaust valves checking valve opening advance )and
γ
(exhaust
δ
( exhaust valve closing delay).
115
- 54 -
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Disassembly / Reassembly
4
Engines with mechanical tappets
Timing angles for checking puposes
(valve clearance = 2 mm)
α
= 14° after S (corresponding to 35 mm on the flywheel)
β
= 6° after I (corresponding to 15 mm on the flywheel)
γ
= 17° before I (corresponding to 43 mm on the flywheel)
δ
= 15° before S (corresponding to 38 mm on the flywheel)
Timing angles for operating purposes
(valve clearance 0.15 mm)
α
= 14° before S (corresponding to 35 mm on the flywheel)
β
= 34° after I (corresponding to 85 mm on the flywheel)
γ
= 46° before I (corresponding to115 mm on the flywheel)
δ
= 14° after S (corresponding to 35 mm on the flywheel)
Timing angles for checking purposes LDW 2004/T
(valve clearance 2 mm)
α
= 15° after S (corresponding to 38 mm on the flywheel)
β
= 21° after I (corresponding to 52 mm on the flywheel)
γ
= 31° before I (corresponding to 77 mm on the flywheel)
δ
= 13° before S (corresponding to 32 mm on the flywheel)
Timing angles for operating purposes LDW 2004/T (valve clearance 0.15 mm)
α
= 12° before S (corresponding to 30 mm on the flywheel)
β
= 48° after I (corresponding to 120 mm on the flywheel)
γ
= 58° before I (corresponding to 145 mm on the flywheel)
δ
= 14° after S (corresponding to 35 mm on the flywheel)
Legend
S = piston at top dead centre
l = piston at bottom dead centre
α = intake valve open
β = intake valve closed
γ = exhaust valve open
δ = exhaust valve closed
116
Engines with hydraulic tappets
Timing belt operating angles (with valve clearance set to zero)
Intake Exhaust r.p.m.
Engine type under
2400 r.p.m.
L
L
L
L
D
D
D
D
W
W
W
W upper
2400 r.p.m.
L
L
L
L
D
D
D
D
W
W
W
W under/upper
2400 r.p.m.
L
L
D
D
W
W
1 5 0 3
1 6 0 3
2 0 0 4
2 2 0 4
1 5 0 3
1 6 0 3
2 0 0 4
2 2 0 4
2 0
2 2
0 4 / T
0 4 / T
α
β
α
β
α
β
= 8° before
= 28° after
= 12° before
= 36° after
= 48° after
I
I
I
S
= 12° before
S
S
γ
δ
γ
δ
γ
δ
= 36° before
= 8° after
S
= 48° before
= 12° after
= 14° after
S
= 58° before
S
I
I
I
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 55 -
4
Disassembly / 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 0,008 mm (ball bearing end play).
117
118
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 torque does not exceed 40 Nm.
The gear ratio between engine r.p.m. and 3rd and 4th p.t.o. is
1:1.
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
119
- 56 -
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Disassembly / Reassembly
4
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 57 -
5
TURBOCHARGER
120
122
123
- 58 -
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. 120) and for air intake on fan side
(fig.121).
121
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, 120 and 121.
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
(Waste gate).
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
124
5
Checking actuator setting - "Waste gate" valve control rod stroke adjustment
Important
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.
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 59 -
6
LUBRICATION SYSTEM
Danger – Attention
The engine may be damaged if operated with insufficient lube oil. It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion.
Use proper lube oil preserve your engine. Good quality or poor quality of the lubricating oil has an affect on engine performance and life.
If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking, and accelerated wear of the cylinder liner, bearing and other moving components increases significantly.
Always use oil with the right viscosity for the ambient temperature in which your engine is being operated. Use the chart when chosing your engine oil.
Danger – Attention
The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.
If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.
Do not disperse the oil in the ambient, as it has a high pollution power.
16
8
LUBRICATION SYSTEM LAYOUT
1
2
9
3
10
15
4
5
11
12
13
6
14
125
Components:
1) Oil fill cap
2) Rocker arm shaft
3) Oil filter
4) Main journal
5) Connecting rod journal
- 60 -
7
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) Hydraulic tappet
16) Turbocharger (LDW 2004/T-2204/T)
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
126 127
Lubrication system
6
Oil pump
Components:
1 Suction port
2 Delivery port
5 External rotor
6 Internal rotor
3 Oil pressure adjusting Valve port 7 Key
4 Gasket
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 129; its value is 0.150 mm; worn limit clearance 0.280 mm.
128 129
Oil pressure adjusting valve
Components:
1 Valve
2 Spring
3 Gasket
4 Plug
Length of spring A = 45.5 ÷ 46.0 mm.
Blow compressed air into the valve seat and carefully clean all components; using a caliper measure the length of spring A.
130 131
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 µm
132
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 61 -
6
Lubrication system
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.
133
134
136
138
- 62 -
Oil pressure curve for LDW 1503 - 1603
Fig. 134 - The curve is obtained at the oil filter level constant engine speed of 850 rpm in no-load conditions.
Fig. 135 - The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power.
135
Oil pressure curve for LDW 2004 - 2204
Fig. 136 - The curve is obtained at the oil filter level constant engine epeed of 850 rpm in no-load conditions.
Fig. 137 - The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power.
137
139
Oil pressure curve for LDW 2004/T - 2204/T
Fig. 138 - The curve is obtained at the oil filter level constant engine epeed of 850 rpm in no-load conditions.
Fig. 139 - The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power.
Note: The max lubrication oil temperature must be lower than the sum: ambient temperature + 95°C.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Lubrication system
6
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 63 -
7
COOLING SYSTEM
Danger – Attention
- The fluid coolant circuit is pressurized.
- Inspections must only be made when the engine has cooled and even in this case, the radiator or expansion chamber plug must be unscrewed with the utmost caution.
- If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the engine is at a standstill.
- Coolant fluid is polluting, it must therefore be disposed of in the correct way. Do not litter.
COOLING SYSTEM LAYOUT
5
1
9
6
2
3
10
7
4
8
140
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) Temperature sensor
10) Heat exchanger (LDW 2004/T - 2204T).
- 64 -
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Cooling system
7
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.
141
142
143 144
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 142.
Compress air at a pressure of 1 bar for approximately 2 minutes.
Check that no leaks occur.
Caution – Warning
In very dusty working conditions verify and clean the outside of the radiator frequently.
Replace coolant as specified on page 22.
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 - 1603 - 2004 - 2204:
The ratio between the pump and engine rpm = 1:1.2
Pump delivery at 3000 rpm is 70 liters/min.
LDW 2004/T - 2204/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.
145 146
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 65 -
8
FUEL SYSTEM
147
148
149
150
- 66 -
Fuel feeding/injection circuit
Components:
1 - Tank
2 - Fuel feeding pump
3 - Fuel filter
4 - Fuel delivery tube
5 - Injector pumps overflow tube
6 - Injection pump
7 - High-pressure tube between pump and injector
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:.....................PF 904
Filtering area:.......................5000 cm2
Filtering degree:...................2/3 m
Max. working pressure: .......4 bar
See page 22 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.
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
(on the bottom of the cam base of the camshaft).
Push rod length = 32.5÷32.7 mm.
Check push rod length and replace push rod if size is inadequate.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Support clump
151
Intake side
Fuel system
8
Electric fuel pump (24V)
The use of the electric pump is foreseen for certain applications
(where the engine has to be started at very low temperatures).
Assembly notes:
When the electric fuel pump is installed in a diesel engine, it is necessary to:
1) Remove the filter fitted at the pump intake (intake side).
2) Insert the prefilter upstream of the pump (intake side).
3) The electric pump on the application must be at such a height from the minimum tank level that it generates a maximum pressure drop equal to a column of 500 mm of water.
4) Avoid running dry due to emptying of the intake pipeline, inserting a non-return valve.
Features:
Pressure: 0.44 / 0.56 bars
Max capacity: 100 l/h
152
Injection pump
The injection pump of a simplified Q type has been designed by
LOMBARDINI for installation on engines of the CHD series.
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 between injector and pump A feature the same shape and dimensions.
Features
Pumping
Sealing
valve
L D W 1 5 0 3 2 0 0 4 L D W 1 6 0 3 2 2 0 4 L D W 2 0 0 4 / T 2 2 0 4 / T
Ø 6 m m Ø 7 m m Ø 7 m m
Volume 25 mm
3
1 hole Ø 0,81
Volume 25 mm
3
1 hole Ø 0,81
Volume 25 mm
3
3 holes Ø 1,5
153
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.
Injection pump components:
1 Delivery union
2 Spacer
3 Spring
4 Gasket
6 Gasket
7 Cap
5 Delivery valve
8 Spring
9 Upper cap
10 Plunger pumping
11 Lever
12 Pin
13 Body
A Fuel feed union
B Fuel dischrge union
C Pump flange
D Barrel pumping
E Fuel control helix
Note: Union A and B, flange C and barrel D form an integral part of the pump body.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 67 -
8
Fuel system
154
155
157
159
- 68 -
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. 154
Tighten delivery union to 35 Nm; it is essential to use a torque wrench.
156
Tool serial number
7107.1460.212
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.
To replace the outlet union with non-return ball valve on QLC type injection pumps (having inlet and outlet unions pressure-fitted on the pump case) use the special tool serial number 7107.1460.212.
Tool B is required for removal of valve A, tool C for driving.
Injection pump control rod
Caution – Warning
Do not unscrew ring nut 2 before removing rod 1.
Control rod 1, operated by the throttle and governed by the speed governor, controls the injection pump.
Ring nut 2 keeps rod 1 in the required position by means of groove 3.
158
160
How to remove injection pump feeding tubes
Caution – Warning
Cutting the pipe in the opposite direction to the arrow A
(horizontally) damages the pump coupling with consequent leakage of fuel.
Cut the nylon tube at
A.
Remove the portion left inside the union using pliers.
Remove the nylon tube without damaging the union seals as shown in the figure 159.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Fuel system
8
How to reassemble injection pump feeding tubes
1 Pliers for 6 mm diam. tubes (intake) - Part No. 7104-1460-
022
2 Pliers for 8 mm diam. tubes (discharge) - 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.
The nylon tubes can no longer be used after disassembly.
Replace them every time they are removed.
161 162
Instrument for equalizing injection pump delivery
Part No. 7104-1460-090
Components:
1 Tank
3 Support
2 Test tube
4 Switching lever
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. 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.
163
Injection pump delivery equalization.
After checking the injection advance go ahead with the delivery balancing of the pumps.
Before connecting the tool serial number 7104-1460-090 to the pumps and refilling tank 1 with fuel, set it to a higher level of at least 200 mm than that of the pumps themselves.
Open taps
5 and 6 and start the engine, set the engine to an idling speed of 2000 rpm. Switch the engine feed from tank 1 to the tubes
2 using the switching lever 4 fig. 163.
After the first minute (minimum testing time), verify that the level between the highest and lowest levels in the tubes is not more than 2 cm³.
At this point, it is possible to either reduce the delivery of the
164
pump that consumes most (tube with the lowest level) or increase the delivery of the pump that consumes the least (tube with the highest level).
To vary the delivery of the pumps, rotate slightly in one direction or the other at the injection pumps.
Unscrew the fastening screws of the pump to be adjusted by a quarter of a turn.
Rotating clockwise the delivery is increased, anti-clockwise the delivery is reduced.
Once adjustment is finished, tighten the fastening screws to 25 Nm.
Important
Whenever an injection pump is disassembled or replaced, delivery balancing must be carried out.
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:
- Make a reference marking on the fastening flanges of the injection pumps and on the base planes of the crankcase.
- 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.
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Fuel system
165
Injection pump P. No. 6590-249 - Plunger and barrel assembly
Components:
1 Pump body
2 Barrel
3 Plunger
4 Plunging blade
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.
Checking injection pump delivery
Components:
1 Delivery adjustment rod
2 Rod 1 stop position
3 Rod 1 max. delivery position
A =18.5÷19.5 mm (rod max. stroke)
α
= 66° (rod max. rotation)
166
Control rod
max. force
Newton
0 , 3 5
Rod stroke from max. delivery point (mm)
9
0
Test data of injection pump
Camshaft
rpm
1
5
1
5
0
5
0
0
0
0
LDW 1503-2004
Delivery mm
3
/stroke
LDW 1603-2204
Delivery mm
3
/stroke
3 0
2 5
5 6
÷
÷
÷
4
3
6
0
5
6
3 1
2 3
5 6
÷
÷
÷
4
3
6
1
3
6
LDW
2004/T-2204/T
Delivery mm
3
/stroke
4 0 ÷ 4 8
2 0 ÷ 2 8
5 8 ÷ 6 4
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Fuel system
8
Checking low pressure injection timing for engines with hydraulic tappets
1 2 °
1 1 °
1 0 °
9 °
8 °
7 °
6 °
5 °
4 °
3 °
1 6 °
1 5 °
1 4 °
1 3 °
167
aaaaa
1 5 0 3 2
L D
0
( m
0
W
4 m
2 0
)
0 4 / T
2 , 1 2
1 , 8 6
0 , 8 3
0 , 6 7
0 , 5 3
0 , 4 1
0 , 3 0
1 , 6 3
1 , 4 0
1 , 2 0
1 , 0 1
0 , 2 1
0 , 1 3
0 , 0 7
1 6 0 3 2
L
2
D
0 4
( m m
W
2 2
)
0 4 / T
2 , 2 7
2 , 0 0
0 , 8 9
0 , 7 2
0 , 5 7
0 , 4 3
0 , 3 2
1 , 7 4
1 , 5 0
1 , 2 8
1 , 0 8
0 , 2 2
0 , 1 4
0 , 0 8
To verify the delivery starting point, the first operation to carry out is to disconnect the nylon tubes at the inlet
4 and outlet 3 of every injection pump.
Then, disassemble the air filter, the intake manifold and the rocker arm cap.
Now disassemble the whole rocker-arm pin and, after removing the push rods, reassemble it.
Screw the special tool 1 serial number 7107-1460-075 (fig. 167) onto the head, making sure the dial indicator tracer 5 sets against the upper spring bearing ring of the intake valve.
Use a provisional fuel tank (e.g. delivery balancing tool) to gravityfeed the injection pump connecting it to the inlet union
4; on the outlet union 3 fit the transparent nylon tube 6 by the means of which we measure the overflow.
Place the pump control rod in the stop position.
Operate the lever 2 of the tool to rotate the crankshaft until the valve touches the piston crown.
This procedure determines the exact TDC (top dead centre of the piston) of the cylinder in question; reset the dial indicator in this position.
Then rotate clockwise the crankshaft on the flywheel side until diesel fuel begins to flow out of the small hose on the pump outlet.
Now change the rotation direction to anticlockwise.
The flow diminishes.
As soon as it stops flowing, the delivery starting point is determined.
Then, lower the tool lever to make contact between the valve and the piston crown and, using the dial indicator
5, measure how much lower the piston is with respect to the TDC (top dead centre) in mm.
Use the transformation chart (mm to degrees) to find out the correspondence between mm measured with the dial indicator 5 and degrees.
Example
LDW 1503-2004-2004/T: an advance of α=15° corresponds to a lowering of the piston with respect to the TDC
(top dead centre) of 1.86 mm.
The same operation must be carried out on each pump.
The difference in adjustment must be limited to about 1°.
Disassemble the various equipment, remove the rocker-arm pin and put back the push rods in their seats.
Then re-assemble the rocker-arm pin.
Rotate the crankshaft so as to position the pistons at half stroke for three-cylinder engines.
For four-cylinder engines, place the piston of cylinder number one at 150° after the top dead centre (in crossover stage).
The rocker-arm pin must be fastened in different stages so as to allow the oil inside the tappets to be drained, thus allowing them to position themselves correctly.
Oil density and ambient temperature are important factors that will affect the waiting time (about 10') between successive fastening operations.
Hurried fastening can cause serious damage to the engine.
As a guideline to each fastening operation, make sure that the cup of the upper spring bearing ring does not touch the valve stem oil sealing ring fitted on the guide.
The final torque of the rocker-arm pin is 50 Nm.
Reassemble the rocker-arm cap and the intake manifold, tightening the screws to the indicated torque.
Engine type
L D
L D
L D
L D
W
W
W
W
L D
L D
W
W
1 5 0 3
1 6 0 3
2 0 0 4
2 2 0 4
2 0
2 2
0 4 / T
0 4 / T
Injection timing value for
r.p.m. ≥ 2400
Injection timing value
for r.p.m. ≤ 2400
1 3 ° ± 1 °
7 ° ± 1 °
1 1 ° ± 1 °
4 ° ± 1 °
Checking low pressure injection timing for engines with mechanical tappets
The check of the advance on engines with mechanical tappets is carried out using the same procedure as that described for the hydraulic tappets; the only difference is in the disassembly and reassembly of the rocker-arm pin and of the push rods which is not necessary.
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8
Fuel system
168
170
171
172
- 72 -
169
Injection timing correction by changing the pad thickness
Should it be necessary to correct the injection static advance, remove the injection pump from the engine block and replace pad
B inside the injection tappets with one of a different thickness (to extract pad B use a magnet C).
Its value is printed on the lower part of the pad.
Eight spare pads are supplied for the advance variations and their thickness can vary from 4 to 4.7 mm.
The gasket A, between the injection pump flange and the engine block, is only one, with the only task of preventing any possible oil leaks.
Previously, to vary the injection advance, gaskets of different thicknesses were used between the injection pump surface and the engine block surface (in effect, gasket A without sealing rubber border).
Injector (pin type)
Components:
1 Fuel inlet
2 Filter
3 Body
4 Delivery duct
5 Pad
6 Clamping ring nut
7 Delivery union
8 Backflow union
9 Setting shims
10 Pressure spring
11 Pressure pin
12 Nozzle
13 Fireproof bulkhead
Whenever maintenance operations are carried out on the injector replace the seal ring 1.
Introduce seal ring 1 into the injector housing with the sealing surface facing upwards (see figure 171).
See page 22 for maintenance intervals.
Fix injector to the head tightening to 70 Nm.
Injector setting
Connect the injector to a injection test stand and check that the pressure setting is 140 / 150 bar.
Adding the shims 9 increases the pressure setting, reducing their number lowers it.
Eleven spare setting shims 9 are included, their measurements range from 1 to 2 mm.
When spring 10 is replaced, calibration must be carried out at a pressure 10 bars higher than the nominal pressure (160 bar) to counterbalance bedding in the operation.
Check needle valve sealing by slowly moving the hand pump until approximately 120 bar per 10 seconds.
Replace nozzle 12 in case of dripping.
The torque of the injector ring nut is 70 ÷ 90 Nm.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
173
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.
Tighten the nut 1 to 60 Nm.
Note: Lube the two bearings with high temperature grease.
The alternator has a W terminal for a speed indicator.
9
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
η
= 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
174
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
175
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177
178
- 74 -
9
Electric system
176
Alternator type Marelli AA 125 R 14V 65A
Characteristics:
Rated voltage ............................14V
Rated current .............................65A
Max. speed ................................14.000 giri/1'
Peak speed (max 15 min) .........15.000 rpm
Bearing on control side ..............6203.2z
Bearing on manifold side ...........6201-2z/C3
Voltage regulator .......................RTT 119 AC
RH direction of rotation.
Tighten the nut 1 to 60 Nm.
Note: Lube the two bearings with high temperature grease.
The alternator has a W terminal for a speed indicator.
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
η
= 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
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
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
179
Electric system
9
Alternator type Iskra, AAK3139 14V 80A
Characteristics:
Rated voltage ...................................................14V
Rated current ....................................................80A
Speed of the load starting point ........................1350 rpm
Maximum permanent intermittent speed (max. 15') ............................13000 -15000 rpm
Front bearing ....................................................6303 - 2RS - C3
Rear bearing .....................................................6201 - 2RS - C3
Max. force on the bearing ................................600 N
Voltage regulator ..............................................AER 1528
RH direction of rotation.
Tighten the nut 1 to 60÷70 Nm.
Note: Lube the two bearings with high temperature grease.
The alternator has a W terminal for a speed indicator.
Characteristic curves for alternator type Iskra, AAK3139
14V 80A
The curves have been detected with electronic voltage regulator after thermal stabilization at23 ± 5°C; test voltage 13 V.
I = Current in Ampere
Note: The alternator rpm is equal to the rpm shown in the table multiplied by 1000.
Ratio between engine/alternator rpm = 1:1.8
180
Characteristic voltage curve for regulator type AER 1528
The electronic voltage regulator is built into the alternator.
The curve changes depending on temperature.
A = Max. voltage curve
B = Min. voltage curve
181
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9
Electric system
182
183
- 76 -
Wiring diagram with alternator 45A / 65A
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
9 Fuse (Accessory)
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)
17 Diode
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.)
22 n.
2 100 ohm resistances in parallel
A Accessory
B Off Position
C On Position
D Starting Position
Battery 3 is not supplied by LOMBARDINI.
Anyhow, for installation we recommend a battery for all the ran ge of engines with the following particulars, see following table.
Normal starting conditions:
Capacity (K20) = 88 Ah
Rapid discharge intensity (DIN standards at -18°C) = 330 A
Heavy starting conditions (max admitted):
Capacity (K20) = 110 Ah
Rapid discharge intensity (DIN standards at -18°C) = 450 A
Note: This electric starting diagram holds for both 45A and 65A alternators.
Connection diagram for preheating control unit
Components:
1 Cable cross-section 2.5 mm
2
at point “50” of the key panel
2 Cable cross-section 6 mm
2
at the fuse holder box
3 Cable cross-section 1.5 mm
2
at the earth
4 Cable cross-section 1 mm
2
at the spark plug warning light (max. 2 W)
5 Cable cross-section 6 mm
2
at point “30” of the key panel
6 Cable cross-section 1 mm
2
at the water temperature sensor
7 Cable cross-section 1.5 mm
2
at the fuse
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
184
Electric system
9
Alternator type Iskra, type AAK3570 28V 35A (for 24 V outfits)
Characteristics:
Rated voltage ................................................. 28V
Rated current .................................................. 35A
Speed of the load starting point ...................... 1140 rpm
Maximum permanent intermittent speed (max. 15') .......................... 13000 -15000 rpm
Front bearing .................................................. 6303 - 2RS - C3
Rear bearing ................................................... 6201 - 2RS - C3
Max. force on the bearing .............................. 600 N
Voltage regulator ............................................ AER 1528
RH direction of rotation.
Tighten the nut 1 to 60 ÷ 70 Nm.
Note: Lube the two bearings with high temperature grease.
The alternator has a W terminal for a speed indicator.
Characteristic curves for alternator type AAK3570 28V 35A
(for 24 V outfits)
The curves have been detected with electronic voltage regulator after thermal stabilization at 23 ± 5°C;test voltage 13 V.
I = Current in Ampere
Note: The alternator rpm is equal to the rpm shown in the table multiplied by 1000.
Ratio between engine/alternator rpm = 1:1.8.
185
Characteristic voltage curve for regulator type AER 1528
The electronic voltage regulator is built into the alternator.
The curve changes depending on temperature.
A = Max. voltage curve
B = Min. voltage curve
186
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9
Electric system
187
188
- 78 -
Wiring diagram 24 V with alternator 35A
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
9 Fuse (Accessory)
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)
17 Diode
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
Normal starting conditions:
Capacity (K20) = 88 Ah
Rapid discharge intensity (DIN standards at -18°C) = 330 A
Heavy starting conditions (max admitted):
Capacity (K20) = 110 Ah
Rapid discharge intensity (DIN standards at -18°C) = 450 A
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.
Connection diagram for preheating control unit
Components:
1 Cable cross-section 2.5 mm
2
at point “50” of the key panel
2 Cable cross-section 6 mm
2
at the fuse holder box
3 Cable cross-section 1.5 mm
2
at the earth
4 Cable cross-section 1 mm
2
at the spark plug warning light (max. 2 W)
5 Cable cross-section 6 mm
2
at point “30” of the key panel
6 Cable cross-section 1 mm
2
at the water temperature sensor
7 Cable cross-section 1.5 mm
2
at the fuse
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
189
Electric system
Starting Motor 12V
Bosch type EV 12V 2.2 Kw
RH direction of rotation.
Note: Apply to a Bosch service center for any tipe of repair.
9
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
190
Key switch electrical layout
A = Accessory
B = Off position
C = On position
D = Starting position
191
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9
Electric system
192
193
194
Starting Motor 24V
Iskra type AZE 4598 24V 3 kW
RH direction of rotation.
Characteristic curves for starting motor Iskra type AZE 4598
24V 3 kW
The thick lines were obtained at a temperature of +20°C; the thin lines were obtained at a temperature of -20°C. Battery type 55
Ah 300A.
U = Motor terminal voltage in Volt
n = Motor speed in rpm.
A =Absorbed current in Ampere
P =Power in kW
M = Torque in Nm
Key switch electrical layout
A = Accessory
B = Off position
C = On position
D = Starting position
Spacer flange for starter motor
The 24V starter motor requires the assembling of the spacer flange.
195
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
196 197
Electric system
9
Pre-heating glow plug
Components: 1 Sheath
2 Regulation filament
3 Heating filament
Installation torque 20 Nm.
Glow plug Type
Nominal voltage
1 2 V
1 2 .
5 V
Current
Sheath surface temperature
1 2 ÷ 1 4 A ( after
5 " )
8 5 0 ° C ( after
5 " )
2 4 V
2 5 V
1 5 A ( after
6 0 " )
8
1
5 0
1 0
° C
0 ° C
( after
( after
9
1
" )
' )
Note:The glow plug is not damaged in any way due to the prolonged activation time.
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.
198
Trasducer
Resistance
Ω
Temperature
°C
3 0
2 0
1
7
1
0
8
0
6
0
0
0 2 4 0 0
+ 2 0
+ 4 0
+ 5 0
1 0 0 0
≤
4 6 0
3 2 0
Heating time in seconds
Pre-heating
12V
-
2 3 .
5 ÷ 2 9 .
5
Pre-heating
24V
~ 3 0
1 9 ÷ 2 3
Starting control andPost-heating
1 3 .
5 ÷ 1 6 .
5 9 .
5 ÷ 1 2 .
5
4 ÷ 7
8 .
5 ÷ 1 0 .
5 5 ÷ 7
6 .
0 ÷ 8 .
0 2 ÷ 4
Stop
199
Workshop Manual LDW CHD _ cod. 1.5302.345 -
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:
Voltage: 6/24 V
Max. installation torque: 30 Nm.
Features of heavy-duty start sensor
Temperature
°C
Resistance Ω
+ 3 7 .
7 1 1 2 5
+ 6 5 .
5
+ 9 3 .
3
+ 1 0 0
+ 1 2 1 .
1
4 0 5
1 7 0
1 4 0
8 0
6° ed_rev. 05
Features of standard sensor
Temperature °C
Resistance Ω
3 0
2 0
1 0
0
+ 2 0
+ 3 7 .
7
+ 6 5 .
5
+ 9 3 .
3
+ 1 0 0
+ 1 2 1 .
1
9 7 9 0 ÷ 1 3 9 4 0
6 3 0 0 ÷ 7 7 0 0
4 9 0 0 ÷ 3 6 0 0
2 1 6 0 ÷ 2 6 4 0
9 0 0 ÷ 1 1 0 0
4 4 8 ÷ 6 7 2
1 8 0 ÷ 2 7 0
8 0 ÷ 1 2 0
7 5 ÷ 9 5
4 5 ÷ 5 5
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9
Electric system
200
202
203
- 82 -
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.
201
Thermistor for electric thermometer
Thermistor features
Temperature °C
Resistance Ω
3 5 7 3 8 0 6 ÷ 5 3 9 8 3
3 0 5 2 9 4 1 ÷ 3 9 2 2 9
1 5
0
+ 3 0
+ 6 0
+ 9 0
+ 1 2 0
2 0 8 2 5 ÷ 1 8 0 0 6
8 9 2 9 ÷ 7 0 9 5
2 0 4 0 ÷ 1 7 1 8
5 8 9 ÷ 5 2 1
2 0 5 ÷ 1 8 9
8 5 ÷ 7 7
Thermistor for preheating water temperature – Thermal contact for water temperature indicator light
Thermal contact T1 features
Temperature °C Resistance Ω
3 0
2 0
0
+ 2 0
+ 4 0
+ 6 0
+ 8 0
+ 1 0 0
+ 1 2 0
9 9 7 1 ÷ 1 4 1 9 9
6 0 4 5 ÷ 8 4 4 5
2 4 5 7 ÷ 3 3 3 3
1 1 6 9 ÷ 1 5 4 1
6 5 9 ÷ 8 4 9
4 3 5 ÷ 5 4 7
3 2 7 ÷ 4 0 5
2 7 5 ÷ 3 3 5
1 4 6 ÷ 2 9 6
Thermal contact T2 features
Circuit
Closing temperature
Unipolar
1 0 7 ÷ 1 1 3 ° C
Contact opening temperature
> 8 5 ° C
Supply voltage
1 2 ÷ 2 4 V
Maximum thermal contact power
3 W
The max. torque is 30 Nm.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
SETTINGS
10
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 screw 1 and increases when tightening it.
204
Full speed setting in no-load conditions (standard)
Before carrying out this operation, make sure that the engine adjustment is standard; i.e. corresponding to one of the power curve diagrams shown on pages 20- 21.
Example of adjustment of an engine at 3000 rpm:
After setting idle speed turn screw 2 and set full speed in noload 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 screw 2 and decreases when tightening it.
205
206
Standard injection pump delivery setting without torque dynamometer
This adjustment must only be carried if necessary and if there is no dynamometric brake, since this type of adjustment is very approximate.
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.
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.
207
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 83 -
10
Settings
208
209
210
211
- 84 -
Fuel limiting device (fig. 208-209)
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.209 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 0°C.
Fuel limiting device adjustment (fig208-209)
• 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 0°C, 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.
Application diagram for tampering system adjustment screw and torque gearing device for EPA-approved engines
Components:
1 Breaking nut
2 STEI screw
3 Rivets (No.2)
4 TCEI screw
5 Special cover fixing screw
6 Lower plate
7 Upper plate.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
ENGINE STORAGE
11
ENGINE STORAGE
- When the engines are not for more than 6 months, they have to be protected performing the operations described in the following pages.
- If the engine is not to be used for extensive periods, check the storage area conditions and the type of packaging and make sure that these are suitable for correct storage.
If necessary, cover the engine with a proper protective sheet.
- Avoid storing the engine in direct contact with the ground, in environments that are humid and exposed to bad weather, near high voltage electric lines, etc.
Important
If, after the first 6 months, the engine is still not used, it is necessary to carry out a further measure to extend the protection period (see “Protective treatment”).
PROTECTIVE TREATMENT
1 - Pour in the engine housing AGIP RUSTIA C protective oil up to the maximum level.
2 - Fill up with fuel containing 10% AGIP RUSTIA NT.
3 - Make sure that the coolant is up to the maximum level.
4 - Start the engine and keep it idle at minimum speed for some minutes.
5 - Bring the engine to ¾ of the maximum speed for 5÷10 minutes.
6 - Turn off the engine.
7 - Empty out completely the fuel tank.
8 - Spray SAE 10W on the exhaust and intake manifolds.
9 - Seal the exhaust and intake ducts to prevent foreign bodies from entering.
10 - Thoroughly clean all external parts of the engine using suitable products.
11 - Treat non-painted parts with protective products (AGIP
RUSTIA NT).
12 - Loosen the alternator/fan belt.
13 - Cover the engine with a proper protective sheet.
Caution - Warning
In countries in which AGIP products are not available, find an equivalent product (with specifications: MIL-L-21260C).
Important
Maximum every 24 months of inactivity, the engine must be started up by repeating all “Engine Storage” operations.
PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT
After the storage period and before starting up the engine and preparing it for operation, you need to perform certain operations to ensure maximal efficiency conditions.
1 - Remove the protective sheet.
2 - Remove any sealing devices from the exhaust and intake ducts.
3 - Use a cloth soaked in degreasing product to remove the protective treatment from the external parts.
5 - Inject lubricating oil (no more than 2 cm3) into the intake ducts.
6 - Adjust the alternator/fan belt tension.
7 - Turn the engine manually to check the correct movement and smoothness of the mechanical parts.
8 - Refill the tank with fresh fuel.
9 - Make sure that the oil and the coolant are up to the maximum level.
10 - Start the engine and after some minutes bring it to ¾ of the maximum speed for 5-10 minutes.
11 - Turn off the engine.
12 - Remove the oil drain plug (see “Oil replacement”) and discharge the AGIP RUSTIA NT protective oil while the engine is hot.
13 - Pour new oil (see “Table of lubricants”) up to the maximum level.
14 - Replace the filters (air, oil, fuel) with original spare parts.
15 - Empty the cooling circuit completely and pour in the new coolant up to the maximum level.
Caution - Warning
Over time, a number of engine components and lubricants lose their properties, so it is important considering whether they need replacing, also based on age (see Replacement table).
Important
Maximum every 24 months of inactivity, the engine must be started up by repeating all “Engine Storage” operations.
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 85 -
12
TORQUE SPECIFICATIONS AND USE OF SEALANT
POSITION
Alternator fixing bolt
Diesel fuel union bolts
Flywheel housing
Preheating glow plug
Roker arm cover
Main bearing cap
Cap vent
Intake manifold
Exhaust manifold
Throttle cover
Camshaft cover
Timing cover
1P hydraulic pump flange cover
Hydraulic pump gear support cover
Oil pump top cover
Oil pump bottom cover
Thermostat cover
Oil sump
Water pump case and pump support
Flange for flywheel control oil sealing ring
Nozzle clamping ring nut
Rod support ring nut
Equalizer unit
Oil pressure indicator
Camshaft gear
Injector
Starting motor
Intermediate pin
Front engine foot
Engine foot on bell
Fuel pump
Injection pump
Feed pump stud bolts
Drive puly
Oil filter nipple
Fuel pump and solenoid valve union
Injection pump union
Intermediate thrust block union
Injection pump union
Water recirculation unions in brass
Revolution counter driving gear
Alternator bracket
Engine mounting bracket
Bracket of the oil suction hose with equalizer
Bracket of the oil suction hose without equalizer
Alternator support
Injection pump control rod support
Rocker arm assembly
Governor lever support
Tank bracket
Thermostat support
Crankcase lubrication port plug
Plug for oil pressure regulating valve
Water drain plug
Oil drain plug
Air bleed plug under oil sump
Head
Connecting rod big end
Oil suction hose
Air bleed tube under oil sump
Water pump control fan and pulley
Flywheel
MAIN TORQUE SPECIFICATIONS
Reference ( fig.
N° and page)
fig. 8 - pag. 29
fig. 197 - pag. 81 fig. 13÷15 - pag. 30 fig. 6 - pag. 28 fig. 7 - pag. 28 fig. 93 - pag. 48 fig. 172 - pag. 72 fig. 171 - pag. 72 fig. 164 - pag. 69 fig. 10 - pag. 29 fig. 154 - pag. 68 fig. 16 - pag. 31 fig.57÷59 - pag.39-40 fig. 61, 64 - pag. 40 fig. 12 - pag. 30
Ø and pitch mm
8x1.25
16x1.5
UNF 3/4
10x1
12x1.5
22x1.5
12x1.5
14x1.5
5x0,8
8x1,25
12x1.75
6x1
8x1
8x1,25
6x1
10x1.5
6x1
8x1.25
8x1,25
14x1.25
16x1,5
14x1.5
18x1.5
12x1.5
8x1,25
8x1,25
8x1,25
6x1
24x2
18x1,5
10x1,5
12x1.5
10x1
24x2
10x1.5
8x1,25
16x1.5
10x1.5
8x1,25
8x1,25
10x1,5
14x1.5
10x1.5
12x1.25
8x1.25
12x1.25
6x1
8x1.25
8x1.25
6x1
6x1
8x1,25
6x1
8x1,25
6x1
6x1
10x1,5
6x1
12x1.5
6x1
12x1.25
- 86 -
70
10
35
10
140
Type of
sealant
Loctite 270
Loctite 518
Loctite 242
Loctite 270
Loctite 270
Loctite 270
Loctite 554
Loctite 242
Loctite 270
Loctite 242
Loctite 554
Loctite 242
Loctite 242
Loctite 518
Loctite 270
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
Torque
Nm
25
25
10
50
5
25
50
10
10
360
-
12
35
150
25
-
50
40
50
35
10
30
25
-
100
70
45
25
200
40
25
25
25
25
25
10
70 ÷ 90
40
60
35
10
25
10
10
25
10
10
25
20
120
10
25
40
40
50
20
Diameter
M12
M14
M16
M18
M20
M22
M24
M27
M30
M3
M4
M5
M6
M8
M10
Torque specifications and use of sealant
Table of tightening torques for standard screws (coarse thread)
4.6
4.8
5.6
Resistance class (R)
5.8
6.8
8.8
10.9
Quality/
Dimensions
12.9
12
154
206
266
394
32
51
79
109
544
Nm
0,5
1,1
2,3
3,8
9,4
18
R>400N/mm
2
205
275
355
525
43
68
105
145
725
Nm
0,7
1,5
13
25
3
5
R>500N/mm
2
260
333
500
680
63
98
135
193
4,7
12
23
40
Nm
0,6
1,4
2,8
344
444
656
906
84
131
181
256
6,3
16
31
54
Nm
0,9
1,8
3,8
R>600N/mm
2
101
158
218
308
413
533
788
1088
7,5
19
37
65
Nm
1
2,2
4,5
R>800N/mm
2
135
210
290
410
550
710
1050
1450
10
25
49
86
Nm
1,4
2,9
6
R>1000N/mm
2
190
295
405
580
780
1000
1500
2000
14
35
69
120
Nm
1,9
4,1
8,5
R>1200N/mm
2
230
355
485
690
930
1200
1800
2400
17
41
83
145
Nm
2,3
4,9
10
Diameter
M 8x1
M 10x1
M 10x1,25
M 12x1,25
M 12x1,5
M 14x1,5
M 16x1,5
M 18x1,5
M 18x2
M 20x1,5
M 20x2
M 22x1,5
M 24x2
M 27x2
M 30x2
Table of tightening torques for standard screws (fine thread)
4.6
4.8
5.6
Resistance class (R)
5.8
6.8
Quality/
Dimensions
R>400N/mm
2
164
229
293
431
84
122
117
173
600
Nm
10
21
20
36
38
56
218
305
390
575
113
163
157
230
800
Nm
14
28
26
48
45
75
R>500N/mm
2
287
367
533
750
153
147
213
204
45
42
70
105
Nm
13
26
24
203
196
288
273
381
488
719
1000
59
56
94
141
Nm
17
35
33
8.8
10.9
12.9
R>600N/mm
2
244
235
345
327
458
585
863
1200
71
68
113
169
Nm
20
42
39
R>800N/mm
2
325
313
460
436
610
780
1150
1600
95
90
150
225
Nm
27
56
52
R>1000N/mm
2
460
440
640
615
860
1100
1600
2250
135
125
210
315
Nm
38
79
73
R>1200N/mm
2
550
530
770
740
1050
1300
1950
2700
160
150
250
380
Nm
45
95
88
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 87 -
13
SPECIAL TOOLS
- 88 -
SPECIAL TOOLS DESCIPTION
Fuel delivery equalization tool. Allows the adjustment of individual unit injector fuel delivery.
Part No.
7104-1460-090
Glass column for fuel delivery equalization tool.
7104-1460-072
Camshaft bushing replacement tool
7104-1460-021
Static timing tool
7271-1460-024
T.D.C. determination fixture.
7107-1460-075
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
Tool for replacement of injection pump outlet union:
1 For extraction
2 For driving
7107-1460-212
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
13
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Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
- 89 -
CHD series Engine
cod. 1-5302-345
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Key features
- Detailed instructions for assembly, disassembly, overhauling, replacement and tuning
- Information on the fluid cooling circuit
- Updates as of December 1st 2009
- Comprehensive troubleshooting guide
- Technical specifications and performance diagrams
- Prescribed lubricant and maintenance schedules
- Safety information and regulations
- Illustrations to facilitate understanding
- Complete chapter index for easy navigation
