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WORKSHOP MANUAL - lombardini service

1. 121 Ji ee P 9 123 Journal connecting rod pins diameters Dimensions mm Ref Tolerance Limit value A mm 50 981 51 000 50 900 B mm 39 984 40 000 39 900 Main bearings and connecting rod big ends diameters Dimensions mm Ref Tolerance Limit value C mm 51 023 51 059 51 098 D mm 40 021 40 050 40 100 The dimensions given refer to tightened bearings gt For tightening torque see figures 97 Clearances between the bearings and corresponding pins See figures 110 111 Dimensions mm Ref Clearance Limit value C A mm 0 023 0 078 0 200 D B mm 0 021 0 066 0 130 Nota Both for crankshaft bearings and for connecting rod big end bearings internal diameter are undersized by 0 25 and 0 50 mm FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 51 Disassembly 5 LOMBARDINI COMPANY 52 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI A KOHL
2. 72 STARTER MOTOR Bosch DW 12V 11 KW nennen nnne nnne nnne eres enn serere 70 Starter motor Bosch DW 12V 1 1 KW Performance 70 Temperature sensor Tor contiol Urit tetto RC REA PERIERE Ra iaeei 71 Wiring diagram for pre heating gear Case 71 74 77 E G R calibration tpe eee te eh tU eS Rt 77 Injection pump flow limiter and engine torque Gearing 75 Purmp injectiorrdelivery seltlltig itu eee tee peterem tated Det tis 75 Pump injection delivery standard setting without dynamometric 04200 75 Pump injector unit delivery setting with braked engine 76 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 7 5 LOMBARDINI A KOHLER Chapter index Pump injector unit timing with speed 74 Required settings as most commonly applies 76 Setting the idle maximum Standard cierren nnii iia a redii iei 74 Setting the idle minimum standatd n eie RIMRER ERR Fe ERES RR 74 Setting thieiSt
3. ced gelatine 44 Piston ring Clearance between grooves 43 Piston ring mounting 43 Piston rngs s End gaps IO secos citt eic ne tei etta ee Pe M e xp eie Ed 43 PISTON dee eevee eaten aides 42 Piston assembly a reine eel o 44 PASLON CLASS foc 42 Piston disassembly ard Inspection ie eere RE Hee tie ie Denken er eae 42 Piston Welglib e EM ep dm etude esiti ahaa id edt hele ES 43 Pre comb stion chamber 217 or ete edere E n rere ut cie Hee a c t Lee ent lec remp reed egeret cit 40 Pre combustion chamber ring nut nennen nnne terere nnne nennen nnns 40 Pre combustion chamber installation 02 0 nennen nnne nnne nn nnn nnnnn nnn ri nnne ness s sss 41 Pre combustion chambet remioval eia te a a A 41 Pump njector unit Disassembly 5 n 35 Pump injector unit non return net 34 Rear and forward main bearing tee tote eae 48
4. 33 Alm ae ten 39 Valve guides and valve guide 39 Valve recess and seat sealing 40 Valve seats and housirgs s idet ebd ab e eR 40 Malve Springs s ter eto rero Ritt Gite SEED te queri OU patentia eden Bde 38 Valve stem sealing rings 38 Valve timing etate deter e eL too eoe n ee een iced ratae beso ean 30 MValve timing CROCK ss i t Ui DF RR PE o Fa E ORO 29 Valve Specifications srs Aprener ie ftu eau caet etu tad cold c td d dede deitas tees dl Ty 39 E 38 6 FOCS Workshop Manual cod 1 5302 858 1 00 5 LOMBARDINI Chapter index COMPANY 5 BH ges Nerius 54 57 Internal oil filter and oil sump return pipe enne nennen nnne nnne nennen entere 55 L0 ET Tuo nido LEE ne 56 Oil pressure check LER ee cie dep edt hee c Cete FU re ced Dee ec Ee 56 Oil pressure regulatirig Valve eite ren o He PR 56 P 55 Oil pump clearance between rotors 55 COOLANT CIRCUIT cor EC 58 59 COOLANT CI
5. 62 Preliminary steps to pump injector unit delivery balancing 1 66 PUMP INJOCTOR c S G 61 Pump injector unit se no 6590 290 control data 63 Pump injector unit Components ns seein ett ein nee 61 Pumping element oat Beute eR Cede inibi nie i REM 62 Settingzotihjector ets eed Bootes ecce 64 Static injection advamGe tun iri Een E ine reed 66 Test head Beassembly chiens ea i i a vl il eed et Se a 66 ELECTRIC SYSTEM RU oe Cx a RR RUE cya Ma Edu Dre Ca na Cua da 68 73 AE EEO NM LU 68 Alternator 14V 33A Performance 68 Coolant high temperature lamp 72 Electric starting layout 12V with alternator 14V 3 69 Oll pressure SWIIGH Senta ea heed a gd 72 Pre heating glow plug writ tes meet rb ce eite Avis oe ee eee 70 Pre heating plug control unit with coolant temperature 71 Pre heating water temperature thermistor and Water temperature indicator thermal
6. gt For tightening the head connecting rod see fig 97 Piston clearance Determinare the value A of each piston using a dial indicator to measure the difference between the two surfaces piston crown and upper cylinder surface To determine the piston clearance and by consequence which copper gaske is most suitable it is necessary to consider the A value of the piston that projects furthest Head gasket AN Important Remove the cylinder head gasket seal from its protective covering only when you are going to mount it The gasket thickness is identified by the number of notches located in point B Choose the appropriate gasket considering that each A value on the table corresponds to a gasket with one hole two holes three holes The A value relates to figure 93 Each time you dismount the head you must replace the gasket A mm N of holes Piston clearance 0 82 0 91 1 hole 0 54 0 63 0 92 1 01 2 holes 1 02 1 10 3 holes 0 55 0 63 44 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI Disassembly Reassembly 4 96 Cylinder head assembly Use a torque wrench equipped with a device for angular tightening Measure the length of each screw normal length 89 5 90 5 mm Replace it if
7. 36 Central main bearing Caps etie te e ili ee E Ue re ate Da De UE euge ee 48 Check the clearances between the bearings and the nennen nennen 48 Clearances between the bearings and corresponding pins nennen nennen nnne 51 GONNEGTING ROD Pat 46 Connecting trod alignmient 2 3 EC n e dire Ue Decree eee a ee e 47 Connecting rod with bearings and DiM sizesis i oni raniker Ee o iat e a ia a aea raaa nts terns inns nnns enne 46 Connecting tod weight eee etc drei Atte amd sa oh etl kx eee ova this te ee 46 vacuum regulator Valve 33 Crankshaft axial clearance cp dude eet i eee eed v ean edu 49 Crankshaft front and back oil seal rings nennen teretes n trennen nennen rris nnne 50 CGrankshaft timing pulley irre ton eee ed HR bn edt it t halla inti 28 Crankshaft check journals and Crank r r Te a ar a r a a a a aa K a Eaa 50 Crankshaft l bricatiorliles risen 50 Gylinder ET E EISE e ETA TE ete E C C PD ORIS RR NR ET 45 FOCS Workshop Manual_cod 1 5302 858_1 ed_ rev 00 5 5 LOMBARDINI Chapter index LEM COHEN Cylinder head tightening procedure enne 45 Gylinder h
8. pressure regulating valve Components 1 Valve 2 Spring 3 Gasket 4 Screw cap Spring length 27 50 27 75 mm Blow the valve s seating with compressed air and carefully clean all the components before remounting them Nota The valve begins to open at a pressure of 4 55 5 bar 129 Oil filter cartridge Components 1 Gasket 2 Plate 3 Rubber element 4 Spring 5 Filtering element 6 By pass valve 7 Spring Characteristics 130 Maximum operating pressure 7 bar Maximum bursting pressure 20 bar Degree of filtration 2 154 By pass valve 1 5 1 7 bar Total filtration surface 730 cm Oil pressure check Once remounted fill the engine with oil fuel and coolant Remove the pressure switch fit a union and connect a 10 bar pressure gauge Start the engine and check how pressure is affected by oil temperature Nota With a maximum operating temperature of 120 at 900 rpm the oil pressure must not be less than 1 bar 131 56 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI COMPANY Notes FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 57 6 COOLANT CIRCUIT Q LOMBARDINI A KOHLER COMPANY AS Danger Attention The coolant circuit is pressurised Do not check it before the engin
9. 3 0 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 A Danger Attention The used engine oil can cause skin cancer if kept frequently in contact for prolonged periods 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 20 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 A LOMBARDINI Maintenance Recommended oil type Refilling 3 COOLANT A 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 an electric fan is installed do not approach a hot engine s
10. ROUTINE ENGINE MAINTENANCE AN Important Non compliance with the instructions provided in the chart entails risk of technical damages to the machine and or the system Carry out maintenance regularly after predefined number of km or within the time intervals scheduled Continue the periodical maintenance after 100 000 km by starting from 7 500 km ORDINARY MAINTENANCE FREQUENCY x KM x 1000 Km OPERATION COMPONENT CLEANING Radiator fins EVERY 10 000 Km Valve and rocker arms clearance Engine oil EVERY 3 500 Km Solenoid valve operation Fuel pipes and connections Coolant EVERY 3 500 Km Alternator belt Timing belt EVERY 50 000 Km Air filter element EVERY 10 000 Km Engine oil EVERY 10 000 Km Oil filter EVERY 10 000 Km Fuel filter Coolant REPLACEMENT Alternator belt Timing belt EVERY 100 000 km or when disassembling Fuel pipe EVERY 4 years 18 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 A LOMBARDINI Maintenance Recommended oil type Refilling 3 KOHLER COMPANY LUBRICANT SAE Classification in the SAE classification oils differ on the basis of their soe ee eee viscosity no other qualitative characteristic is taken 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 into acc
11. 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 A 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 A Dange
12. Pre heating glow plug Characteristics Nominal voltage 12 5V Current absorption 12 14 after 5 seconds Sheath surface temperature 850 after 5 seconds Components 1 Sheath 2 Primary Heating Coil 3 Secondary Heating Coil O When remounting tighten at a torque of 20 Nm 70 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI KOHLER COMPANY Electric System 8 168 Time sec Pre glow time at 11v 0 30 26 10 0 10 20 30 40 50 60 70 80 Temp 169 170 172 Pre heating plug control unit with coolant temperature sensor To avoid white smoke immediately following start up post heat for about 180 seconds see table Thermistor input Glow plug heat time sec Resistance Coolant temp Pre heat Post heat ohm 170 190 Wiring diagram for pre heating gear case 6 mm cable to 30 terminal of key switch 1 5 cable to ground 1 5 cable to 15 54 terminal of key switch 2 5 mm cable to 50 terminal of key switch 6 cable to glowplugs 1 mm cable to glowplugs warning light max 2w 1 mm cable to water temperature transducer NOoRWOD Tempe
13. Stainless steel or brass casing 2 Wax bulb 3 Air relief hole Characteristics Opening temperature 83 87 Max stroke at 94 C 7 Liquid recycling 30 80 l h FOCS Workshop Manual cod 1 5302 858_1 ed_ 00 59 FUEL SYSTEM 5 LOMBARDINI A KOHLER COMPANY 137 A la D 2 138 140 Fuel feeding injection circuit Components 1 Fuel Tank 2 Fuel filter 3 Fuel feeding tube 4 Fuel lift pump 5 Injection pump 6 Injector 7 Fuel rail passage rubber joint 8 Injector exhaust pipe 9 Fuel tank cap 10 Solenoid valve Note The tank complete with filter is supplied on request Fuel filter detached from the tank on request 1 Air relief valve 2 Bearing 3 Cartridge 4 Rubber element 5 Filtering element Cartridge characteristics Filtering paper PF 905 Filtering 2400 Degree of filtration 2 3 Maximum operating pressure 4 bar gt See page 18 for periodic maintenance details Fuel lift pump Components 1 Fuel lift pump 2 Push rod 3 Seal ring The fuel pump is membrane type It is driven by camshaft cam via a drive rod It is equipped wit
14. ed_ rev 00 5 LOMBARDINI KOHLER CO MPANY Disassembly Reassembly 4 51 52 53 Pump injector unit Disassembly When the removal but not replacement of a unit injector is required the following procedure may be used to avoid the need for other adjustments Rotate the crankshaft until the unit injector cam lobe 2 forces the cam follower 1 to the highest position then insert a suitable sized hardened pin into the hole 3 and rotate the crankshaft until the cam follower 1 is at the lowest position In this way the injection advance regulator 4 remains calibrated Note f you dismount more than one pump injector unit make sure to reinstall them in the appropriate housing with relative drive rod 5 before mounting lubricate the drive rod at its two ends with MOLYSLIP AS COMPOUND 40 type Rocker arm assembly Remove the nuts attaching the rocker arm assembly to the cylinder head O When refitting tighten the nuts at a torque of 40 Nm The pin that is hollow inside to allow lubrication is closed at its ends by two caps Note The rocker arm assembly may be removed without removal of the unit injectors Rocker arm pivot dismounting and remounting To remove pivot 1 from the support 2 it s necessary to drill out pin 3 using a 4mm drill bit
15. gt For electrical connections of the pre heating gear case see figure 170 Note Battery 3 not supplied by LOMBARDINI For assembly we recommend a battery with the following characteristics see table below E Heavy duty starting conditions Normal starting conditions max allowed Starter motor class epicyclic type Kw Capacity K20 Ah Rapid discharge DIN Standards at 18 Rapid discharge intensity DIN Standards at 18 C A Capacity K20 Ah intensity C A FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 69 Electric System 5 LOMBARDINI A KOHLER IMPANY 164 n min 3 0 2 8 2 8 24 2 2 1 8 1 8 1 4 1 2 1 0 0 8 o Nw m m T T 167 STARTER MOTOR Bosch DW 12V 1 1 KW Rotation Clockwise 17 5 19 5 mm distance from starter mounting flange to ring gear face Note Please refer to your local BOSCH distributor for service parts repair criterion and warranty service Starter motor Bosch DW 12V 1 1 KW Performance Curve The curve was obtained at room temperature of 20 C with a fully charged 66Ah battery U Starter Motor Voltag n Armature r min Absorbed Amperage P Starter Output Power KW M Starter Output Torque Nm
16. 00 33 4 Disassembly C LOMBARDINI Injection pump control rod The injection pump control rod will link injectors to the engine governor Screws 1 and 2 are pivoted on the delivery control lever of each pump injector B unscrew the screws and remove spring 3 When refitting tighten the screws 1 and 2 at a torque of 1 1 Nm and make sure that they stop on lever B of each pump injector and not on rod A To carry out the delivery equalisation of the injection pumps see page 67 gt carry out the timing of the injection pumps and speed governor see page 74 45 46 B Fuel rail a XS When removing the fuel feeding pumps A with the rail holders B SS B pay attention that the sealing O rings C remain in their seats When refitting tighten the rail holder screws at a torque of 4 Nm Pump injector unit non return valve Non return valve A immediately stops the engine whenever the stop is activated Dimensions mm LDW 1003 B D E 0 5 1 15 5 95 6 5 7 0 7 1 Note f the value of is not achieved the two rings are not subject to enough compression to ensure the seal any fuel loss would contaminate the lubrication oil and consequently damage the engine metal gasket 34 FOCS Workshop Manual cod 1 5302 858_1
17. AVIATION FUEL attached near the fuel inlet Aviation fuels suitable for use in this engine include JP5 JP4 JP8 and JET A if 5 percent oil is added FOCS Workshop Manual cod 1 5302 858_1 4_ 00 21 4 DISASSEMBLY REASSEMBLY C LOMBARDINI A KOHLER COMPANY RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING A 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
18. KOHLER COMPANY MANUFACTURER AND ENGINE IDENTIFICATION Manufacturer identification MADE 1N ITALY 6 TN LOMBARDIN Engine type Maximum operating speed gt On e ce epe LOY 1095 Engine serial number Number of the customer version Approval data form K 14 FOCS Workshop Manual cod 1 5302 858 1 ed rev 00 5 LOMBARDINI Technical information ENGINE TYPE Displacements Compression rate Rpm Maximum power 80 1269 5 1585 DIN 70020 Maximum torque Nm RPM Specific fuel consumption g KWh Oil consumption Kg h Dry weight of engine Kg Combustion air volume at 3600 Rpm 1 Cooling air volume at 3600 Rpm m3 min Axial load allowed on crankshaft both directions Instant operation up to 1 min Intermittent operation up to 30 min At max power FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 15 2 Technical information e C CONVERSA PERFORMANCE DIAGRAMS LDW 1003 70 60 50 40 Nm 30 20 10 ka o e 600 0 T T T T 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2
19. RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING nnne 22 RECOMMENDATIONS FOR OVERHAULS AND TUNING eese 22 2 pee Gi peine na e E HR IRR EORR 35 Rocker armovanie adea a a pa a AE a raa E aeria RR 32 Rocker arm cover gasket te ten Etc dire 33 Rocker arm pivot dismounting and 35 Sho lder REOR OUI AEn RR DR RES 49 Shoulder half rings oversized 49 SPOS GOVEMNOM ah ITE 30 Speed governor Limiting speed 31 Speed governor Heassembly uoi tete atii eise di 31 Speed governor comporients 2 iiti rae i e oc dc eee A a eel 30 Stop pin rings dismounting and nennen nennen 42 Tightening pulley merian redeo reote cree e te eet Pv ee 27 Timing belt Timing pulley arrangement 444404410 nint internen nint nter 27 TAMING ere t eee nio e c e na ater dite Deep t mitunter tarte d eus 27 Timing belt removal eee eel ee de tes de ed ad eee el de dds 27 Vacuum pump and vacuum pump 25 Valve Rocker arm clearance iiti eO re
20. The FOCS oil pump is supplied as an assembly Lombardini therefore recommends that the oil pump be handled as an assembly from a service standpoint Lombardini does not recommend that the oil pump be disassembled then reassembled for purposes of installation on the engine except during emergency situations Rotate the crankshaft until the crankshaft timing pulley keyway is vertical as shown Remove the oil pump assembly retaining bolts When the crankshaft timing pulley keyway is vertical the oil pump drive keyway A will be at 3 00 o clock allowing removal of the oil pump assembly via relief B Oil pump Reassembly The pump rotors should be coupled on the same side see references 2 and 3 Replace the O ring 1 Tighten the fastening screws to the crankcase at 25 Nm and those of the plate at 10 Nm gt See page 55 for technical details ROCKER ARM COVER The engine control components are all on the cylinder head The cover contains part of the lubrication duct of the camshaft and of the rocker arms as well as part of the engine vent system Components 1 preassure switch 2 Camshaft lubrification port 3 Rocker arm lubrification port 4 Oil exhaust hose from sump vent system 5 Air valve with oil decanting wire gauze Note During remounting be careful with oil exhaust hose 4 that needs to be properly inserted into its housing on the cylinder head 32 FOCS Workshop Manual cod 1 5302 858 1 rev
21. 00 5 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 43 44 Rocker arm cover gasket The rocker arm cover gasket A ensures the seal of the lubrication circuit for the camshaft and rocker arm shaft Always replace it and mount it with especial care above all in zones 1 and 2 where for greater safety it is advisable to apply a few drops of silicon sealant O Tighten the rocker arm cover screws at a torque of 9 Nm Crankcase vacuum regulator valve Components 1 Gland Nut 2 Bushing 3 Body 4 Diaphragm 5 Cap Cover 6 Clip Lock 7 O Ring 8 Washer 9 O Ring 10 Valve 11 Spring 12 Tube 13 Hose The vacuum relief valve is an engine safety device Its function is that of limiting the vacuum whenever it tends to increase Without this should the air filter be clogged the oil contained in the carter may be sucked back into intake manifold causing the condition for engine runaway Valve Rocker arm clearance AN Important Setting should be performed when the engine is cold Bring each cylinder piston to top dead center on the compression stroke and set clearance A at 0 20 mm for both the intake and exhaust valves For greater convenience clearance check B is accepted In this case the value is 0 15 mm FOCS Workshop Manual cod 1 5302 858_1 ed_ rev
22. 5302 858 1 00 LOMBARDINI e CHIEN Fuel system 7 Pump injector unit se no 6590 290 control data 1 Delivery control lever on stop position 2 Delivery control lever on maximum delivery position start position Rod stroke form max delivery Rpm mm stroke position mm 9 5 3600 19 23 9 5 1200 15 24 start position 300 35 38 Injector setting pressure 140 155 bar Rpm rating is that of the crankshaft REFERENCE NUMBER OFFSET HOLES CURRENT PUMP INJECTOR 148 REFERENCE T INJECTION ADVANCE INJECTOR SETTING 1460 074 d 6090290 o etm 1460 048 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 63 Fuel system 5 LOMBARDINI A KOHLER MPANY 150 151 XX TT Em P Setting of injector Remove the non return valve leaving its metal gasket and fit a cap screw in its place that is part of tooling 7107 1460 074 Mount then head 1 and coupling 2 Then connect a hand pump as shown in the picture The pressure setting must be 140 155 mm bar Injector nozzle projection To avoid excessive compression of the spark arrester A fig 152 check projection B of the nozzle fig 150 6 80 7 05 mm If this measure is large
23. C Nozzle D Spacer E Pressure rod F Spring G Spacer Casing L Control spiral M Plunger guide O When remounting the injector tighten ring nut A at 70 Nm FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 61 Fuel system 5 LOMBARDINI A KOHLER COMPANY 144 Plunger barrel ring nut assembly disassembly To disassemble ring nut 9 fig 142 use the suitable wrench A se no 7107 1460 029 When refitting tighten it a torque of 34 Nm Injection pump assembly disassembly Disassemble the unit following the progressive order of fig 142 Reassemble following the same steps in reverse order During reassembly turn the plunger spiral L towards the non return valve 19 as follows Plunger injection pump reassembly To be able to insert the plunger in its barrel press with a finger and at the same time slowly rotate lever 8 fig 144 until guide M of the plunger fig 145 enters the lever seating Note f by mistake the plunger is mounted with the spiral in the wrong direction the pump won t function there is no danger that the engine runs away 145 Pumping element 1 Plunger 2 2 Upper plunger section 3 Plunger barrel D 4 Delay notch 5 Control slot Dimensions INJECTION F 146 6590 290 6 5 0 9 1 55 1 53 10 035 9 635 62 FOCS Workshop Manual cod 1
24. Extract the ring inserting a pointed tool in hollow A On remounting insert rings with the points turned downwards inside the corners 15 Piston disassembly and inspection Remove the stop rings and remove the pin see fig 83 Remove the piston rings and clean the slot Measure diameter Q at height A from the base of skirt A 9 mm If the diameter is worn more than the 0 05 mm minimum given value replace piston and rings Note The provided oversize elements are of 0 50 mm and 1 00 mm The pistons are subdivided according to their diameters into categories A B C These references are shown on the top of the piston see fig 82 Class Cylinder mm 0 Piston Clearance mm A 74 990 75 000 74 930 74 940 75 000 75 010 74 940 74 950 0 050 0 070 75 010 75 020 74 950 74 960 Pistons at the nominal diameter are only supplied in category Pistons oversized by 0 50 and 1 00 mm are supplied with reference to the increased level on the piston crown 2 75 5 76 0 42 FOCS Workshop Manual cod 1 5302 858 1 rev 00 Disassembly 4 5 LOMBARDINI KOHLER Piston weight Weigh pistons when replacing them in order to avoid unbalance The difference in weight should not exceed 4 g 86 Piston rings End gaps mm Pl
25. On remounting insert a new pin and reinsert it in bearing surface A 0 to 1 mm Check the rod s state of wear and tear diam B and that of the rocker arm holes diam C Remove the closing caps 4 at the end and carefully clean inside Dimensions mm C B limit value 17 989 18 000 FOCS Workshop Manual cod 1 5302 858_1 ed_ 00 35 Disassembly 5 LOMBARDINI A KOHLER COMPANY 56 58 59 CAMSHAFT Camshaft disassembly Loosen the screws and remove the cover 1 Check gasket ring 2 for integrity Remove the drive rod from the fuel pump Gently remove the camshaft slight rotations may be required to avoid binding the camshaft lobes against the camshaft bearing surface bores Note The lift pump drive eccentric 3 is included on the flywheel end of the camshaft and fixed with a screw O Incase of replacement tighten the eccentric screw at a torque of 80 Nm Camshaft journal and housing measurement Use an inside micrometer gauge for housing diameters and an outside micrometer gauge for journal diameters Camshaft journals and housings Dimensions mm A B limit value 37 035 37 060 36 975 37 000 0 035 0 085 0 170 Camshaft lobe measurement Use an outside micrometer gauge 36 FOCS Workshop Manu
26. combustion chamber into the cylinder head so that the side hole of the pre combustion chamber aligns with the glow plug hole To make sure that both the holes align appropriately use tool 7107 1460 031 1 inserting it into the glow plug hole O Tighten the ring nut twice 1st tighten at a torque of 100 Nm 2nd tighten at a torque of 180 Nm Chack that clearance is 3 56 4 04 mm Oil pan removal 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 Remove the fixing screws 1 When reassembling replace the seals 2 O Tighten the screws at a torque of 10 Nm Before starting the engine make sure that 1 the oil drain plug is tightened correctly 2 the engine has been refilled with the prescribed quantity of oil see page 20 FOCS Workshop Manual cod 1 5302 858 1 rev 00 41 4 Disassembly 5 LOMBARDINI A KOHLER COMPANY Piston class PISTON Remove the connecting rod big end cap Remove the piston connecting rod assembly Note The combustion chamber is a Ricardo type Stop pin rings dismounting and remounting
27. reassembling it check value A 45 to 46 mm and the parallelism of the two levels B that must not exceed 0 05 mm Speed governor Limiting speed governor With applications for the automotive sector the regulator spring C fig 31 is replaced by a device plunger barrel that only enables a constant speed at the minimum and maximum rpm rating Components 1 Nut 2 Idle speed spring 3 Max speed spring 4 Case 5 Register 6 Spring ring 7 Actuation rod Speed governor Reassembly Caution Warning While reassembling check the integrity of the components and check that they operate correctly y Bad operation of the speed governor can cause serious damage to the engine and to people being near to it Remount in reverse order to Fig 30 When inserting the bearing in the camshaft do it so that the four blocks enter opened so that they can receive the hose and close over it Check the integrity of the sealing rings of the cover Tighten the three screws at a torque of 10 Nm Note With the speed governor mounted the camshaft axial clearance should be zero FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 31 Disassembly 5 LOMBARDINI A KOHLER COMPANY OIL PUMP Oil pump disassembly
28. sealing width S PRE COMBUSTION CHAMBER Components 1 Pre combustion chamber 2 Pre heating glow plug 3 Pre combustion chamber ring nut 4 Cylinder head The pre combustion chamber does not normally require removal or service if service is necessary follow the procedure described below Pre combustion chamber ring nut removal The pre combustion chamber is fixed to the cylinder head by a ring nut so before removing the pre combustion chamber it is necessary to unscrew the pre combustion chamber ring nut Use the special tool 7107 1460 027 1 to romve the ring nut 2 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 78 79 80 Pre combustion chamber removal Before proceeding with removing the pre combustion chamber it is necessary to remove the pre heating glow plug Screw special tool 7107 1460 030 1 into the pre combustion chamber Carefully but sharply slide the slide hammer 2 up the special tool shaft until contact is made with end of the tool The hammer effect of the special tool will extract the pre combustion chamber 3 Pre combustion chamber installation The pre combustion chamber has a hole on the side where the pre heating glow plug 2 must be inserted When re fitting introduce the the new pre
29. 200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 rpm N 80 1269 CEE ISO 1585 DIN 70020 AUTOMOTIVE RATING intermittent operation with variable speed and variable load The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 5 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C above 25 C Note Consult LOMBARDINI for power torque curves and specific consumptions at rates differing from those given above A Important Non approval by Lombardini for any modifications releases the company from any damages incurred by the engine 16 FOCS Workshop Manual_cod 1 5302 858_1 ed_ rev 00 Technical information 2 5 LOMBARDINI A KOHLER COMPANY TECHNICAL SPECIFICATIONS LOMBARDINI A1 gt BIN 3 0 IIO 2 lt lt gt FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 17 MAINTENANCE RECOMMENDED OIL TYPE REFILLING 5 LOMBARDINI A KOHLER MPANY
30. 3 9 SETTINGS 5 LOMBARDINI KOHLER 29 S X AQ v SPEED SETTINGS Setting the idle minimum standard After filling the engine with oil fuel and coolant start it and let it warm up for 10 minutes Turn the screw 1 to adjust the idle speed at 850 to 900 rpm Tighten then the locknut Note you loosen screw 1 speed decreases To the opposite 178 te CES Pd ZAN 12 ARN CO eS gt 2 direction speed increases Setting the idle maximum standard After setting the idle speed turn screw 2 and regulate the idle maximum at 3800 rpm Block then the locknut When the engine reaches its setting power the maximum rpm will stabilise at 3600 rpm Note f you loosen screw 2 speed increases To the opposite direction speed decreases Setting the stop Remove the rocker arms cover and completely unloosen screw B Push rod A to the right and keep it in this position see figure Tighten screw B until it touches rod A Release rod A and tighten again screw B by a 0 5 1 0 turn Tighten the lock nut Pump injector unit timing with speed governor Loosen the screws C of each pump injector unit If it is not connected connect spring D to rod A with this operation the speed governor blocks are closed Move plates B of e
31. 4 Components 9 Oil filler cap 10 Camshaft 1 Pressure gauge 2 Rocker shaft 3 Connecting rod pin 11 Oil pressure regulating valve 4 Oil filter cartridge 12 Oil pump 5 Journal 13 Crankshaft 6 Oil drain plug 14 Oil suction filter 7 Oil dipstick 8 Bleed 54 FOCS Workshop Manual cod 1 5302 858_1 ed_ 00 5 LOMBARDINI KOHLER Lubrification circuit 5 128 Internal oil filter and oil sump return pipe Clean with petrol the internal oil filter 1 and oil sump return pipe 2 blow also some compressed air Replace sealing rings 3 and 4 O Tighten oil drain plug at a torque of 40 Nm Oil pump Oil pump delivery test at 1000 revs per minute with an oil temperature of 120 C Delivery 1 1 Pressure bar 4 4 3 3 3 5 Delivery test at 3600 rpm with an oil temperature of 120 C Delivery 1 1 Pressure bar 19 3 4 4 5 Oil pump clearance between rotors Measure the clearance A between teeth as in figure the maximum value is 0 171 mm Clearance wear limit should be 0 250 mm gt See page 32 for assembly and disassembly FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 55 Lubrification circuit 5 LOMBARDINI A KOHLER MPANY
32. 4 on pump 1 This will automatically position the control lever to the maximum delivery The tool is provided with 3 4 couplings for connection to a tank that must be not lower than 30 cm from the pumps level Coupling 2 is equipped with a plastic pipe 5 with internal drip collecting wire Put cylinder 1 under compression and open the tank tap Fuel diesel will start to flow out from coupling 2 Slowly rotate the engine towards TDC 1 until the diesel fuel stops leaking out At this point with lever 1 of fig 153 move again the valve until it touches the piston and read on the dial gauge how many hundredths are missing from the previously reset value TDC To convert hundredths into degrees consult the table below Repeat the operation on the other cylinders Injection advance Code Reference n Rpm a 6590 290 235 4 gt 3600 13 15 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 65 Fuel system 5 LOMBARDINI A KOHLER COMPANY 156 157 158 Static injection advance tuning If the injection advance value found does not correspond to the previously described value adjust the screw E and repeat the test Rotating screw by 12 turn will change the injection advance by 5 If turned clockwise injection is advanced In the opposite direction i
33. ER COMPANY Disassembly Reassembly FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 53 5 LUBRIFICATION CIRCUIT 5 LOMBARDINI COMPANY A Danger Attention The engine can be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed Use suitable oil in order to protect the engine Nothing more than lubrication oil can influence the performances and life of an engine Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston rings to jam and will lead to rapid wear on the cylinder liner the bearings and all other moving parts Engine life will also be notably reduced The oil viscosity must suit the ambient temperature in which the engine operates A Danger Attention Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time Wear protective gloves to avoid touching used oil If contact with the is unavoidable you are advised to wash your hands with soap and water as soon as possible Dispose of old oil in the correct way as it is highly polluting LUBRIFICATION CIRCUIT 4 3 S N e lt 2 lt a apt SN e y 4 11 12 13 5 14 7 6 12
34. ER COMPANY 42100 Reggio Emilia Italia ITALY Via Cav del Lavoro Adelmo Lombardini 2 Cas Post 1074 Tel 39 0522 3891 Telex 530003 Motlom I Telegr Lombarmotor UN EN 180 9001 cait n 0445 R E A 227083 Reg Impr RE 10875 Cod fiscale e Partita IVA 01829970357 CEE Code IT 01829970357 E MAIL atlo lombardini it Internet http www lombardini it
35. HE MAIN COMPONENTS Riference Diam amp pitch Torque Nm Sealant POSITION figure and page n mm Injection pump control rod 45 46 p 34 M 3 spec Connecting rod 97 p 46 8x1 Glow plugs 166 167 p 70 12x1 25 filter cartridge M 20x1 5 union 20X1 5 Camshaft bearing M 6 screws 6 Rocker arm cover 39 p 33 6x1 Main bearing caps 107 111 p 48 M 10 Oil pan 80 p 41 M6 Silicon 7091 Camshaft bearing support screw 34 p 31 Glow plug cable nuts 5x0 8 Fuel lift pump nuts 140 p 60 Belt tensioner nut 25 p 29 External Stop control lever nut Pump injector unit fixing nut 152 p 64 Rocker arm assembly support nut 51 35 Flywheel side seal ring flange Pre combustion chamber ring nut 73 79 40 41 Vacuum pump fixing screws 7 8 25 Belt tensioner Crankcase Speed governor lever screw Driving pulley 12 p 26 16x1 5 sin Camshaft timing pulley 20 p 28 10x1 25 Oil pressure switch 173 p 72 12x1 5 i i 125 126 55 12 1 5 95 96 45 18 Injection pipe 47 p 34 TCEI 4x1 5 Flywheel 11 p 26 10x1 5 Tighten the two nuts that fasten each pump injector unit at the same time For engines with the injectors fixed with self locking nuts tighten the nuts at 23 Nm Tighten these in two phases the first phase at 100 Nm the second phase at 180 Nm Se
36. IGANT et a te NS Le dues 20 ROUTINE ENGINE iicet te dere DEL Cc eee Pole eL e C de 18 SAE GlassiflCatlOn o 24 i ete nte era HR UR DEOR UE dme e RE ee ue mt qe 19 4 DISASSEMBLY REASSEMBLY 21e Eee III 22 53 Alternator Cooling fan belt e ee ete qe E o m a ern e pe iR dba ge aite Ra 25 Big end bearilng a eth ee ce M lu eo tec RD eer gs teg 46 CERT 36 Camshaft journals and housings Dimensions nmeenren nennen nnne 36 Camshaft lobeimeasureMent atin snare ite eee ee a 36 er E MEINT p 28 Camshaft timing Belt Reassembly 0 24041 4 00000 00 00 ENAK enne nnne 28 Camshaft timing Belt Tightening and 29 Camshaft timing Belt tightening tool nnne nnnen nennt nnne eterne nnne nnne treni 29 Camshaft timing pulley cinta Ee URP ED dero eee aod iol m E e DO RE 28 Camshaft timing pulley Disassembly Assembly nennt 28 Camshaft timing pulley Reference marks 121411111 1 0 0 sensns etre n nn 28 Camshaft disassembly cg ve a avra ae ee gus 36 Camshaft journal and housing measurement 1 0 0 eene nennen
37. MANUAL NOTES ettet eR eie em eden studeas 9 GLEOSSARY AND TERMINOLOGY va octet tees tees reser es a adie iae ied qe ber tre oa Eee er pee e ee crece s 9 SAFETY AND ENVIRONMENTAL IMPACT sess nennnnn nnne 11 SAFETY AND WARNING DECALS viinien tere e pe ee e doe 10 SAFETY REGUEATIONS 5 5 ent ette x ER ER Reha tide d HAEC 10 11 WARRANTY GERTIFIGATE atest elie us erede t f ctt dee gat hea die ee dre tu fae icd 9 2 TECHNICAL INFORMATION 4 12 17 MANUFACTURER AND ENGINE IDENTIFICATION 1 14 15 PERFORMANCE DIAGRAMS d uu e be tele tuia du Ute EPUM ete erg 16 TEGHINIGAL SPECIFICATIONS sii Roe ce a ee ee eL LEER 17 TROUBLESHOOTING ii ciate ndr REB DB tini tia teslis 12 13 3 MAINTENANCE RECOMMENDED OIL REFILLING 22 42122 18 21 ACEA Regualtions ACEA Sequences og ee Read ue e umb e eo 19 Wits seth dt dd Anetra ines teh eee 19 COOLANT PEU e D ene ute tiere medi d Get 21 FUEL ertet ere tec p rv ETE e OE eb va d s 21 International SpecifiCatioris EETA CRUS Rte red 19 EE 19 PRESCRIBED LUBR
38. RCUM eee ete t b e e ee ier baie eO ee 58 Coolant circulation pump comporients 1 2 59 Radiator and compensation check and seal tank 2 59 Thermostatic valve 59 FUEL SYSTEM inen 60 67 Fuel feeding injection circuits re deh es A i e ES 60 Fuel filter detached from the tank on request 60 Fuel Imt DUET eet tt ihe ide in pep engi bide 60 Fuel pump drive rod projection 60 Injection oA a eS Se le eee oie es 65 Injection advance control and 65 Injection pump assembly disassembly lt 355 2 i nhe eter eee eee pli c eee 62 Injection pumps delivery nennen nennen 67 Injector nozzle projection Ae create N nts OY Ev LOVER eed i Dep A NE E 64 Ihjector Spark arrester er Rn Hee RR ie RI MD OR Iis 64 Instr rment conriectlOr s 3522 o steve o Ie eai idt deer a aod dedi ete 66 Plunger barrel ring nut 62 Plunger injection pump reassembly 4422444 nnne nn nnns
39. STIA C protective oil up to the maximum level 2 Fill up with fuel containing 10 AGIP RUSTIA NT 3 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 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 21260 N Important Maximum every 24 months of inactivity the engine must be started up by repeating all Engine Storage operations 78 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 LOMBARDINI A MEE 10 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 exhaus
40. WORKSHOP MANUAL 1003 FOCS Engine Series cod 1 5302 858 TQNet ICM Na S LOMBARDINI SERVICE A KOHLER COMPANY 1003 FOCS 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 LOMBARDINI series engines is properly trained and 3 equipped to safely and professionally perform the subject operation 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 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 t
41. ace piston rings squarely into the unworn part of the lower cylinder and measure the end gap A Piston ring A limit value 17 0 25 0 45 2 0 25 0 45 1 0 3 0 20 0 45 Piston ring Clearance between grooves A 0 090 0 125 0 050 0 085 0 040 0 075 88 89 D Piston ring mounting order 1 ring internal tapered and torsional 2 ring internal tapered and torsional C 3 Oil control ring D Chrome plated area 46 Chrome plated area B Note When there is writing on the surface of a piston ring mount that surface with face upward 90 FOCS Workshop Manual cod 1 5302 858 1 rev 00 43 5 LOMBARDINI A KOHLER COMPANY 4 Disassembly Reassembly Piston assembly AN Important Before re mounting lubrificate the piston pin piston cylinder and conncecting rod big end bearing Couple the piston to the connecting rod inserting the pin after lubricating it just via thumb pressure Insert the two pin stop rings and check that they are properly housed in their seats see fig 84 Using piston ring compression pliers introduce the piston into the cylinder so that combustion chamber A is directly under the precombustion chamber parallel to the head Couple the piston connecting rod to the crankshaft
42. ach pump injector unit rightwards see figure with this operation the pumps injector unit are at their maximum delivery Tighten screws C at 1 1 Nm Re balance the deliveries Note Spring D is the start up fuel supplement spring with the engine stopped pull rod A to the right by bringing the pump injector unit delivery to the maximum value until the speed governor comes into operation with the engine running 74 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI Settings 9 A KOHLER COMPANY Injection pump flow limiter and engine torque gearing device Flow limiter C has the function of limiting the injection pump s maximum delivery The same mechanism acts also as a torque gearing device Indeed under torque spring N operating lever L overcomes the resistance of spring M located in the plunger barrel The stroke H that the torque gearing device allows to be carried out by lever L will increase the injection pump delivery and the torque will hit its maximum value PUMP INJECTION DELIVERY SETTING Pump injection delivery standard setting without dynamometric brake This adjustment must be performed with the dynamometric braked engine Without this the regulation is approximate In this case proceed as follows Unlock the maximum flow limiter lock nut Fully screw in flow limiter C Run the engine to the maximu
43. al cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 LA 60 Intake exhaust injection camshaft lobe height A1 1st cylinder intake camshaft lobe A2 2nd cylinder intake camshaft lobe 3rd cylinder intake camshaft lobe I1 1st cylinder injection camshaft lobe 12 2nd cylinder injection camshaft lobe 13 3rd cylinder injection camshaft lobe 1 1st cylinder exhaust camshaft lobe 2 1st cylinder exhaust camshaft lobe 3 1st cylinder exhaust camshaft lobe H 29 598 29 650 mm intake exhaust camshaft lobe height H1 28 948 29 000 mm injection camshaft lobe height If wears on the cams exceeds by 0 1 mm the minimum value given and H1 replace the crankshaft Cylinder head removal AN Important Do not remove the cylinder head when hot to avoid deformation If cylinder head is deformed by more than 0 10 mm level it off by removing a maximum of 0 20 mm gt For the cylinder head tightening procedure see page 45 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 37 Disassembly Reassembly 5 LOMBARDINI KOHLER MPANY VALVES To remove the valves it is necessary to remove the collets place a spacer under the valve head press
44. e has cooled down and also in that case open the radiator cap or expansion tank plug with caution When there is an electric fan do not approach a hot engine because it could also come on with the engine off The liquid coolant is a pollutant and therefore must be disposed of with care according to environmental provisions COOLANT CIRCUIT 2 6 7 8 132 Components 1 Coolant filler plug 6 Circulation pump 2 Compensating tank 7 Fan 3 Thermostatic valve 8 Radiator 4 Cylinder block 5 Thermostat for liquid temperature indicator 58 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI A KOHLER COMPANY Coolant circuit 6 133 134 59 135 136 Radiator and compensation check and seal tank Remove the cap from compensation tank cap and check that the liquid is at the correct level Replace the cap with a new one provided with hand air pump socket Compress air at a pressure of 1 bar for about two minutes Check that there are no drips in the radiator The tank cap is supplied with a vacuum relief valve 1 and an overpressure valve 2 Overpressure valve opening pressure of 0 7 bar Coolant circulation pump components 1 Rotor 2 Front seal gasket 3 Pump casing 4 Exhaust hole 5 Bearing 6 Pulley 7 Shaft Thermostatic valve 1
45. e page 40 41 figures 73 79 t See page 45 Aluminium connecting rod with 35 Nm tightening torque 80 FOCS Workshop Manual cod 1 5302 858_1 ed_ 00 LOMBARDINI Torque specifications and use of sealant 11 COMPANY Table of tightening torques for standard screws coarse thread Resistance class R Quality Dimensions R gt 400N mm R gt 500 R gt 800N mm R21000N mrr R gt 1200N mm Nm Nm Nm Nm Nm Nm M3 0 5 0 7 0 6 1 4 1 9 2 3 M4 1 1 1 5 1 4 2 9 4 1 49 M5 2 3 3 2 8 6 8 5 10 M6 3 8 5 4 7 10 14 17 M8 9 4 13 12 25 35 41 18 25 23 49 69 83 32 43 40 86 51 68 63 79 98 Diameter Table of tightening torques for standard screws fine thread Resistance class R Quality Dimensions R gt 400N mm R gt 500 R gt 600N mm R gt 800N mm gt 1000 R gt 1200N mm Diameter Nm Nm Nm Nm Nm Nm Nm 10 14 13 20 27 38 45 21 28 26 42 56 79 95 20 26 24 39 52 73 88 36 48 45 71 95 38 45 42 68 90 56 75 70 84 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 81 12 SPECIAL TOOLS C LOMBARDINI COMPANY SPECIAL TOOLS DESCIPTION PART Injection pumps delivery balancing instrument 7107 1460 127 Precombustion chamber extractor 7107 1460 030 Sheet metal for i
46. ead removal ee pneu e em 37 Gylindet ro ghn ess iced e HC Ee He cO e DL Cae re OUR ERE e Led eee e ED side eee 47 Gylinder CASS oue PRU ium M 47 GYHNDERS tnne EEUU III LII III 47 Driving pulley ue epdiiei mauu E euin utes 26 LEE 23 E G R Circuit Disassembly Reassemibly s ectetuer HE HER 24 Exhaust manifold iiio troie bare PER cbe 25 Flywheel 26 HUN 34 Governor Spriligs tier tte ute oe D EDO te en sabe tek do OU OD aie HEAD teh divs e HE OE RE 31 H ad gasket mi ete ette d debe eere need aoe te pti pieles fro anaes tee Pt dx 44 Injection pump Control rod iip ARE Live co cus 34 Intake manifold Remote air 22241 01 nennt nennen nnne tenent ran 23 Intake exhaust injection camshaft lobe height 37 Journal and connecting rod pins 51 Main bearings and connecting rod big ends diameters 51 Oil pan removals E 41 Oil pump Disassembly Reassembly 32 oe eb testa ate At ae 42 PISTON lt
47. en 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 number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely It is important to wear the personal safety devices pr
48. erials 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
49. ernator 14V 33A Performance Curve The curve was obtained at room temperature of 25 with 13 5 V battery voltage Note The rpm shown on the table are referred to the alternator Engine rpm alternator rpm ratio with driving pulley diameter 105 mm 1 1 79 68 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI KOHLER COMPANY Electric System 8 14 WHITE CON WE BLACK BROWN i 13 12 11 10 BLACK i He QNSE gt E gt ie im mi af 9 15 54 Y on 30 21 1 C T a s 4mm 502 602 BLUE emni 9o3 1204 ws BLACK BLUE NEN 4 502 602 z 50 903 80 1204 8 4 an a te Electric starting layout 12V with alternator 14V 33A 1 Alternator 2 Starter Motor 3 Battery 4 Glow Plugs 5 Coolant temperature thermistor 6 Glow Plug Controller Timer 7 Key Switch 8 System Fuse 50 9 Fuse Accessory 5A 10 Fuel Solenoid Valve 11 Glow Plug Indicator Lamp 12 Coolant High Temperature Lamp 13 Coolant High Temperature Switch 14 Oil Pressure Low Lamp 15 Oil Pressure Switch 16 Alternator Charging Lamp 17 Air Filter High Restriction Indicator Lamp 18 Air Filter Restriction Switch 19 Low Fuel Level Lamp 20 Low Fuel Level Switch 21 Diode A Accessory Position B Off Position C On Position D Starting Position
50. ers are found on the crankcase in the points shown by the arrows see picture Note The cylinders are not to be changed Cylinder roughness Caution Warning Do not treat the cylinder s internal surfaces with an emery cloth The angle of the crossed processing marks must be between 45 and 55 These must be uniform and distinct in both directions Average roughness must be between 0 5 and 1 um The whole surface of the cylinder affected by contact with the piston rings must be rendered with the plateau method FOCS Workshop Manual cod 1 5302 858 1 rev 00 47 4 Disassembly Reassembly 5 LOMBARDINI A KOHLER COMPANY 107 108 109 Central main bearing caps The central support caps are marked with locations that can be numbers as in the diagram or dots The same locations are given on the crankcase Couple the caps with the same references and on the same side In any case locate the bearing s two centring notches that are to be found on the same side O Tighten the screws simultaneously at a torque of 60 Nm Rear and forward main bearing caps AN Important Before the final tightening and after it using a ground bar check the coplanarity of the horizontal and vertical levels On remounting the rear main bearing cap 1 replace the lateral rubber gasket
51. escribed 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 In order to minimise the impact on the environment the identify assess and monitor the influence of its own activities manufacturer now provides a number of indications to be products services etc on the environment followed by all persons handling the engine for any reason Procedures for identifying the extent of the impact on the during its expected lifetime environment must consider the following factors Allpackaging c
52. essed to the LOMBARDINI 5 1 service agents GENERAL SERVICE MANUAL NOTES 1 Use only genuine LOMBARDINI S r l repair parts Failure to use genuine LOMBARDINI S r l parts could result in sub standard performance and low longevity 2 All data presented are in metric format That is 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 GLOSSARY AND TERMINOLOGY For clarity here are the definitions of a number of terms used recurrently in the manual Cylinder number one is the flywheel side piston Rotation direction anticlockwise viewed from the flywheel side of the engine FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 9 LOMBARDINI A KOHLER COMPANY 1 General remarks and safety information SAFETY AND WARNING DECALS Caution Warning Important remarks and features of the text are highlighted This indicates that it is necessary to take proper precautions using symbols which are explained below to prevent any risk to the health and safety of individuals and avoid financial damage Danger Attention AN Important This indicates situations of grave danger which if ignored may seriously threaten the health and safety of individuals This indicates particularly important technical informa
53. h an external manual fuel lever Characteristics With the control cam at 1500 rpm the delivery rate is 75 l hours and the self adjusting pressure is at 0 55 to 0 65 bar Fuel pump drive rod projection Assembly Rotate the timing shaft so that the eccentric is on the base radius and the drive rod is in place in its spherical seat in the control bush The projection of the drive rod 2 from the head level should be 222 5 mm The check should be carried out with cam 1 at rest as shown in the figure Tighten the two fuel pump fastening nuts at 24 Nm Check the length of the drive rod and if it is not the right size replace it Drive rod length 153 15 153 35 mm 60 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI KOHLER Fuel system Pump injector unit series engines each one of which feeds a cylinder Designed by LOMBARDINI the pump injector is exclusive to FOCS The injection system includes three identical pumps injector units E c D De 142 Pump injector unit components 1 Seeger ring 2 Tappet 3 Stop plate 4 Plunger 5 Spring 6 Screw 7 Bearing 8 Lever 9 Ring nut 10 Plunger guide O ring 11 Cylinder 12 Delivery valve 13 Gasket 14 Spring 15 Filler 16 Pin 17 O ring 18 Non return valve 19 O ring 20 Cap screw old type 21 Metal gasket new type A Ring nut B O ring
54. iable 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 f 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 S r l 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 S r l directly or through its authorized network will repair and or replace free of charge any own part or component that upon examination by LOMBARDINI S r l by an authorized LOMBARDINI S r l agent is found to be defective in conformity workman
55. ince 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 1003 CAPACITY Litres Without radiator 1 30 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
56. it exceeds 92 mm Proceed as follows Cylinder head tightening procedure Important Once the head has been correcily tightened it should not be retightened except if it is disassembled again Following the numerical order shown in the diagram the bolts must be tightened in three phases 1 phase 50 Nm 274 phase Rotate the wrench 90 in a clockwise direction 3 4 phase Rotate the wrench again 90 in a clockwise direction FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 45 Disassembly Reassembly 5 LOMBARDINI KOHLER MPANY CONNECTING ROD Caution Warning While reassembling the big end bearings we suggest cleaning all parts thoroughly as well as proper greasing in order to avoid risks of seizure at the first start Big end bearing After connecting rod from crankshaft disconnection check the following While reassembling be sure the two centring notches A an B are on the same side O Tighten the connecting rod big end cap screws simultaneously at a torque of 40 Nm Note The big end bearing is supplied both at the nominal value and undersized by 0 25 and 0 50 mm Connecting rod weight Weigh connecting rods when replacing them in order to avoid unbalance The difference in weight should not exceed 10 g The difference in weight of the pre assembled connecting r
57. ivery if the level increases FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 LOMBARDINI 7 Injection pumps delivery balancing In case the balancing error read on the test pieces is greater than 2 cm min then injection pumps deliveries should be adjusted Plate 4 and rod 3 are blocked by screws 1 and 2 Loosen them Move plate 4 rightwards with respect to rod 3 if you want to increase delivery If moved leftwards delivery decreases Make very small movements with the plate O Tighten screws 1 and 2 at a torque of 1 1 Nm Note Each time a pump injector is replaced it is necessary to balance the deliveries FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 67 8 ELECTRIC SYSTEM 5 LOMBARDINI A KOHLER MPANY 161 ZA E CI Qutput Character istics 13 5V constont Output Current 162 0 3 25 Alternator speed Alternator 14 Nominal voltage 12V Nominal current output 55A Maximum Rpm 18 000 giri 1 Rotation viewed at puley end Clockwise Tighten nut 1 at a torque of 60 70Nm Alt
58. ld be carefully fitted on the appropriate connections O Tighten the screws to specified torque see Table of tightening torques for the main components on page 80 gt For the calibration of the E G R system see E G R calibration on page 77 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 A LONBARDINI Disassembly Reassembly 4 Vacuum pump and vacuum pump flange Unscrew the three fastening screws 1 that fix the vacuum pump to the flange and remove the vacuum pump Unscrew the fastening screws that fix the flange to the engine crankcase and remove it Components Vacuum pump Clic clamp 86 50 Vacuum pump flange Vacuum pump gasket O ring Three way union for vacuum pump Vacuum pump pipe Screw Q9 NO 9 Q When reassembling tighten the screws 8 that fix the flange to the cylinder head to the specified torque of 10 Nm Exhaust manifold engines with EGR Remove the E G R pipe 1 K Unscrew the locking nuts 2 and remove the exhaust manifold bit the seal M 3 Note When reassembling the exhaust manifold check that the inside is properly clean and free from cracks or breaks i5 Note Replace the gasket each time the manifold is reassembled O Tighten the nuts at the prescribed torque of 25 Nm Alternator Cooling fan belt drive Danger Attention Check the belt tensio
59. m speed that is 3800 rpm Loosen flow limiter C until the engine revs start to decrease Screw flow limiter C by 2 5 turns Tighten the lock nut Note f the engine under maximum load emits too much smoke unscrew C Tighten C if at this load there is no smoke and if the engine does not reach its maximum power FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 75 9 Settings A uiv pee Pump injector unit delivery setting with braked engine QT 1 Run the engine to the maximum speed a gt 2 Screw flow limiter see fig 182 A 3 Load the engine up to the power and number of revs required by ECE A the application s manufacturer 4 Check that consumption is within the values allowed for in the settings table see below If consumption is not within the given figures it is necessary to change the balance conditions shown to the brake altering the load and the speed governor Redo the consumption check on the stabilised engine 5 Unscrew limiter C until the engine rpm start to decrease Lock the limiter using the lock nut 6 Completely release the brake and check the rpm at which the engine stabilises The performance of the speed governor must meet the class required by the application s manufacturer 7 Stop the engine 8 Recheck the valve clearance with the engine cold 183 Required settings as m
60. moke Oil preassure too low Oil level increase Excessive oil consumption Oil and fuel dripping from the exhaust Engine overheats Inadequate performance High noise level High oil level Low oil level Dirty or blocked pressure regulation valve Worn oil pump Air to the oil suction hose Faulty manometer or pressure switch Oil in sump suction hose blocked Oil in sump drainage pipe blocked Faulty spray nozzles Turbo engines only LUBRICATION CIRCUIT Damaged injector Damaged injection pump valve Incorrectly calibrated injector Worn or damaged pumping element Incorrect injection pump delivery setting delivery equalisation Hardened pump injector control rod Cracked broken pre combustion chamber Incorrect adjustment of the injection systems delivery equalisation advance Insufficient refrigerant fluid 2 o 5 Defective fan radiator or radiator cap Defective thermostatic valve Loss of refrigerant fluid from the radiator hoses engine crankshaft or water pump Inside of radiator or coolant lines obstructed COOLING CIRCUIT Defective or worn water pump Alternator fan drive belt loose or torn Heat exchange surface of the radiator clogged FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 13 2 Technical information 5 LOMBARDINI
61. n only with the engine off Tension adjustment Loosen screws 1 and 2 Adjust the belt tension so that a 100N force at the midpoint of the 2 belt center as shown results in a 10 15mm deflection gt 18 for periodic maintenance details FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 25 Disassembly 5 LOMBARDINI A KOHLER COMPANY 11 Flywheel A Danger Attention During dismounting be particularly careful not to let the flywheel fall as this can be very dangerous for the operator Use protective goggles while removing the starter ring gear Unscrew the screws that fasten it to the crankshaft In order to replace the ring gear it is necessary to disassemble the flywheel Cut the ring gear in several places using a chisel and remove it Heat the new ring gear uniformly and keep it at a temperature of 300 C for 15 20 minutes Insert the ring gear into its seat and place it carefully on the rim of the flywheel eave to the ring gear to cool gently before reassembling the flywheel O When refitting tighten the screws at 80 Nm Driving pulley AN Important To loosen or screw in screw 1 at the set torque you must always stop the crankshaft and not other parts of the engine Lock the crankshaft Remove the pulley after having u
62. nce A between the crankshaft flywheel side shoulder and the main bearing half rings B 23 05 23 10 23 50 If the clearance is not within the given value check value B If need be fit oversized half rings see below 113 114 Shoulder half rings oversized elements Dimensions mm B Std 22 787 22 920 23 050 23 100 1 22 987 23 120 23 250 23 300 0 130 0 313 2a 3 087 23 220 23 350 23 400 23 187 23 320 23 450 23 500 115 116 of Fig 113 B of Fig 114 Grinding B as per relevant table you can mount the following half rings 15 Oversized element Half rings 1 and 2 0 10 mm on both sides of the bearing 274 Oversized element Half rings 1 and 2 0 10 mm on one side of the support and 0 20 mm on the other side 3 Oversized element Half rings 1 and 2 0 20 mm on both sides of the bearing FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 49 Disassembly Reassembly 5 LOMBARDINI A KOHLER COMPANY 117 118 119 120 Crankshaft front and back oil seal rings The front oil seal ring 1 inserted into the oil pump cover and the back one 2 in the flywheel side flange warped hardened or cracked replace them F
63. ng lever FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 27 4 Disassembly Reassembly 5 LOMBARDINI A KOHLER Crankshaft timing pulley Al rimontaggio fare attenzione che la chiavetta rimanga inserita nella propria sede Note Reference mark 1 on the crankshaft timing pulley and reference mark 2 on the oil pump housing are timing marks When aligned No 1 piston flywheel side is at TDC CAMSHAFT TIMING PULLEY Camshaft timing pulley Disassembly Assembly Unscrew screw 1 and remove the pulley No extractor is needed O When refitting tighten the screw at a torque of 80 Nm Note Assess any wear caused by the lip of the seal ring on the pulley tang Camshaft timing pulley Reference marks 1 Timing reference mark on cylinder head 2 Timing system reference on the pulley Align references 1 and 2 as shown in the figure to set the correct timing CAMSHAFT TIMING Camshaft timing Belt Reassembly Important Remove the distributor toothed belt from its protective wrapping only when mounting it Insert the belt as in figure 22 taking account of the direction of the arrows A impressed on it direction of rotation Tighten the nut 1 by hand until the belt tightener rests on surface of the crankcase Start by mounting the camshaft pulley belt then mount crankshaf
64. ngine refrigerant fluid reaches a temperature of 40 C b the on off sensor control cam 12 opens the vacuum valve 11 at a determined accelerator position Once the E G R valve is opened the exhaust gas enters the intake manifold 13 via the intake flange The same logic controls the closure of the E G R valve FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 23 Disassembly 5 LOMBARDINI KOHLER COMPANY E G R Circuit Disassembly Disengage the control rod catch 1 with a screwdriver from the accelerator control rod 2 fig 3 Disconnect the accelerator control rod from the accelerator control lever 3 fig 3 Disconnect the thermovalve vacuum pump connection pipes 7 fig 2 and vacuum valve thermovalve connection pipe 8 fig 2 from the thermovalve 10 fig 2 Unscrew the two fastening screws 5 that fix the E G R pipe 6 to the E G R valve 4 fig 4 Remove the intake manifold See Intake manifold Remote air filter on page 23 Figure 1 Unscrew the fastening screws of the E G R pipe support bracket 7 fig 5 from the engine crankcase and disengage the E G R pipe from the exhaust manifold Reassembly When reassembling pay attention to the repositioning of the gaskets and to the precise connection of the pipes 6 7 8 9 fig 2 These pipes shou
65. njection is delayed Preliminary steps to pump injector unit delivery balancing test Closing the oilhole To perform this test you must remove the rocker arms cover and close hole 1 with an M 8x1 25 or M 10x1 5 screw on latest model engines not longer than 8 mm Also remove the copper gasket If the camshaft and rocker arms are dry lubricate them with engine oil Note f you only want to check the nozzle it is not necessary to balance the deliveries provided that when you dismount the rod you do not loosen adjusting screws 1 and 2 fig 160 Test head B assembly Remove fuel pipe A and mount one test head B in its place per pump injector The test heads complete with pipes are supplied together with instrument ref 7104 1460 069 Instrument connection Place the instrument 1 se no 7104 1460 127 at least 20 cm above the pump injector level Connect pipe A outlet from every instrument test piece with pipe A inlet of every pump injector and pipe B return to the instrument with pipe B outlet from the pump injector Open tap 2 and 3 of each pipe and fill the instrument with diesel Start the engine and bring it to 1500 rpm idle running Close the fuel supply to the engine from the instrument s tank using lever 4 and after 1 minute observe the levels in the test piece If a level goes down more than the others it is necessary to decrease the delivery of the corresponding pump see below and vice versa to increase the del
66. nscrewed central screw 1 and proceed with the four lateral screws The central bolt 1 is left handed O When reassembling apply some Moly slip antiseizure compound on the screw thread and tighten at 360 Nm 12 Note When pulley reference mark A aligns with the timing cover reference mark B the flywheel side piston is at TDC 26 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI Disassembly Reassembly 4 Timing belt cover Loosen the five screws and remove the cover O When rifitting tighten the screws at a torque of 10 Nm Check the peripheral rubber sealing gasket and the two dust protection rings of the two pulleys if mounted Timing belt Timing pulley arrangement Components 1 Camshaft pulley 2 Timing belt 3 Crankshaft pulley 4 Coolant pump pulley 5 Belt tensioner pulley Timing belt removal AN Important When you remove the distributor belt replace it even if its prescribed operation time has not expired yet Danger Attention Always check that the positive pole of the battery is insulated Remove the belt tensioner 1 Remove the timing belt off the timing pulley gt For assembly see fig 22 25 Tightening pulley Components 1 Nut 2 Washer 3 Pulley 4 Bearing 5 Shaft Support 6 Mounting plate 7 Tensioni
67. nsertion of main bearings in the crankcase 7107 1460 053 Ring nut wrench for fastening pump injector 7107 1460 029 pumping element Precombustion chamber wrench 7107 1460 027 Precombustion chamber adjusting rod 7107 1460 031 Device for mounting valve guide gasket intake and exhaust side 7107 1460 047 Valve lowering device for injection advance 7107 1460 048 control Timing belt tightening tool 7107 1460 049 Tool for injection advance control and setting of injector for pump injector unit se no 7107 1460 074 6590 290 82 FOCS Workshop Manual cod 1 5302 858 1 rev 00 5 LOMBARDINI KOHLER COMPANY Notes FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 83 Notes 5 LOMBARDINI COMPANY 84 Manuale officina FOCS cod 1 5302 350 7 06 1003 FOCS Engine Series cod 1 5302 858 La Lombardini si riserva il diritto di modificare qualunque momento i dati contenuti in questa pubblicazione Lombardini se r serve le droit de modifier n importe quel moment les donn es report es dans cette publication Data reported in this issue can be modified at any time by Lombardini Lombardini beh lt sich alle Rechte vor diese Angabe jederzeit zu ver ndern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicaci n A LOMBARDINI SERVICE A KOHL
68. o 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 LOMBARDINI SERVICE A KOHLER COMPANY FOCS Workshop Manual_cod 1 5302 858_1 ed_ rev 00 3 Q LOMBARDINI REGISTRATION OF MODIFICATIONS THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Drafting Document Model Review body code Issue date date Endorsed 1 5302 858 51199 ESSE 31 10 2008 31 10 2008 4 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 LOMBARDINI e ARE CHAPTER INDEX COMPANY This manual contains pertinent information regarding the repair of LOMBARDINI water cooled indirect injection Diesel engines type LDW 1003 updated October 31 2008 CHAPTER INDEX 1 GENERAL REMARKS AND SAFETY INFORMATION 4 2444 422411222 Pag 9 11 GENERAL SAFETY DURING OPERATING PHASES sese neret nennen nnns eterne trennen 11 GENERAL SERVICE
69. od piston and pin must not exceed 14 g Connecting rod with bearings and pin Dimensions mm B 20 015 20 025 C 40 021 40 050 bearing tightened at 40 Nm D 19 996 20 000 E 54 000 55 100 B D 0 015 0 039 B D limit value 0 060 Note When driving the small end bearing make sure both oilholes are aligned 46 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 106 45 55 Connecting rod alignment Using a gauge on a comparison plan check the axial alignment by placing the connecting rod on a V blocks as shown Maximum Axial Mis alignment 0 015mm Limit 0 030mm Minor mis alignment may be corrected by skillfully and gradually working the connecting rod between centers on a press CYLINDERS Reset the dial gauge with a calibrated ring check the diameter D in points 1 2 and 3 repeat the same operation rotating the dial gauge by 90 at the same heights Check any wear in zone X where the piston rings operate and if it is greater than the 0 05 mm max limit given adjust the cylinder to the next increased value 75 000 mm max limit Cylinder class The pistons A B C locations are shown on the piston crown while those for the cylind
70. omponents mustbe disposed of in accordance Liquid waste with the laws of the country in which disposal is taking place Waste management Keep the fuel and engine control systems and the exhaust Soil contamination pipes in efficient working order to limit environmental and Atmospheric emissions noise pollution Use of raw materials and natural resources When discontinuing use of the engine select all components Regulations and directives regarding environmental impact according to their chemical characteristics and dispose of them separately FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 11 2 TECHNICAL INFORMATION LOMBARDINI A KOHLER MPANY 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 POSSIBLE CAUSE TROUBLE Engine does not start Engine starts but stops No acceleration Non uniform speed Black smoke White smoke Oil preassure too low Oil level increase Excessive oil consumption Oil and fuel dripping from the exha
71. op eed eniin det artic teal Fea iot mcs Lob de LEE 74 SPEED SETTINGS Urbe rte tete e a ep tede elei 74 10 STORAGE m E M 78 79 ENGINE STORAGE Oe coto dt din Sen a 78 PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT 79 PROTECTIVE TREATMENT er ten He eae ec b eie ere ede ch p de rede Ut Dod 78 11 TORQUE SPECIFICATIONS AND USE SEALANT 22 2 222 80 81 Table of tightening torques for standard screws coarse thread 81 Table of tightening torques for standard screws fine thread 81 Table of tightening torques for the main 80 12 SPECIAL E O E 82 8 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI GENERAL REMARKS AND SAFETY INFORMATION 1 KOHLER COMPANY WARRANTY CERTIFICATE The products manufactured by LOMBARDINI S r l 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 var
72. or the replacement Carefully clean the housing Keep the ring immersed in engine oil for about half an hour Drive it into its housing with a buffer exercising a uniform pressure on the whole front surface Be sure that the two surfaces A and B meet on the same level Refill the interior hollow with grease and lubricate the seal lip with thickened oil Note Before major engine overhaul in case of oil leakage in the seal area of rings 3 and 4 you can remedy this by replacing the rings and pushing them about 2 mm deeper with respect to the previous ones the rings are black it means zones 3 and 4 of the crankshaft are tempered In this case it is necessary to remount a ring of the same colour If the rings are brown it means that zones 3 and 4 of the crankshaft are not tempered this case it is necessary to remount brown coloured rings Crankshaft lubrication lines Caution Warning During repairs when compressed air is used it is important to wear protective goggles Put the crankshaft in a bath of crude oil Use compressed air to clean the inside of the lines Reposition the new caps in their seating and check the seal Crankshaft check journals and crank Use a micrometer for the outsides 50 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 LOMBARI DINI COMPANY Disassembly Reassembly 4
73. ost commonly applies Refers to power curve N see pages 16 and after run in Power au N curve Specific fuel consumption Time sec per Kwh 100 4 7200 1003 3600 2000004 76 FOCS Workshop Manual cod 1 5302 858 1 rev 00 LOMBARDINI i e KOHLER COMPANY Settings 9 E G R calibration Mount a T branch on vacuum valve E G R valve connection pipe 1 and connect it to a vacuum pressure gauge with 1 bar bottom scale so as to be able to read the degree of vacuum within the pipe Note is also possible to use a mercury column 1 metre long since the maximum suction pressure exerted by the vacuum pump is 720 mmHg Adjust the position of the accelerator lever via the regulator block so that the internal adjusting nut 2 is about 5 mm from the end of the thread Accelerate the engine up to 3 600 rpm with valve closed this means that the value showed on the vacuum pressure gauge or on the mercury column should be 0 In case it is different from zero adjust the regulator block nuts to move it in relation to the rod 3 in the direction that goes from the flywheel to the timing With the brake at a braking curve N constant load the engine slowing it down to 2 800 rpm Acting on the accelerator look for the E G R valve closing point pressure of the vacuum pressure gauge or mercury gauge equal to zero Note Pay at
74. ount The first number refers to the viscosity when the engine is cold symbol winter while the second considers 777 viscosity with the engine at r gime The ito for must during winter the 2 lowest outside temperature to which the engine will be 122 subject and the highest functioning temperature during summer Single degree oils are normally used when the running 2928200222 4 temperature varies scarcely Multi degree is less sensitive to temperature SAE 5W 30 SAE 5W 40 SAE 0W 30 Mineral base SAE Grade Semi synthetic base Synthetic base 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 American Petroleum Institute MIL 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
75. r Attention During repair operations when using compressed air wear eye protection 22 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 LOMBARDINI i A KOIR Disassembly Reassembly 4 COMPANY Intake manifold Remote air filter Unscrew the the fastening screws 1 that fix the intake duct to the intake manifold unit Unscrew the two fastening screws 2 of the intake manifold from the engine crankcase Disassemble the inlet manifold by disengaging the hook of the min max cylinder from the manifold E G R CIRCUIT Components Exhaust manifold E G R Pipe E G R Valve Vacuum pump Three way union Vacuum pump pipe Thermovalve vacuum pump connection pipe 8 Vacuum valve thermovalve connection pipe 9 Vacuum valve E G R connection pipe 10 Thermovalve 11 Vacuum valve 12 ON OFF sensor control cam 13 Intake duct The main function of the E G R Exhaust Gas Recirculation system is the reduction in emission of NOx nitrogen oxides gases harmful to people and the environment via lowering the combustion temperature The system takes a certain quantity of exhaust gas from the exhaust manifold 1 fig 2 via the E G R pipe 2 to the E G R valve 3 This valve is opened by the vacuum created in pipes 6 7 8 and 9 by vacuum pump 4 fig 2 only when a thermovalve 10 placed in contact with the e
76. r put spacer 2 between ring nut 1 and copper gasket 3 0 25 mm thick spacers are available Injector spark arrester Every time you remove the pump injector you must replace the spark arrester the copper gasket the oil O ring as well as the 2 fuel O rings Insert the spark arrester in the injector housing with surface A pointing upwards O Tighten simultaneously both nuts that fasten it to the head at 20 Nm For engines with the injectors fixed with self locking nuts tighten the nuts at 23 Nm gt See page 18 for periodic maintenance details 64 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI KOHLER COMPANY Fuel system 7 Injection advance control and regulation Dismount the rocker arm cover see page 32 Position the device on the head in contact with cylinder no 1 Mount the dial gauge on the valve controlled by tool ref 1460 048 Via lever 1 of the tool open the valve until it comes into contact with the piston Then rotate the crankshaft until the TDC is read in the dial gauge Then reset the hundredths Remove the fuel pipes Remove the O ring in contact with the non return valve and replace it with the appropriate gasket equipment component part ref 1460 074 Once the check has been completed remove the gasket and refit the O ring Connect tool 1460 07
77. rature sensor for control unit In engines fitted with the above mentioned type of control unit the introduction of the glow plugs depends on a temperature sensor that varies preheating temperature in relation to the coolant temperature Characteristics Temperature range 30 50 Voltage 6 24 V Temperature max 150 Max tightening torque 30 Nm FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 71 Electric System 5 LOMBARDINI A KOHLER COMPANY Oil pressure switch Fig 174 Characteristics Opening pressure 0 15 0 45 bar O Tightening torque 25 Nm M12 M16 Coolant high temperature lamp sensor Fig 175 Characteristics eig EA single pole Voltage 6 24 V Max Power Absorption 3W Closing temperature 107 113 C 18 Tightening torque 25 Nm Pre heating water temperature thermistor Water temperature indicator thermal contact Thermistor features Temperature C Resistance Ohm 552 639 402 470 296 349 264 204 158 Electric System 0 175 72 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI KOHLER COMPANY Notes FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 7
78. ron with a pearlitic matrix Dimensions mm A P Dj E 36 4 36 6 11 045 11 054 11 000 11 018 5 80 6 20 9 75 9 85 Note Valve guides are supplied in finished form further machining is prohibited Valve guides with outside diameter B increased by 0 5 mm are available 68 Valve guide insertion Fit the guides with a punch taking account of value A in relation to the cylinder head surface Dimensions mm OA B e 39 5 40 0 7 005 7 020 6 960 6 990 Clearance mm 69 0 015 0 050 limite usura 0 10 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 39 4 Disassembly 5 LOMBARDINI A KOHLER COMPANY 71 72 Valve seats and housings Dimensions mm mm a Q1 35 220 35 245 35 306 35 315 44 53 45 59 53 60 31 220 31 241 gt 31 308 31 316 Press valve seats into the housings Note Valve seatsare supplied in finished form further machining is rohibited Valve recess and seat sealing width Dimensions mm mm Limit value D 0 7 1 0 1 3 5 1 6 2 0 Grind valve seats with fine emery paste After grinding check the valve recess D relative to the cylinder head surface and the seat
79. ry 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 mat
80. s 2 keeping in mind that projections A and B of the support must be 0 5 1 0 cut off any exceeding portions Do the same with the front bearing cap Before reintroducing the bearings in the crankcase place between their surfaces two plates C and D 0 1 mm thick se no 7107 1460 053 O Tighten the screws at a torque of 60 Nm Note lt is advisable to apply a few drops of silicon sealant on the surface of the gasket slot 2 Check the clearances between the bearings and the journal Use the Perfect Circle Plastigage type calibrated wire A and put it at the centre of the bearing with a bit of grease O Tighten the screws at a torque of 60 Nm Find out the clearance value checking the wire s compression with the appropriate graduated scale supplied in the same pack and available on the market gt For clearance values between the journals connecting rod pin and the relevant bearings see page 51 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 A LOMBARDINI Disassembly Reassembly 4 Shoulder half rings So as to keep them in their seats during assembly put a bit of grease The half rings must be assembled with the slots A as in the figure Thickness of half rings is equal to 2 31 2 36 mm They are supplied as spare parts as increased thickness 0 1 and 0 2 mm see below 112 Crankshaft axial clearance After tightening the main bearings measure the axial cleara
81. sembly Reassembly 5 LOMBARDINI A KOHLER MPANY 28 29 30 Valve timing Angles The angle values are determined by turning the driving shaft clockwise S Piston at top dead centre Piston at bottom dead centre Intake valve open p ntake valve closed Exhaust valve open Exhaust valve closed Timing angles for operating purposes valve clearance 0 25 mm 16 before S 36 after r 36 before I 16 after S Timing angles for checking puposes valve clearance 2 21 S closes in 1 2 after I 20 before S SPEED GOVERNOR The weight type mechanical governor is driven directly by the camshaft and is housed with the cylinder head Components 1 Thrust washer 2 Spool 3 Flyweight assembly Speed governor components 1 Oil seal 2 Screw 3 Support 4 O Ring 5 Bearing 6 Retainer 7 Screw 8 Flyweight assembly 9 Spool 10 Thrust washer 30 FOCS Workshop Manual cod 1 5302 858 1 00 A LOMBARDINI Disassembly Reassembly 4 A KOHLER COMPANY Governor springs Unscrew the pin that attaches it to the cylinder head To remove it as shown in the figure it is necessary to dismount the camshaft It could also be removed from the accelerator box side by unscrewing the torque gearing device Before
82. ship 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 S r l warranty obligations here above described will be cancelled if LOMBARDINI S r l engines not correctly installed and as a consequence the correct functional parameters are not respected and altered LOMBARDINI S r l engines are not used according to the instructions reported in the Use and Maintenance booklet supplied with each engine seal affixed to the engine by LOMBARDINI S r l has been tampered with or removed J Spare parts used are not original LOMBARDINI S r l A 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 not supplied or installed by LOMBARDINI S r l 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 S r l 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 addr
83. strongly on the spring cap as shown in the picture Components 1 Valve stem 2 Valve stem seal ring 3 Spring seat 4 Spring 5 Spring cap 6 Collets Valve stem sealing rings Reassembly To prevent deformation of the sealing ring 1 as it is inserted onto the valve guide insert it onto tool 7107 1460 047 2 after lubricating the sealing ring and proceed as shown int the picture ensuring that gasket 1 is completely fitted 64 65 Valve springs Measure free height with a gauge Free height 46 Note f the free height A is less than 43 5 mm replace the spring 66 38 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 C PT phu Disassembly Reassembly 4 COMPANY Valve specifications A i E Exhaust valve A 1 Shaft and head made of 2 different materials Men 2 Welded joint 3 Chromium plated joint d 4 Portion made of X 45 Cr Si 8 UNI 3992 i Tj 5 Portion made of X 70 Cr Mn NI N 216 UNI 3992 5 D 30 20 45 30 45 45 2 gt d PEN S Intake valve B 67 Material 45 Cr 8 UNI 3992 1 Chromium plated joint C 34 40 60 30 60 45 Valve guides and valve guide housings Both intake and exhasut valve guides are identical dimensionally and are made from phosphoric gray i
84. 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 API CF4 CG4 Fuel with high sulphur content 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 0 Winter up to 10 Alpine to 20 Arctic 30 C BIODIESEL FUEL Fuels containing less than 20 methyl ester or B20 are suitable for use in this EMISSIONCONTRODINEORMATION engine Biodiesel fuels meeting the specification of BQ 9000 or equivalent are LOW SULFUR FUEL OR recommended DO NOT use vegetable oil as a biofuel for this engine ULTRA LOW SULFUR FUEL ONLY Any failures resulting from the use of fuels other than recommended will not be warranted EPA CARB emission label must be
85. sure that all guards have been refitted 10 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI A KOHLER COMPANY General remarks and safety information 1 During operation the surface of the engine can become dangerously hot Avoid touching the exhaust system in particular Before proceeding with any operation on the engine stop it and allow it to cool Never carry out any operation whilst the engine is running The coolant fluid circuit is under pressure Never carry out any inspections until the engine has cooled and even in this case only open the radiator plug or expansion chamber with the utmost caution wearing protective garments and goggles If there is an electric fan do not approach the engine whilst it is still hot as the fan could also start operating when the engine is at a standstill Only clean the coolant system when the engine is at a standstill When cleaning the oil cooled air filter make sure that the old oil is disposed of in the correct way in order to safeguard the environment The spongy filtering material in oil cooled air filters must not be soaked in oil The reservoir of the separator pre filter must not be filled with oil The oil must be drained whilst the engine is hot oil T 80 C Particular care is required to prevent burns Do not allow the oil to come into contact with the skin Pay attention to the temperature of the oil filter wh
86. t 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 34 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 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 79 11 TORQUE SPECIFICATIONS AND USE OF SEALANT Q LOMBARDINI MPANY TABLE OF TIGHTENING TORQUES FOR T
87. t s pulley Do not mount driven belts FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI KOHLER COMPANY Disassembly Reassembly 4 26 Camshaft timing Belt tightening tool Position belt preload tool 7107 1460 049 1 over the timing belt idler adjustment ear 2 See Camshaft timing Belt Tightening and Fastening Camshaft timing Belt Tightening and Fastening Insert the torque wrench in the suitable tool so that the A axis of the key fig 25 is at 90 to the B axis of the tool in fig 24 Tighten in clockwise direction at 20 Nm O Maintaining the belt tension tighten nut 3 with another torque wrench at 40 Nm after having remounted the drive pulley Rotate the crankshaft a few times and check that the tension is as described above The check must be carried out with the appropriate Nippon Denso tension measuring instrument halfway along the longest section of the belt the value for a cold engine must be 15 2 Valve timing check A Intake valve B Exhaust valve Rotate the engine in the normal direction of rotation until the No 1 piston flywheel side approaches TDC compression stroke Check the balance of intake and exhaust valves A and B placing the two micrometers testers on the valve collars FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 29 Disas
88. tention to determine the precise closing point by slightly accelerating the engine the vacuum value in the E G R operation pipe should immediately increase Measure the engine consumption in order to calculate the mm3 stroke value If the calculated value is less than 18 8 mm stroke adjust the adjusting nut making it closer to the end of the rod 3 to increase the calibration When the required value of 18 8 mm stroke has been reached and a power of around 7 KW tighten the adjusting nuts FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 77 10 STORAGE LOMBARDINI A KOHLER COMPANY 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 A 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 the engine housing AGIP RU
89. the right characteristics Usually a specification showing a following letter or number is preferable to one with a preceding letter or number An SF oil for instance is more performing than a SE oil but less performing than a SG one ACEA HRegualtions ACEA Sequences LIGHT DUTY DIESEL ENGINES HEAVY DUTY DIESEL ENGINES BilZLow viscosity for frictions reduction ETS BSOUETE B2 Standard B3 SHigh performances indirect injection E2 Standard B4 High quality direct injection conditions Euro 1 Euro 2 engines Heavy conditions Euro 1 Euro 2 Euro engines 5 performances in heavy conditions Euro 1 Euro 2 Euro 3 engines API MIL Sequences DIESEL PETROL CURRENT FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 19 3 Maintenance Recommended oil type Refilling Q LOMBARDINI A KOHLER COMPANY PRESCRIBED LUBRICANT SINT 2000 specifications 5W 40 API SJ CF 4 ACEA A3 96 B3 MIL L 46152 D E 96 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 OIL CAPACITY LDW 1003 OIL VOLUME OIL FILTER INCLUDED 4 1 3 1 OIL VOLUME WITHOUT OIL FILTER A Danger Attention 4 0 Litres
90. tion 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 extraordina
91. ust Engine overheats Inadequate performance High noise level Clogged fuel pipes Clogged fuel filter Air or water in the fuel circuit Tank cap breather blocked FUEL CIRCUIT Faulty fuel pump Lack of fuel Glow plug fuse burned Faulty glow plug control relay Flat battery Unclear or mistaken cable connection Faulty starter switch os iu On us iu Faulty starting motor Faulty glow plugs MAINTENANCE Clogged air filter Prolonged operation at idle Incomplete run in Overloaded engine Excessive valve clearances Absence of valve clearances Incorrect speed governor leverages SETTINGS REPAIRS Speed governor spring broken or disengaged Idle low Worn out or stuck rings Worn out cylinders Worn out valve guides Bad valve seal Bearing shells of bearing cap piston rod rocker worn out E G R valve blocked open Governor leverages not running Cylinder head gasket damaged Faulty timing system Supplementary starter spring broken or disengaged 12 FOCS Workshop Manual cod 1 5302 858_1 ed_ rev 00 5 LOMBARDINI KOHLER COMPANY Technical information 2 TROUBLE POSSIBLE CAUSE Engine does not start Engine starts but stops No acceleration Non uniform speed Black smoke White s

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