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WORKSHOP MANUAL - BoatService Haarlem

1. How to reassemble injection pump components Fit the plunger with helix E directed towards the discharge union B if it is erroneously fitted with spiral facing the fuel feed union A the injection pump will not operate thus the possibility of the engine overspeeding is completely ruled out complete reas sembly following fig 154 Tighten delivery union to 35 Nm it is essential to use a torque wrench Injection pump non return valve The discharge union is fitted with a non return valve A this valve improves injection by bleeding the air inside the fuel and stops the engine immediately after the stop device is operated To replace the outlet union with non return ball valve on QLC type injection pumps having inlet and outlet unions pressure fitted on the pump case use the special tool serial number 7107 1460 212 Tool B is required for removal of valve A tool C for driving Injection pump control rod A Caution Warning Do not unscrew ring nut 2 before removing rod 1 Control rod 1 operated by the throttle and governed by the speed governor controls the injection pump Ring nut 2 keeps rod 1 in the required position by means of groove 3 How to remove injection pump feeding tubes A Caution Warning Cutting the pipe in the opposite direction to the arrow A horizontally damages the pump coupling with consequent leakage of
2. 36 Pist n Refitting iecit ee eee IR EE E e eet Re EIE Eae 38 Pistori avallabllity 2 nt PR eter ed e RETE SURE RR 36 2 t EE petit eite doles aee ge ibo ge D PII qute DoD e De e UI 41 Piston position and Clearance E 38 Piston rings Clearance between ENEAN EEEE EEEE 37 Piston rings ENG Japs omo da oi D e er e m eerta iih piede aaa ee 37 Piston firigs Fitting 2 eec paciente nee i Feci ete tk da dE Freue ne rua s Exe RED IIR BER Tasa fede pg 37 Piston cL 37 Precombustion chamber erri rte ed ote Roe Eee ee ee ui eds Te nae Re duet 34 Recommendations for disassembling and assembling nennen enne 26 Recommendations for overhauls and 0 26 Rocker armi assemly i E et e Uere ore ener ee REL UA nex die nei e ir ue erue na eoa Tig ek e AT ERAS E 31 Rocker arm cover for engines with recirculating emen nennen nnne nennen enne 30 Rocker arm cover with vent into the air nem eene nennen nre enn inneren nes enne nnne 30 lere se
3. 43 Checking camshaft bushing internal 52 Checking main journals and crank 46 GOMMECUING MOG ni P 40 agamen a ooi eran raTa 41 Connecting ANd PISTON PIN Dm 40 Connecting WeIGMtS c M 40 Connecting rod piston 41 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 5 l LOMBARDINI A KOHLER COMPANY Chapter index liac daa 29 Crankshaftiend ee 44 Crankshaft for engines with dynamic equalizer only four cylinder 5 47 Crankshaft front and rear oll seal 5 5 de pice eie ut He dee 45 Crankshaft Iubricatiori ducts eie Eier treu dime X rte ne 45 45 Cylirider head ERREUR rte OE 31 Cylinder head Neri cp RR 3
4. 56 Hydraulic diagram for feeding the tappets 34 Hydraulic pump p t o eerte Re a eee EE ete Le YE Eee pe E ee dr de PE ede tees 56 1 34 aea 35 Hydraulic tappet valve coritrol 2 eee nir qme de uie An avara 34 2 48 Injection pump folloWer 5 9 2 tirer tc e Et EHI te De eet Gr ete Ine th 35 Intake Manifold Q 28 Intake exhaust and injection cam height for models LDW 2004 2004 53 Intake exhaust and injecton cam height for model LDW 1503 enne rennen 53 Main bearing and connecting rod big bearing inside diameter mm 46 Main bearing caps timing side flywheel 42 Main journal and connecting rod big end journal diameter 46 Oil seal in the valves guides intake and 33 Oil bath air cleanier cemere emer E enr UM 27 Oil b th 1 ER 27 Mio C
5. 2 2 p M 22 Prescribed 24 Routine engine maintenance 22 temm M 23 4 DISASSEMBLY REASSEMPBLY padar eaaa anaiai naian aa as aaia Ea 26 56 Air filt r clogging INDICATOR PORRO TREE 28 Assembling and tightening the cylinder head on engines with hydraulic tappets 39 GANS eA 51 Camshaft bushing replacetrient 5 terne d Qa mra a 52 play ei 56 Camshaft gear Speed governor counter weights 50 Camshaft journals and bushings in model LDW 1503 52 Camshaft journals and bushings in models LDW 2004 20041 enne 52 Camshaft removal m 51 Camshaft iming POP ee 54 DeanngS r eii RH E EREEEA 42 Check clearance between main bearings and
6. 87 13 214264 8 9 El 88 8 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed 05 L LOMBARDINI GENERAL REMARKS AND SAFETY INFORMATION 1 WARRANTY CERTIFICATE The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24 months from the date of delivery to the first end user For engines fitted to stationary equipment working at constant load and at constant and or slightly variable speed within the setting limits the warranty covers a period up to a limit of 2000 working hours if the above mentioned period 24 months is not expired 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 authorized dealers is reported in the Service booklet supplied with each engine Special applications
7. 49 Speed Governor counter springs eed rude qub esie cep ee hoop 50 Spring for extra fuel Supply at startigi uterine ee ect edge en cb a eu dnte ev dre ea eere 51 Summary tables of the governor equipment according to the speed 51 Table of pin rocker arm dirienslons 2 tte olde orbe ode etait ip e ee REG Reed fene 31 TAM A 29 Thrust bearing OVErSIZES E 44 Thrust bearings ent bee De n ned oim imet ine RD 43 Timing angles for checking 2 55 Timing angles for checking purposes LDW 200417 55 Timing angles for operating p rposes 2 eric rettet Deere E ele eL dee Ded ue tpe e db vean Lg e Ene ded de 55 Timing angles for operating purposes LDW 200 55 6 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 L LOMBARDINI Chapter index Timing belt operating angles with valve clearance set to 55 V iene eee ee ieee ee ee ee C 29 Valve guide insertion after nne 33 Valve guides and cylinder Nead ete ee Lp 32 PELLENTE 32 Valve recess and
8. SON LDW 1503 2004 36258 36120 3562 3568 3385 3390 LDW 2004 7 3554 35 60 3524 3530 3385 3390 Limit value mm 0A A1 1 cyl intake cam 51 1 cyl exhaust cam 11 1 cyl injection cam A2 2 cyl intake cam 52 2 cyl exhaust cam 12 2 cyl injection cam 3 cy intake cam 53 3 cyl exhaust cam 3 cyl injection cam A4 4 cyl intake cam S4 4 cyl exhaust cam 4 4 cyl injection cam Intake exhaust and injection cam height for models LDW 2004 2004 T 35 44 35 50 3514 3520 3395 3400 112 2 3 4 A1 1 cyl intake cam 51 1 cyl exhaust 1 cyl injection cam A2 2 cyl intake cam S2 2 cyl exhaust cam 12 2 cyl injection cam 3 cyl intake cam S3 3 cyl exhaust 3 cyl injection cam A4 4 intake cam S4 4 cyl exhaust cam 14 4 cyl injection cam Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 53 LOMBARDINI KOHLER 4 Disassembly Reassembly Camshaft timing Fit idler gear B by making timing mark 2 coincide with timing mark 1 on the camshaft control gear A and mark 3 with 4 on the timing gear C Valve timing without considering timing marks Locate piston 1 on flywheel at the top dead center Position two small rods A of the same length onto the tappets Rotate camshaft stop
9. 1528 RH direction of rotation O Tighten the nut 1 to 60 70 Nm Note Lube the two bearings with high temperature grease The alternator has a W terminal for a speed indicator Characteristic curves for alternator type Iskra AAK3139 14V 80A The curves have been detected with electronic voltage regulator after thermal stabilization at23 5 C test voltage 13 V Current in Ampere Note The alternator rpm is equal to the rom shown in the table multiplied by 1000 Ratio between engine alternator rpm 1 1 8 Characteristic voltage curve for regulator type AER 1528 The electronic voltage regulator is built into the alternator The curve changes depending on temperature Max voltage curve B Min voltage curve Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 75 9 Electric system LOMBARDINI A KOHLER 16 imm 1mm 14 Ne SS sp NL IR NERO NOIR BLACK SCHWARZ 1 2 NEGRO INS SS GRIGIO GRIS GREY GRAU GRIS 11 10 a immi J SA ROSA NERO ROSE NOIR 9 PINK BLACK ROSA SCHWARZ ROSA NEGRO 45 54 7 0 30 182 NEGRO Imm BIANCO BLANC WHITE WEISS BLANCO 1mm 1mm 1 5 mm NERO NOIR BLACK SCHWARZ NEGRO BLACK VERT SCHWARZ GREEN RUN VERDE m 15 AZZURRO AZUR BLUE BLAU AZUL 2 DE v id AZZURRO NERO 2 ES AZUR NOI
10. CF SH for Diesel engines oil corresponding to the military specification MIL L 2104 C 46152 D LDW 2004 2004 T CHD ENGINES OIL CAPACITY LDW 1503 1603 2903 22041 OIL VOLUME AT MAX LEVEL Sheet STD oil sump 4 4 6 4 5 3 OIL FILTER INCLUDED Litres ENHANCED aluminium oil sump 7 1 9 5 OIL VOLUME AT MAX LEVEL Sheet STD oil sump 3 8 5 7 4 5 WITHOUT OIL FILTER Litres ENHANCED aluminium oil sump 6 4 8 8 With dynamic balancer N Important If you are using oil of a quality lower than the prescribed one then you will have to replace it every 125 hours for the standard sump and every 150 hours for the enhanced sump Danger Attention The engine may be damaged if operated with insufficient lube oil It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion Use proper lube oil preserve your engine Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly Always use oil with the right viscosity for the ambient temperature in which your engine is being operated A Danger Attention The used engine oil can cause skin cancer if k
11. The identification plate shown in the figure can be found directly on the engine It contains the following information A Manufacturer s identity B Engine type C Engine serial number D Maximum operating speed E Number of the customer version form K F Approval data Approval data The approval reference directives EC are on the engine plate Plate for EPA regulations placed on the recoil starter or the rocker arm It contains the following information 1 Current year 2 Engine displacement 3 Rated power measured in kW 4 EPA family ID 5 Injection timing 6 Injection opening preassure 7 Valve clearance 14 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed rev 05 2 LOMBARDINI Technical information OVERALL DIMENSIONS LDW 1503 1603 4 l Ou at BL Pa f bY 2 A WI 4 Puy sail We 9 Note Dimensions shown in mm DIMENSIONS mm 468 75 Q 215 7 235 220 233 max 231 3 310 R 240 S T U Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 Technical information L LDW 2004 2204 To xS a
12. This is in any case avoided as the diaphragm valve 7 by winning the resistance of spring 6 properly calibrated closes duct 5 and stops the oil from reaching manifold 4 via hose 3 30 Workshop Manual LDW cod 1 5302 345 6 ed rev 05 2 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 16 Ege m ri D cumulum Rocker arm assemly Loosen the screws which fasten the assembly to the head O When refitting tighten to 50 Nm Inside the rocker arm pin flows the oil that lubricates the rocker arms and feeds the hydraulic tappets To clean the rocker arm pin inside remove the two tightening screws C at the ends fig 17 When refitting apply a drop of Loctite 270 onto the threads To checkthe pin and the rocker arm pin bearings for wear compare the measured values with the parameters in the table below Table of pin rocker arm dimensions 14 032 14 050 13 989 14 000 With bushing fitted to the rocker arm and reamed Cylinder head Caution Warning Do not demount when hot or the part could become deformed Do not remove when hot to avoid deformation Check cylinder head plane using a metal straight edge and thickness gauge if warpage exceeds 0 10 mm level off by removing a maximum 0 20 mm gt See pictures
13. 6x1 Rocker arm assembly fig 16 pag 31 10x1 5 Loctite 270 Governor lever support 6x1 Tank bracket 8x1 25 Thermostat support 8x1 25 Loctite 242 Crankcase lubrication port plug 14x1 25 Loctite 554 Plug for oil pressure regulating valve 16x1 5 Water drain plug 14x1 5 Loctite 242 Oil drain plug 18x1 5 Air bleed plug under oil sump 12x1 5 Loctite 242 Head fig 57 59 pag 39 40 Connecting rod big end fig 61 64 pag 40 10x1 5 Oil suction hose 6x1 Air bleed tube under oil sump 12x1 5 Loctite 518 Water pump control fan and pulley 6x1 Flywheel fig 12 pag 30 12x1 25 Loctite 270 86 Workshop Manual LDW cod 1 5302 345 6 ed rev 05 2 LOMBARDINI A KOHLER COMPANY Torque specifications and use of sealant 12 Table of tightening torques for standard screws coarse thread Resistance class R Quality Dimensions Diameter R gt 500 R gt 600N mm R gt 1200N mm Nm Nm Nm M3 0 6 1 2 3 M4 1 4 2 2 4 9 M5 2 8 4 5 10 M6 4 7 7 5 17 M8 12 19 41 23 37 83 40 65 63 98 Table of tightening torques for standard screws fine thread Resistance class R Quality Dimensions
14. Reassembly L LOMBARDINI Checking camshaft bushing internal diameter Use a bore gauge If the diameter size does not correspond to the given value remove the bushings using the special tool pic 109 and 110 and replace Camshaft journals and bushings in model LDW 1503 Clearance Worn limit mm mm A B C D A B C D Dimensions mm 0040 0085 42 000 42 025 41 940 41 960 Note C values refer to driven in and bored bushings 107 Camshaft journals and bushings in models LDW 2004 2004 T Dimensions Clearance mm Worn limit mm mm A B C D E F A B C D E F 44 000 44 025 43 940 43 960 434000 43 025 0040 0085 42 940 42 960 42 000 42 025 41 940 41 960 108 Camshaft bushing replacement Tool part No 7104 1460 021 Components 1 Mandrel 2 Centering bushing 3 Bushing diam 44 mm 4 Bushing diam 43 mm 5 Bushing diam 42 mm N Important Before driving in the bushing position it in such a way that the lubricating hole maiches with the hole in the crankcase 109 110 52 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed 05 2 LOMBARDINI KOHLER COMPANY Disassembly Reassembly 4 Intake exhaust and injecton cam height for model LDW 1503
15. To verify the delivery starting point the first operation to carry out is to disconnect the nylon tubes at the inlet 4 and outlet 3 of every injection pump Then disassemble the air filter the intake manifold and the rocker arm cap Now disassemble the whole rocker arm pin and after removing the push rods reassemble it Screw the special tool 1 serial number 7107 1460 075 fig 167 onto the head making sure the dial indicator tracer 5 sets against the upper spring bearing ring of the intake valve Use a provisional fuel tank e g delivery balancing tool to gravity feed the injection pump connecting it to the inlet union 4 on the outlet union 3 fit the transparent nylon tube 6 by the means of which we measure the overflow Place the pump control rod in the stop position 1603 2204 2204 T Operate the lever 2 of the tool to rotate the crankshaft until the wa valve touches the piston crown This procedure determines the exact TDC top dead centre of the piston of the cylinder in question reset the dial indicator in this position Then rotate clockwise the crankshaft on the flywheel side until diesel fuel begins to flow out of the small hose on the pump outlet Now change the rotation direction to anticlockwise The flow diminishes As soon as it stops flowing the delivery starting point is determined Then lower the tool lever to make contact between the valve and the piston crown and using the dial indicator
16. 0233 0050 0 050 36 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Disassembly Reassembly 4 2 51 Piston weight Weigh the pistons when replacing them in order to avoid unbalance The difference in weight should not exceed 6 g Piston rings End gaps Place piston rings into the cylinder and measure end gap A 1st ring 0 30 0 0 3rd ring A 020 0 50mm Piston rings Clearance between grooves NATURALLY ASPIRA LDW TURBO TED LDW 0 02 0 08 mm 0 06 095mm 0 05 0 08 mm 0 005 008mm Piston rings Fitting sequence A 1st chrome plated compression ring B 2nd tapered compression ring C 3rd spiral spring oil scraper ring The first ring in the LDW TURBO engine is different from the NATURALLY ASPIRATED version it has a trapezoidal cross section Assemble the segments with the TOP marking facing the piston crown Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 37 4 Disassembly Reassembly LOMBARDINI KOHLER Engine type LDW 1503 1603 2004 2004 2204 2204 1503 1603 2004 2
17. 2 ien Bee Eee b de peste tc iic n deser 61 Oil PrESSure CheGk AMEN RH u d ates 62 Oil pressure curve for LDW 1503 1608 2 enciende cien edes iced dene 62 Oil pressure curve for LDW 2004 2204 5 iieteett EU DES DER eres re FR MEER 62 Oil pressure curve for LDW 2004 224 62 ie He E 61 Oil p mp rotor clearance ierit E detecte irent Deep ee e a eee ade eee ea 61 7 GOOLING SYSTEM 64 65 Gooling systemlayout ee omne ee 64 65 Checking for cooling system leaks 1 eint nente tct ted oec teet 65 Coolant circulating e Pu orm 65 eere eod aet RED ERA ROUES EE KEEPER ERU 65 8 FUEL SYSTEM ete ial ve a 66 72 Checking Injection purmp dellVery coercet tt pa 70 Checking low pressure injection timing for engines with hydraulic 1 71 Checking low pressure injection timing for
18. Injection pump delivery equalization After checking the injection advance go ahead with the delivery balancing of the pumps Before connecting the tool serial number 7104 1460 090 to the pumps and refilling tank 1 with fuel set it to a higher level of at least 200 mm than that of the pumps themselves Open taps 5 and 6 and start the engine set the engine to an idling speed of 2000 rpm Switch the engine feed from tank 1 to the tubes 2 using the switching lever 4 fig 163 After the first minute minimum testing time verify that the level between the highest and lowest levels in the tubes is not more than 2 cm At this point it is possible to either reduce the delivery of the pump that consumes most tube with the lowest level or increase the delivery of the pump that consumes the least tube with the highest level To vary the delivery of the pumps rotate slightly in one direction or the other at the injection pumps Unscrew the fastening screws of the pump to be adjusted by a quarter of a turn Rotating clockwise the delivery is increased anti clockwise the delivery is reduced O Once adjustment is finished tighten the fastening screws to 25 Nm N Important Whenever an injection pump is disassembled or replaced delivery balancing must be carried out Note A reference notch is located between the pump flange and its mounting on the crankcase If one or more pumps are disassembled and reassembled do as follows Ma
19. Max explosion pressure 20 bar Low temperature limit 35 C By pass valve setting 2 1 2 8 bar Total filtering surface 2000 cm2 Degree of filtration 15 um Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 61 Lubrication system LOMBARDINI A KOHLER 134 2 w 70 80 90 100 120 C 135 80 90 EE 100 120 C 80 90 100 1209 60 70 136 137 B0 90 100 120 12 2 70 80 90 100 1209c 60 70 139 80 90 100 120 c Oil pressure check On completing assembly fill with engine oil and fuel connect a 10 bar pressure gauge to the pressure switch fitting Start the engine and check pressure as a function of the oil temperature Oil pressure curve for LDW 1503 1603 Fig 134 The curve is obtained at the oil filter level constant engine speed of 850 rpm in no load conditions Fig 135 The curve is obtained at the oil filter level with engine working at 3000 rpm at t
20. The injection pump of a simplified Q type has been designed by LOMBARDINI for installation on engines of the CHD series The injection system includes three or four separate pumps each of which feeds a cylinder Located on the crankcase at the level of the corresponding cylinder pumps are directly operated by the camshaft All high pressure tubes between injector and pump A feature the same shape and dimensions Featues LDW 1503 2004 LDW 1603 2204 2004 2204 T Volume 25 mm 3 holes 2 1 5 Sealing Volume 25 mm Volume 25 mm valve 1 hole 0 81 1 hole 0 81 Injection pump disassembly Release the spring from the cap and remove the plunger Two pins keep the upper cap connected to the pump body pry with a tool between the pump body and the cap Injection pump components 1 Delivery union 8 Spring 2 Spacer 9 Upper cap 3 Spring 10 Plunger pumping 4 Gasket 11 Lever 5 Delivery valve 12 Pin 6 Gasket 13 Body 7 Cap A Fuel feed union B Fuel dischrge union C Pump flange D Barrel pumping E Fuel control helix Note Union and B flange and barrel D form an integral part of the pump body Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 67 8 system LOMBARDINI KOHLER 154 2 5 s SS 155 Tool serial number 7107 1460 212 156
21. 35 40 45 50 in the SAE classification oils differ on the basis of their viscosity and no other qualitative characteristic is taken SAE 10W into account The first number refers to the viscosity when the engine SAE 20W is cold symbol winter while the second considers SAE 30 viscosity with the engine at r gime SAE 40 The criteria for choosing must consider during winter the SAE 10W 30 lowest outside temperature to which the engine will be subject SAE 10W 40 and the highest functioning temperature during summer SAE 10W 60 Single degree oils are normally used when the running temperature varies scarcely SAE TAKEN Multi degree oil is less sensitive to temperature changes SAE 15W 40 SAE 20W 60 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 A P I 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
22. 5 measure how much lower the piston is with respect to the TDC top dead centre in mm Use the transformation chart mm to degrees to find out the correspondence between mm measured with the dial indicator 5 and degrees Example LDW 1503 2004 2004 T an advance of a 15 corresponds to a lowering of the piston with respect to the TDC top dead centre of 1 86 mm The same operation must be carried out on each pump The difference in adjustment must be limited to about 1 Disassemble the various equipment remove the rocker arm pin and put back the push rods in their seats Then re assemble the rocker arm pin Rotate the crankshaft so as to position the pistons at half stroke for three cylinder engines For four cylinder engines place the piston of cylinder number one at 150 after the top dead centre in crossover stage The rocker arm pin must be fastened in different stages so as to allow the oil inside the tappets to be drained thus allowing them to position themselves correctly Oil density and ambient temperature are important factors that will affect the waiting time about 10 between successive fastening operations Hurried fastening can cause serious damage to the engine As a guideline to each fastening operation make sure that the cup of the upper spring bearing ring does not touch the valve stem oil sealing ring fitted on the guide The final torque of the rocker arm pin is 50 Nm R
23. 5302 345 6 ed_rev 05 73 9 Electric system LOMBARDINI KOHLER 176 pu kw 09 7A 5 70 4 1 m 95 50 SUE 40 t E 30 NUR Tz 4 20 JH eue qu ETT 20 be yp tof e MM bot ILI foto 4 4 i a tat EE 111195 ie deep pop ME SN si Hd l L 0 3 45 amp 7 B8 9 0 M 1213 Timin U mm 177 178 Alternator type Marelli AA 125 R 14V 65A Characteristics Rated voltage 14V Rated 65A Max 14 000 giri 1 Peak speed max 15 min 15 000 rpm Bearing on control side 6203 2z Bearing on manifold side 6201 2z C3 Voltage regulator RTT 119 AC RH direction of rotation O Tighten the nut 1 to 60 Nm Note Lube the two bearings with high temperature grease The alternator has a W terminal for a speed indicator Characteristic curves for al
24. AZUR BLUE BLAU AZUL E 4 35 E 2 55mm 5004 us Ok NOIR BLACK SCHWARZ 3 NEGRO T MARRONE MARRON _ BRowN BRAUN MARRON 35mm 188 Wiring diagram 24 V with alternator 35A 1 Alternator 2 Starter Motor 3 Battery See below for sizing details 4 Glow Plugs 5 Thermistor Glow Plug Controller Circuit 6 Glow Plug Controller Timer 7 Key Switch 8 System Fuse 9 Fuse Accessory 10 Fuel Valve 11 Glow Plug Indicator Lamp 12 Coolant High Temperature Lamp 13 Coolant High Temperature Switch N O 14 Oil Pressure Low Lamp 15 Oil Pressure Switch N C 16 Alternator Charging Lamp Off if Charging 17 Diode 18 Air Filter High Restriction Indicator 19 Air Filter Restriction Switch N O 20 Low Fuel Level Lamp 21 Low Fuel Level Switch N O A Accessory B Off Position C On Position D Starting Position Normal starting conditions Capacity K20 88 Ah Rapid discharge intensity DIN standards at 18 C 330A Heavy starting conditions max admitted Capacity K20 110 Ah Rapid discharge intensity DIN standards at 18 C 450A Note This electric starting diagram holds for both 45A and 65A alternators Battery 3 is not supplied by LOMBARDINI Anyhow for installation we recommend a battery for all the range of engines with the following particulars see following table Co
25. CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES LDW 1503 LDW 1603 CV W Nm Kom ET Ma tom PET AG 4 NNN INT LIN ER TEILTE EER BEN 80 1269 CEE ISO 1585 AUTOMOTIVE RATING intermittent operation with variable speed and variable load NB ISO 3046 1 IFN RATING WITH NO OVERLOAD CAPABILITY Continuous light duty operation with constand speed and variable load NA ISO 3046 1 CONTINUOUS RATING WITH OVERLOAD CAPABILITY continuous heavy duty with constant speed and constant load MN Torque curve N curve MB NB curve MA NA curve C Specific fuel consumption curve NB curve Max power tolerance is 5 Power decreases by approximately 1 every 100 m altitude and by 2 every 5 C above 25 C Engine power can be influenced by the type of coupling used with the cooling fan 20 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 L LOMBARDINI Technical information 2 A KOHLER COMPANY CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES LDW 2204 LDW 2204 T N 80 1269 CEE ISO 1585 AUTOMOTIVE RATING intermittent operation with variable speed and variable load NB ISO 3046 1 IFN RATING WITH NO OVERLOAD CAPABILITY Continuous light duty operation
26. Remove screw B By making the driving shaft turn check the clearance between the ring gear A and the gear of mass D set a comparator with the feeler on one tooth of the timing system control gear G by turning the driving shaft a little way check the clearance which must be 0 026 0 067 If the clearance measured does not come within the values given repeat the operation placing the 0 05 mm shims provided for adjustment between the support C and the crankcase When mounting the balancer lubricate the bushings with Molikote then couple the two masses taking into account the references and I Permanently fix the support C to the crankcase by tightening the screws to 50 Nm plus one turn of the wrench clockwise through 45 The four screws will have to be mounted with a few drops of Loctite 242 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 47 48 Disassembly Reassembly AlN 7 241 l LOMBARDINI A KOHLER MPANY Front cover To remove front cover 1 bring the 1st cylinder to the top dead center remove throttle cover 2 and release spring 3 When refiting replace gasket 4 and 5 O Tighten front cover 1 to 25 Nm Idler gear and hub Components 1 Idle wheel 4 Fitting 2 Hub 5 Oil seal ring 3 Thrust washer 6 Bushing lubrication hole Note Unscrew fitting 4 clockwise and when
27. Y amp B Jes i 94 Il As oar y e IY IET H M 9 4 U aa de L M M 2 4 A vo SCARICO ACQUA WATER DRAIN PLUG TAPPO SCARICO OLIO OIL DRAIN PLUG Note Dimensions shown in mm DIMENSIONS mm 350 187 5 356 3 16 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI Technical information LDW 2004 T 2204 T 07 TURBO Note Dimensions shown in mm DIMENSIONS mm 186 3 Q 235 366 233 1 68 168 7 133 452 5 468 1 208 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 17 2 Technical information LOMBARDINI A KOHLER COMPANY TECHINICAL SPECIFICATIONS ENGINE TYPE CHD LDW 1503 LDW 2004 LDW 2004 4 4 88 88 85 85 Displacement Compression ratio N 80 1269 CEE ISO 1585 DIN 70020 NB ISO 3046 1 IFN DIN 6270 NA ISO 3046 1 ICXN DIN 6270 Max torque Nm RPM Max torque 3rd 4th p t o Nm RPM Oil consumption Kg h Dry weight Kg Combustion air volume at 3000 r p m l min Cooling air volume at 3000 r p m m min Max permissible driving shaft axial load in both dir
28. applications requiring a certain power capacity at low speeds are fitted with the frame 2 complete with the idling speed spring which allows satsifying the above described requirements without the engine tending to stop Components 1 Rocker arm with speed governor springs 2 Frame for idling speed spring Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 Summary tables of the governor equipment according to the speed variation LDW 1503 1603 Idle frame Anti hunting LDW 2004 2204 2004 7 2204 7 rpm Weight type Spring serial number TU mw a eii 2000 Light 5655135 ERI RE 777703 sass Idle frame Anti hunting 5655405 1 2 1 2 2 2 2 2 Spring for extra fuel supply at starting The device is operated automatically when the engine is stopped spring 1 acts on the injection pump control lever 2 providing maximum fuel delivery until the governor starts operating CAMSHAFT Camshaft removal To remove camshaft first remove valve tappets 1 injection pump follower 2 bearing stop plate 3 and fuel pump control rod 5 Note To remove follower 2 loosen screw 4 by three or four turns Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 51 4 Disassembly
29. engines with mechanical 71 Electric fuel pumnp 24V tei cere CERERI c Rep Per eee RE DR Piste rtp Pier es 67 Fuel 22 2 Led ei eui I eeu IN tete ace se tese E Utt exei dede 66 Fuel feeding pump drive rod protrusion 04 inet eite EAn AEAEE EAEan 66 Fuel feeding injection CInCUit sre ie eroe en tect eere dee opes nee In decer ded seeded dene Yee 66 Buel isnt nent 66 How to reassemble injection pump 68 How to reassemble injection pump feeding tubes ccccccecceeeeeeeee cece eeeeeeeeeeeecesaeeeeeeeesaaaeceeeeseeaeeeeeeeeccueeeeeeensnaeeeeees 69 How to remove injection pump feeding 68 Injection pump ecce teet sheen acest ad SCR tbe C eret er ER A ER EE Re RE 67 Injection pump control 2 ei aa de uie strae tiende omi iege de dont de derbi ped tese eU tesa A 68 Injection pump delivery 69 Injection pump disassembly cree e rper tte ete gere un irren nde terea Pede ede eg ideas acetate deed serere idee 67 Injecaon pump non return Valven e eee ORO og beo ost byte n ere ine
30. fuel Cut the nylon tube at A Remove the portion left inside the union using pliers Remove the nylon tube without damaging the union seals as shown in the figure 159 68 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 2 LOMBARDINI A KOHLER COMPANY Fuel system 8 162 164 How to reassemble injection pump feeding tubes 1 Pliers for 6 mm diam tubes intake Part No 7104 1460 022 2 Pliers for 8 mm diam tubes discharge Part No 7104 1460 023 Feeding and discharge tubes are made of nylon they fit into the injection pump unions by exerting pressure and using special pliers and a plastic hammer The nylon tubes can no longer be used after disassembly Replace them every time they are removed Instrument for equalizing injection pump delivery Part No 7104 1460 090 Components 1 Tank 2 Test tube 3 Support 4 Switching lever 5 Injection pump discharge tube cut off valve 6 Injection pump intake tube off valve A Tube for connection to injection pump intake union B Tube for connection to injection pump discharge union Remove feed tubes from all injection pumps and fit the instrument tubes making sure that each pump has its own intake and discharge tubes Connect the instrument A with the engine A and the instrument B with the engine B Proceed in a similar manner with the other pumps
31. involving considerable modifications to the cooling lubricating system for ex dry oil sump filtering System turbo charged models will require special written warranty agreements Within the above stated periods Lombardini Srl directly or through its authorized network will repair and or replace free of charge any own part or component that upon examination by Lombardini or by an authorized Lombardini agent is found to be defective in conformity workmanship or materials Any other responsibility obligation for different expenses damages and direct indirect losses deriving from the engine use or from both the total or partial impossibility of use is excluded The repair or replacement of any component will not extend or renew the warranty period Lombardini warranty obligations here above described will be cancelled if Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected and altered Lombardini engines are not used according to the instructions reported in the Use and Maintenance booklet supplied with each engine Any seal affixed to the engine by Lombardini has been tampered with or removed Spare parts used are not original Lombardini Feeding and injection systems are damaged by unauthorized or poor quality fuel types Electrical system failure is due to components connected to this system which are not supplied or installed by Lombardini En
32. is in its seat To remove the starter ring gear it is recommended to cut it into several portions with an iron hacksaw and then use a chisel To remove the starter rim it is advisable to cut it into several parts with a hacksaw and to then use a chisel To replace slowly heat for 15 20 minutes to a temperature of 300 C max Fit the rim into the flywheel housing make sure that it rests evenly against the support of the housing itself Allow it to slowly cool Rocker arm cover with vent into the air Components 1 Decanting device 2 fill cap 3 Gasket Inside the decanting device 1 there is a small metal skein that separates the oil from the bled vapours before reassembling it clean it and verify its intactness A Important Every time the rocker arm cap is removed replace the gasket 3 Rocker arm cover for engines with recirculating vent Components 1 Recirculating vent system 2 Oil refilling plug 3 Rubber hose for the passage of the oil vapours 4 Intake manifold Inthe rocker arm cap we find most ofthe recirculating vent system 1 This device is used to separate the oil vapours and to convey them via a rubber hose 3 into the intake manifold 4 The vapours are then recirculated inside the engine and not released into the air as they can be polluting Aclogged up air filter and a consequent increase in suction vacuum could cause the oil to be sucked into the combustion chamber and the engine over revving
33. the crankshaft shoulder on the flywheel side and main bearing halves Clearance mm 008 028 If the end play does not fall within the given values check and possibly fit the oversize thrust bearings Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 86 Crankshaft front and rear oil seal The front oil seal A is located in the oil pump cover while the rear oil seal ring B is positioned in the flange on the flywheel side Replace seals if warped hardened or damaged In case of replacement e Carefully clean the seat e Soak the seal in engine oil for approximately half an hour e Fill the inside with grease and lubricate and sealing lip with thick oil e Drive the seal into its seal exerting a uniform pressure over the entire front area Warning case of room temperature below 35 C seals could become damaged Crankshaft timing gear If gear A has to be replaced use a bearing puller to remove it To reassemble it you need to heat it up to a temperature of 180 200 C and then fit it snugly Crankshaft lubrication ducts AN Important During repair operations when using compressed air wear eye protection Dip crankshaft into a bath use a cleaning product Remove plugs and clean ducts A B
34. useful reference when buying a kind of oil Codes are usually printed out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics Usually a specification showing a following letter or number is preferable to one with a preceding letter or number An SF oil for instance is more performing than a SE oil but less performing than a SG one ACEA 5 ACEA Sequences PETROL HEAVY DUTY DIESEL ENGINES A1 Low viscosity for frictions reduction A2 Standard High performances E2 2 Standard 2 Heavy conditions Euro 1 Euro 2 engines LIGHT DUTY DIESEL ENGINES 4 conditions Euro 1 Euro 2 Euro engines 5 performances in heavy conditions Euro 1 Euro 2 Euro B1 Low viscosity for frictions reduction 3 engines B2 Standard B3 High performances indirect injection B4 High quality direct injection API MIL Sequences DIESEL PETROL Workshop Manual LDW CHD _ cod 1 5302 345 6 ed rev 05 23 CORRENTI CURRENT 3 Maintenance Recommended oil type Refilling c LOMBARDINI PRESCRIBED LUBRICANT AGIP SINT 2000 n API CF SH TURBODIESEL 5 ACEA B3 B4 5 40 MIL L 2104 C 46152 D In the countries where AGIP products are not available use oil
35. using symbols which are explained below This indicates that it is necessary to take proper pre cautions to prevent any risk to the health and safety of individuals and avoid financial damage Danger Attention Important This indicates situations of grave danger which if igno red may seriously threaten the health and safety of This indicates particularly important technical information individuals that should not be ignored SAFETY REGULATIONS e 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 e 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 ope ration in particular along with the relative routine maintenance work e The user must read these instructions carefully and become familiar with the o
36. 004 2204 2204T 1503 1603 2004 2004 2204 2204T 0 68 0 83 0 68 0 81 0 83 0 98 0 81 0 94 0 98 2 110 0 94 1 07 No of notches 24 Piston Refitting Connect piston to connecting rod after lubricating piston pin and introducing it by exerting pressure with your thumb Position the two piston pin circlips and check that they are well inside their seats Using a ring compressor introduce the piston into the cylinder with combustion chamber facing the injection pump side Piston position and clearance To obtain a clearance of 0 67 0 90 mm measure protrusion A of all pistons from the cylinder plane and consider the A value of the most protruding piston Perform this measurement along the engine axis Cylinder head gasket Caution Warning Remove the head gasket from its protective wrapping only when ready for fitting At B the gasket shows small semi circular notches indicating thickness Choose the proper head gasket considering that for each value of A maximum projection of the piston from the cylinder surface there is a matching gasket among the three available with no notch one notch or two notches to achieve a clearance volume between 0 66 and 0 90 mm In the LDW 1503 1603 engines the head gasket is made of fibre while in the LDW 2004 2204 T 2204 2204 T engines the head gasket is metal Resulting clea rance mm 0 67 082 0 72 085 Not
37. 125 R 14 45 73 Characteristic curves for alternator type Marelli AA 125 R 14V 65 74 Characteristic curves for starting motor Iskra type AZE 4598 24V 80 Characteristic curves for starting motor type Bosch EV 12V 2 2 nnne enne 79 Characteristic voltage curve for regulator type AER 1528 75 Characteristic voltage curve for regulator type AER 1528 77 Characteristic voltage curve for regulator type RTT 119 73 Characteristic voltage curve for regulator type RTT 119 74 Connection diagram for preheating control 76 Connection diagram for preheating control 78 Coolant high temperature lamp switch cei edente dinde 82 Glow plug controller relay with coolant temperature 81 Heavy starting conditions max 76 Heavy starting conditions max admitted 78 Thermistor for preheating water temperature Thermal contact for water temperature indicator light 82 Wiring diagram 24 V with alternator 78 Wiring diagram with alternator 45A 65 76 10 e LI 83 84 Appl
38. 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Lubrication system Wee b o 0 126 127 LD or B 9 128 129 131 132 a QNM Oil pump Components 5 External rotor 6 Internal rotor 7 Key 1 Suction port 2 Delivery port 3 Oil pressure adjusting Valve port 4 Gasket The oil pump is driven by the crankshaft via key 7 Rotor 6 is locked in the circumferential but not in the axial direction This allows the shaft to move axially while rotors 5 and 6 are prevented from damaging the pump sealing surfaces Oil pump capacity 24 5 litres min at a pressure of 4 5 4 75 bar engine speed 3000 rpm oil temperature 38 42 C Oil pump rotor clearance Measure clearance A between the teeth located along the axis of the keyway as shown in the figure 129 its value is 0 150 mm worn limit clearance 0 280 mm Oil pressure adjusting valve Components 1 Valve 2 Spring 3 Gasket 4 Plug Length of spring A 45 5 46 0 mm Blow compressed air into the valve seat and carefully clean all components using a caliper measure the length of spring A Oil filter cartridge Components 1 Gasket 4 Blade 2 Plate 5 Filtering material 3 Gasket 6 By pass valve Specifications Max working pressure 7 bar
39. 5 6 ed rev 05 LOMBARDINI KOHLER COMPANY ENGINE STORAGE 11 ENGINE STORAGE When the engines are not for more than 6 months they have to be protected performing the operations described in the following pages If the engine is not to be used for extensive periods check the storage area conditions and the type of packaging and make sure that these are suitable for correct storage If necessary cover the engine with a proper protective sheet Avoid storing the engine in direct contact with the ground in environments that are humid and exposed to bad weather near high voltage electric lines etc N 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 pro tection period see Protective treatment PROTECTIVE TREATMENT 1 Pourin the engine housing AGIP RUSTIA C protective oil up to the maximum level 2 Fill up with fuel containing 10 AGIP RUSTIA NT 3 Make sure that the coolant is up to the maximum level 4 Startthe 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 Sealthe exhaust and intake ducts to prevent foreign bodies from entering 10 Thoroughly clean all external parts of the engine using suitabl
40. 56 59 pages 39 40 for cylinder head tightening Valve removal Components 1 Valve 2 Lower spring seat 3 Valve guide seal for intake only 4 Spring 5 Spring cap 6 Cotters To remove the cotters firmly press down as shown in the figure 20 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 31 4 Disassembly Reassembly LOMBARDINI KOHLER 21 WITH A WEIGHT WITH A WEIGHT OF 205N 20 2KG 315N 32 1KG B 34 8 mm C 25 8 NOMINAL LENGHTS A 52 00 mm Permissible tollerance weights and lenghts 5 22 EXHAUST VALVE INTAKE VALVE 23 24 Valve spring Check Check the overall state of the valve springs Replace if damaged or if they have lost their original elasticity First of all use a gauge to check that the free length matches the measurements given below A 52 mm Valve spring check under load Verify with a dynamometer that the length under load matches the nominal length If it is shorter than that quoted in figure 22 replace the spring Valve material 6 985 7 00mm 40 30 40 50mm 45 30 45 45 60930 60 45 Valve guides and cylinder head Intake and exhaust valve guides are both made of gray cast iron with pearlitic and phosphoric matirx oe Valve guides with ou
41. 6 ed_rev 05 TURBOCHARGER LOMBARDINI KOHLER IMPANY Turbocharger It is installed on the engine in two versions with air intake on the flywheel side and with air intake on the fan side To control the supercharge air pressure screw the pressure gauge into the M8 holes A and B both for the version with air intake on flywheel side fig 120 and for air intake on fan side fig 121 Turbocharger components 1 Flexible hose 2 Actuator 3 Collar 4 Turbine body 5 Snap ring 6 Compressor volute 7 Thickness 8 Nut 9 Lock nut 10 Shaft with turbine 11 Segment 12 Flame shield 13 Bearing 14 Snap ring 15 Thickness 16 Segment 17 Oil deflector 18 Thrust block sleeve 19 O ring 20 Thrust block bearing 21 Thrust block ring 22 Bearing 23 Snap ring 24 Snap ring 25 Bearing support Turbocharger Testing Get a pressure gauge with scale from zero to 2 bar connect it according to fig 120 and 121 Start up the engine warm it up for a few minutes then take it to 3000 rpm at the power NB f The supercharge air pressure value to be measured is 89 93 KPa 0 89 0 93 bar If the setting pressure does not come within the required value it is necessary to adjust the stroke of the valve control rod C Waste gate 58 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 2 LOMBARDINI A KOH
42. 8 Cylinder head tightening for engines without hydraulic 39 Cylirider head tightening Steps el ee Here Rete RE He e do Je Fato T a 39 Cylirnider roughness ar ee t Renta erri Rete peer ree E 36 Cylinders AUR 36 Dimensions for injection pump delivery control yoke 49 Driving 2 sides 29 t ar chet demde abe deett ec motn Re cria AUI ctos eec S 27 Dry air Comporierits n cicer tct petente iy Pe yb eB Fire esta coser are Rede espere nina dA duds Loa 28 Dynamic balancer on request Adjustment of clearance between teeth D and ring 47 Engines with hydraulic tappets eap Eie eod 55 Engines with mechanical 55 5 3 oa ee tite ie t esed Honda colon eec a ante 28 dall J 30 Frame with idling speed governor spring 0 50 todo Een eite rie ibn Ee 48 GR 1 and GR 2 hydraulic pump
43. 8x1 25 Oil pump top cover 6x1 Loctite 270 Oil pump bottom cover 6x1 Loctite 518 Thermostat cover 8x1 25 Oil sump 8x1 25 Water pump case and pump support 8x1 25 Flange for flywheel control oil sealing ring 6x1 Nozzle clamping ring nut fig 172 pag 72 24x2 Rod support ring nut 18x1 5 Equalizer unit 10x1 5 Loctite 242 Oil pressure indicator 12x1 5 Camshaft gear 10x1 Injector fig 171 pag 72 24x2 Starting motor 10x1 5 Intermediate pin 8x1 25 Front engine foot 16x1 5 Engine foot on bell 10x1 5 Fuel pump 8x1 25 Loctite 270 Injection pump fig 164 pag 69 8x1 25 Feed pump stud bolts 8x1 25 Drive puly fig 10 pag 29 16x1 5 Oil filter nipple UNF 3 4 Loctite 270 Fuel pump and solenoid valve union 10x1 Injection pump union fig 154 pag 68 12x1 5 Intermediate thrust block union 22x1 5 Loctite 270 Injection pump union 12x1 5 Water recirculation unions in brass 14x1 5 Loctite 554 Revolution counter driving gear 5x0 8 Alternator bracket 8x1 25 Engine mounting bracket 12x1 75 Bracket of the oil suction hose with equalizer 6x1 Bracket of the oil suction hose without equalizer 8x1 Loctite 242 Alternator support 8x1 25 Injection pump control rod support
44. Diameter R 600N mm R 800N mn R gt 1000N mm Nm Nm Nm M 8x1 20 27 38 M 10x1 42 56 79 M 10x1 25 M 12x1 25 39 52 73 M 12x1 5 M 14x1 5 M 16x1 5 M 18x1 5 M 18x2 M 20x1 5 M 20x2 M 22x1 5 M 24x2 M 27x2 M 30x2 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 87 13 sPECIAL TOOLS L LOMBARDINI SPECIAL TOOLS DESCIPTION Fuel delivery equalization tool Allows the adjustment of individual unit injector fuel 7104 1460 090 delivery Glass column for fuel delivery equalization tool 7104 1460 072 C haft bushi t aft bushing replacemen 7104 1460 021 Static timing tool 7271 1460 024 T D C determination fixture 7107 1460 075 Pliers for injection pump feeding tubes 1 Fortube diam 6 mm 1 7104 1460 022 2 For tube diam 8 mm 2 7104 1460 023 Tool for replacement of injection pump outlet union 7107 1460 212 1 For extraction 2 For driving 88 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 L LOMBARDINI 13 COMPANY ipo REPE EN Workshop Manual LDW cod 1 5302 345 6 ed rev 05 89 series Engine cod 1 5302 345 La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubb
45. E SERED 3 3000112 BB S B 2j 3 S f 1110004 4 Fi 0 150 300 450 600 750 900 1050 1200 1350 Starting Motor 24V Iskra type AZE 4598 24V 3 kW RH direction of rotation Characteristic curves for starting motor Iskra type AZE 4598 24V 3kW The thick lines were obtained at a temperature of 20 C the thin lines were obtained at a temperature of 20 C Battery type 55 Ah 300A U Motor terminal voltage in Volt n Motor speed in rpm A Absorbed current in Ampere P Power in kW M Torque in Nm 193 Key switch electrical layout A 7 Accessory B Off position C On position D Starting position 194 Spacer flange for starter motor The 24V starter motorrequires the assembling of the spacer flange 195 80 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Electric system 9 197 L 198 M14x1 5 199 Pre heating glow plug Components 1 Sheath 2 Regulation filament 3 Heating filament O Installation torque 20 Nm 12 14 after 5 15A after 60 Current ft fi Sheath surface after 850 C after 5 850 C 9 temperature 1100 C after 1 Note The glow plug is not damaged in any way due to the prolonged activ
46. LER COMPANY 5 Checking actuator setting Waste gate valve control rod stroke adjustment A Important This test must be done with the engine stationary Disconnect pipe 7 from the compressor side Using a T coupling connect up with a pressure gauge 4 scale from zero to 2 bar and with the compressed air mains pipe complete with reduction unit 5 The mains air pressure must be 1 5 2 0 bar Make a hole B diameter 1 5 mm in the pressure gauge pipe where part of the air will escape which has the purpose of stabilizing the pressure in the pressure gauge Use the reduction unit to send air to the actuator so as to make terminal 2 of A move forward A 1 Position a comparator 6 so that the feeler rests on the terminal 2 The pressure read on the pressure gauge must be 830 890 mm Hg 1 11 1 19 bar If the pressure is lower than the given value proceed as follows Unscrew the lock nut 1 Remove the split pin 9 and disconnect the rod 8 Keeping the rod stationary screw the terminal 2 to reach the setting pressure While the terminal is rotating the rod must undergo no twisting Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 59 6 LUBRICATION SYSTEM L LOMBARDINI A KOHLER COMPANY Danger Attention The engine may be damaged if operated with insufficient lube oil It is also dangerous to supply too much lube oil to
47. M 553 55553 ANNANS DA gt SSS M SSS SS WSs 53 37 Difficult operating conditions For correct functioning of the hydraulic tappets the pressure chamber of plunger 3 must always be filled with oil However this is not possible in some conditions in that when the engine is not running oil leakages may cause partial emptying of the tappets This situation will cause excessive clearance which will make itself apparent through an unusual ticking sound that is not to be confused with the normal ticking of the injectors 1 Starting from cold the engine has not been used for some time and oil may have leaked out of the pressure chamber of the tappets Moreover lubricant flows with greater difficulty at low temperatures and hence several seconds may go by before the tappets are once again supplied with oil 2 Engine very hot at minimum speed the oil pressure is low and tiny air bubbles may form inside it more than 5 of its volume This causes the lubricant to become compressible and the tappet is squeezed slightly creating clearance and thus making a noise 3 Starting and stopping the engine repeatedly very rare in this situation the tappets may empty temporarily In all three cases the ticking should not last too long If this is not the case the problem is definitely due to a manufacturing fault wear and tear or dirt which can be drawn in by the oi
48. PANY ELECTRIC SYSTEM 9 173 174 TA TET Tyr 40 20 20 40 60 80 Alternator type Marelli AA 125 R 14V 45A Characteristics Rated voltage 14V Rated current 45A Max 14000 giri 1 Peak speed max 15 min 15000 rpm Bearing on control side 6203 2z Bearing on manifold side 6201 2z C3 Voltage regulator RTT 119 AC RH direction of rotation O Tighten the nut 1 to 60 Nm Note Lube the two bearings with high temperature grease The alternator has a W terminal for a speed indicator Characteristic curves for alternator type Marelli AA 125 R 14V 45A The curves have been detected with electronic voltage regulator after thermal stabilization at 25 C test voltage 13 5 V P1 Power in kW Current in Ampere n Alternator efficiency Note The alternator rpm is equal to to the rpm shown in the table multiplied by 1000 Ratio between engine alternator rpm 1 1 8 Characteristic voltage curve for regulator type RTT 119 AC The electronic voltage regulator is built into the alternator The curve changes depending on temperature Max voltage curve B Min voltage curve Workshop Manual LDW CHD _ cod 1
49. R BLUE BLACK BLAU SCHWARZ AZUL NEGRO 3 E m mamoe MARRON 8ROWN e BRAUN 7 E MARRON 4 45A 65A 80A 183 Wiring diagram with alternator 45A 65A 1 Alternator 2 Starter Motor 3 Battery See below for sizing details 4 Glow Plugs 5 Thermistor Glow Plug Controller Circuit 6 Glow Plug Controller Timer 7 Key Switch 8 System Fuse 9 Fuse Accessory 10 Fuel Valve 11 Glow Plug Indicator Lamp 12 Coolant High Temperature Lamp 13 Coolant High Temperature Switch N O 14 Oil Pressure Low Lamp 15 Oil Pressure Switch N C 16 Alternator Charging Lamp Off if Charging 17 Diode 18 Air Filter High Restriction Indicator 19 Air Filter Restriction Switch N O 20 Low Fuel Level Lamp 21 Low Fuel Level Switch N O 22 n 2 100 ohm resistances in parallel A Accessory B Off Position C On Position D Starting Position Battery 3 is not supplied by LOMBARDINI Anyhow for installation we recommend a battery for all the ran ge of engines with the following particulars see following table Normal starting conditions Capacity K20 88 Ah Rapid discharge intensity DIN standards at 18 C 330A Heavy starting conditions max admitted Capacity 20 110 Ah Rapid discharge intensity DIN standards at 18 C 450A Note This electric starting diagram holds for both 45A and 65A alternators Connectio
50. R STRETCH SLEEVES SETTING AND INJECTORS CLEANING FUEL PIPES MANIFOLD RUBBER INTAKE HOSE AIR FILTER INTAKE INTERIOR RADIATOR CLEANING ALTERNATOR AND STARTER MOTOR ENGINE LUBRICANT OIL FILTER FUEL FILTER ALTERNATOR FAN BELT COOLANT LEVEL PARTIAL OVERHAUL TOTAL OVERHAUL FUEL PIPES MANIFOLD RUBBER INTAKE HOSE AIR FILTER INTAKE REPLACEMENT SLEEVES DRY AIR CLEANER EXTERNAL CARTRIDGE DRY AIR CLEANER INTERNAL CARTRIDGE AFTER 6 CHECKS WITH CLEANING STANDARD OIL SUMP 9 ENHANCED OIL 5 AFTER 3 CHECKS WITH CLEANING In case of low use every year case of low use every 2 years The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates The air filter must be cleaned and replaced more frequently in very dusty conditions If you are using oil of a quality lower than the prescribed one then you will have to replace it every 125 hours for the standard sump and every 150 hours for the enhanced sump 22 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 L LOMBARDINI Maintenance Recommended oil type Refilling 3 LUBRICANT SAE Classification 6 NOTES NET t 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30
51. WORKSHOP MANUAL CHD series Engine cod 1 5302 345 5 AN LOMBARDINIE SERVICE UNI EN ISO 0001 18O T8 10049 AM KOHLER COMPANY Every attempt has been made to present within this service manual accurate and up to date technical information However development on the LOMBARDINI series is continuous Therefore the information within this manual is subject to change without notice and without obligation The information contained within this service manual is the sole property of LOMBARDINI As such no reproduction or replication in whole or part is allowed without the express written permission of LOMBARDINI Information presented within this manual assumes the following 1 The person or people performing service work on LOMBARDINI series engines is properly trained and 2 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 to car
52. al 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 C Winter upto 10 C Alpine up to 20 C Arctic up to 30 C BIODIESEL FUEL Fuels containing less than 20 methyl ester or B20 are suitable for use in this engine Biodiesel fuels meeting the specification of BQ 9000 or equivalent are recommended DO NOT use vegetable oil as a biofuel for this engine Any failures resulting from the use of fuels other than recommended will not be EMISSION CONTROL INFORMATION d LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY AVIATION FUEL Aviation fuels suitable for use in this engine include JP5 JP4 JP8 and JET A if EPA CARB emission label must be 5 percent oil is added attached near the fuel inlet Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 25 4 DISASSEMBLY REASSEMBLY L LOMBARDINI RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING N 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 asse
53. and C with a pointed tool Finally blow with compressed air Re place plugs using a calking tool and check for sealing Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 45 4 Disassembly Reassembly L LOMBARDINI Checking main journals and crank pins Use an outside micrometer gauge The main bearing the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for LDW1503 from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004 T Pre and post modification single parts are not interchangeable Main journal and connecting rod big end journal diameter LDW R 1503200420047 LDW ef z Dimensions mm 1603 2204 2204 Pre modification Post modification Dimensions mm A 57 980 58 000 59 981 60 000 59 981 60 000 B 49 989 50 000 49 984 50 000 49 984 50 000 The crakshaft is made of spheroidal graphite cast iron hardened at the level of the oil seal rings 1 and 2 Hardness 55 hrc hardening depth 0 5 1 5 mm 88 Main bearing and connecting rod big bearing inside diame ter mm gt See fig 73 and 74 page 43 for checking procedures Note Both main bearing and connecting rod big end bearings are available with inside diameter measuring 0 25 and 0 50 mm LDW 1503 2004 2004 LDW Dimensions 1603 2204 2204 t Pre modifi
54. ation time Glow plug controller relay with coolant temperature sensor To avoid white smoke generation at cold start up post heating is maintained for approximately 5 sec after starting Trasducer Heating time in seconds C 4 2V 24V andPost heating ape pL _ 12 5 Temperature sensor Thermistor The thermistor is located on the thermostat housing adjacent to the high coolant temperature switch The thermistor must be installed in the thermostat housing in the port located nearest to the cylinder head See the figure to the left Characteristic Features of standard sensor Voltage 6 24 V EODEM Max installation Temperature C torque 30 Nm Features of heavy duty start sensor C Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 9 Electric system L LOMBARDINI Coolant high temperature lamp switch Circuit closing temperature 107 113 C pa M Characteristics e Single pole circuit normally open Supply 6 24V qi Absorbed power 3W We O When refitting tighten to 25 Nm 2227 _ ts 208 201 Thermistor for electric thermometer Thermistor features 35 me eem s omm 2040 1718 589 521 4 1 5 205 189 202 Thermistorf
55. before B 28 after I after S a 12 before S 8 before 36 after 2 after 5 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 55 Disassembly Reassembly LOMBARDINI KOHLER 117 Camshaft end play Check camshaft end play after removing the cylinder head the injection and the fuel pumps from the engine Check that plate 1 is tightened Position the dial gauge on the camshaft front surface push and pull the camshaft Maximum end play should be 0 008 mm ball bearing end play Hydraulic pump p t o 3rd p t o with hydraulic pump Gr 2 B 4th p t o with hydraulic pump Gr 1 Hydraulic pumps of either GR 1 or GR 2 type can be fitted even simultaneously on the erd and 4th p t o provided the resulting torque does not exceed 40 Nm The gear ratio between engine r p m and 3rd and 4th p t o is 1 1 GR 1 and GR 2 hydraulic pump 3rd p t o O R O R Center ring Circlip Thrust washer GR 2 hydraulic pump flange GR 1 hydraulic pump flange Bushing Trust washer GR 2 hydraulic pump drive gear GR 1 hydraulic pump drive gear Control gear gt Nao 56 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed rev 05 2 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly Workshop Manual LDW CHD _ cod 1 5302 345
56. cation Post modification Dimensions Soe 58 041 58 091 59 04 59 969 59 04 59 969 ys UE Clearance Clearance Clearance 0 035 0 077 0 077 0250 0035 0077 oso 0035 0 077 0 200 0 031 0 096 0 200 0 031 0 096 0 200 46 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI Disassembly Reassembly 4 92 Crankshaft for engines with dynamic equalizer only four cylinder engines The crankshaft comes with seat for the control gear of the counter rotating shaft dynamic balancer Components 1 Control gear for counter rotating shafts 2 Seat for the control gear of counter rotating shafts Dimensions mm 132 00 13203 13207 13209 To replace the gear heat it to 180 200 C Locate it into its seat so that the timing reference marks on the teeth are found on the flyweel side Dynamic balancer on request Adjustment of clearance between teeth D and ring gear A Follow figures 91 and 92 Screw the screw B into support C taking care to centre the hole in the mass of the gear D to lock it Fit the mass assembly under the crankcase so that the tooth with reference E goes between the teeth with references F Fix the mass assembly with the four M10 screws to the crankcase provisionally tightening it to 40 Nm
57. cond power take off must be at maximum 70 Nm The driving pulley drives the alternator and the water pump and consequently the cooling fan Bolt D can be loosened by turning clockwise When refitting lubricate the bolt with Molyslip and tighten it at 360 Nm Tank A Danger Attention To avoid explosions or fire outbreaks do not smoke or use naked flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the plug to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting Remove fuel line and loosen clamp screws Completely empty the tank and check that no impurities are found inside Check that cap breather hole is not clogged Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 29 Disassembly Reassembly LOMBARDINI A KOHLER IMPANY 14 15 y Caution Warning During the demounting phases pay particular attention to prevent the flywheel from dropping as this could seriously injure the operator Wear protective goggles when removing the flywheel ring Remove the bolts which attach the flywheel to the crankshaft when refitting tighten to 140 Nm after checking that the locating pin
58. device has the aim of preventing excessive smoke at the exhaust Use the delivery adjustment rod of the injection pumps 5 Fig 209 in a constant manner when ambient temperature is above 15 C As the temperature gradually falls this device gradually lessens its action to then exclude it at 0 C Fuel limiting device adjustment fig208 209 e Take the engine to the setting speed and power e Loosen the lock nut 2 e Unscrew the screw 1 to bring lever 4 close up to rod 5 until the engine speed tends to decrease e Screw the screw down by at most 1 2 3 4 of a turn so as to distance lever 4 from rod 5 by 1 2 1 8 mm Screw down the lock nut 2 e When the temperature falls under 0 C lever A turns pin 6 of the thermostat 3 comes back in to go into position B thereby allowing rod 5 to go into the supplement position Stop setting Unscrew the screw 2 Move rod 1 fully to the left Screw down screw 2 to touch rod 1 Continue screwing screw 2 by 1 2 turn Lock nut 3 Note In these conditions the injection pump delivery control limit stops cannot be damaged by violent impact caused by operation of any electro stops that may be fitted Application diagram for tampering system adjustment screw and torque gearing device for EPA approved engines Components 1 Breaking nut 2 STEI screw 3 Rivets No 2 4 TCEI screw 5 Special cover fixing screw 6 Lower plate 7 Upper plate 84 Workshop Manual LDW CHD cod 1 5302 34
59. e The notches shown above protrude from the cylinder head plane you can thus determine the gasket thickness before taking down the head 0 69 082 0 67 082 0 66 0 79 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 A LDW 1503 Ory Ur 07770 1603 8 74 778 8 7 5 1 3 9 what A o na B LDW 2004 1 1 ors 2004 T li ELLE 2204 X 2204 11 OU 57 58 Cylinderheadtightening for engines without hydraulic tappets Use a torque wrench fitted with tool for angular tightening It is recommended to replace the screws whenever the head is disassembled AN Important The cylinder head must never be retightened It is advisable to lubricate the lower part of the screws with anti seize of the type MOLYSLIP AS COMPOUND 40 Cylinder head tightening steps Following the number sequence shown in the figure 57 bolts should be tightened in four susequent steps with the following torque values ist step 40 Nm 2nd step 70 Nm 3rd step 100 Nm 4th steps For bolts 10 R Rotate wrench by 180 in two steps 90 90 For bolts 12 R present only in the TURBO engines perform a rotation of the
60. e products 11 Treat non painted parts with protective products AGIP RUSTIA NT 12 Loosen the alternator fan belt 13 Cover the engine with a proper protective sheet Caution Warning In countries in which AGIP products are not available find an equivalent product with specifications MIL L 21260C A Important Maximum every 24 months of inactivity the engine must be started up by repeating all Engine Storage operations PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT After the storage period and before starting up the engine and preparing it for operation you need to perform certain opera tions to ensure maximal efficiency conditions 1 2 3 8 9 10 11 12 13 Remove the protective sheet Remove any sealing devices from the exhaust and inta ke ducts Use a cloth soaked in degreasing product to remove the protective treatment from the external parts Inject lubricating oil no more than 2 cm3 into the intake ducts Adjust the alternator fan belt tension Turn the engine manually to check the correct movement and smoothness of the mechanical parts Refill the tank with fresh fuel Make sure that the oil and the coolant are up to the ma ximum level Start the engine and after some minutes bring it to 94 of the maximum speed for 5 10 minutes Turn off the engine Remove the oil drain plug see Oil replacement and discharge the AGIP RUSTIA NT protec
61. eassemble the rocker arm cap and the intake manifold tightening the screws to the indicated torque njection timing Injection timing value Checking low pressure injection timing for engines with value for for r p m 2400 mechanical tappets r p m gt 2400 B LDW 1503 The check of the advance on engines with mechanical tappets LDW 1603 E is carried out using the same procedure as that described for the LDW 2004 E hydraulic tappets the only difference is in the disassembly and LDW 2204 reassembly of the rocker arm pin and of the push rods which is not necessary LDW 2004 T US LDW 2204 T i i Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 71 Fuel system l LOMBARDINI A KOHLER MPANY Injection timing correction by changing the pad thickness Should it be necessary to correct the injection static advance remove the injection pump from the engine block and replace pad B inside the injection tappets with one of a different thickness to extract pad B use a magnet C Its value is printed on the lower part of the pad Eight spare pads are supplied for the advance variations and their thickness can vary from 4 to 4 7 mm The gasket A between the injection pump flange and the engine block is only one with the only task of preventing any possible oil leaks Previously to vary the i
62. ections Kg Max 60 seconds Max inclination Lasting up to 30 seconds Permanent Firing Order Referred to max power At NA power xd Depending on the application LDW 1503 J 9 LDW 2004 LDW 2004 18 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 2 LOMBARDINI KOHLER COMPANY Technical information 2 ENGINE TYPE CHD PLUS LDW 1603 LDW 2204 LDW 2204 T Cylindres 3 4 4 Bore 88 88 88 Stroke Displacement Compression ratio R P M 80 1269 CEE ISO 1585 DIN 70020 Power KW NB 150 3046 1 IFN DIN 6270 NA ISO 3046 1 ICXN DIN 6270 Max torque Nm RPM Max torque 3rd 4th p t o Nm RPM Oil consumption kg h Dry weight kg Combustion air volume at 3000 r p m l min Cooling air volume at 3000 r p m m min Max permissible driving shaft axial load in both directions kg Max 60 seconds Max inclination Lasting up to 30 seconds Permanent Firing Order Referred to max N power At NA power Depending on the application LDW 1603 sem LDW 2204 LDW 2204 Workshop Manual LDW cod 1 5302 345 6 ed rev 05 19 2 Technical information LOMBARDINI KOHLER IMPANY PERFORMANCE DIAGRAMS
63. ept 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 24 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 L LOMBARDINI Maintenance Recommended oil type Refilling 3 COOLANT Danger Attention The fluid coolant circuit is pressurized Inspections must only be made when the engine has cooled and even in this case the radiator or expansion chamber plug must be unscrewed with the utmost caution If an electric fan is installed do not approach a hot engine since the fan itself could start up even when the engine is at a standstill Coolant fluid is polluting it must therefore be disposed of in the correct way Do not litter The anti freeze protection liquid AGIPANTIFREEZE 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 LDW LDW LDW ENGINE TYPE 4603 4603 2004 2204 2004 T 2204 T CAPACITY Litres Without radiator 4 00 5 50 5 70 For information concerning the capacity of Lomba
64. filters must not be soaked in oil The reservoir of the separator pre filter must not be filled with oil e 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 e Pay attention to the temperature of the oil filter when the filter itself is replaced e 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 Nitro samine 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 e During operations that involve access to moving parts of the engine and or removal of rotating guards disconnect and insula te the positive wire of the battery to prevent accidental short circuits and to stop the starter motor from being energized e Only check belt tension when the engine is off e Only use the eyebolts installed by LOMBARDINI to move the engine These lifting points are not suitable for the entire machine in this case the eyebolts installed by the manufacturer should be used GENERAL SAFETY DURING OPERATING PHASES The procedures contained in this manual have been tested and selected by the manufacturer s technical experts and hence are to be recognised as authorised operating methods Some t
65. g pump is of the diaphragm type operated by a camshaft eccentric through a push rod If features an external lever for manual operation Fuel feeding pump drive rod protrusion Push rod 2 shows a protrusion A of 1 5 1 9 mm from the crankcase plane Check this value with eccentric 1 at the lowest point on the bottom of the cam base of the camshaft Push rod length 32 5 32 7 mm Check push rod length and replace push rod if size is inadequate 66 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI A KOHLER COMPANY Fuel system 8 Support clump _ 151 Intake side 153 Electric fuel pump 24V The use of the electric pump is foreseen for certain applications where the engine has to be started at very low temperatures Assembly notes When the electric fuel pump is installed in a diesel engine it is necessary to 1 Remove the filter fitted at the pump intake intake side 2 Insert the prefilter upstream of the pump intake side 3 The electric pump on the application must be at such a height from the minimum tank level that it generates a maximum pressure drop equal to a column of 500 mm of water 4 Avoid running dry due to emptying ofthe intake pipeline inserting a non return valve Features Pressure 0 44 0 56 bars Max capacity 100 I h Injection pump
66. gines have been disassembled repaired or altered by any part other than an authorized Lombardini agent Following expiration of the above stated warranty periods and working hours Lombardini will have no further responsibility for warranty and will consider its here above mentioned obligations for warranty complete Any warranty request related to a non conformity of the product must be addressed to the Lombardini Srl service agents GENERAL SERVICE MANUAL NOTES 1 Use only genuine Lombardini repair parts dimensions are presented in millimeters mm torque is Failure to use genuine Lombardini parts could result in presented in Newton meters Nm weight is presented sub standard performance and low longevity in kilograms Kg volume is presented in liters or cubic centimeters cc and pressure is presented in barometric 2 All data presented are in metric format That is units bar GLOSSARY AND TERMINOLOGY For clarity here are the definitions of a number of terms used Cylinder number one is the piston timing belt side recurrently in the manual viewed from the flywheel side of the engine Rotation direction anticlockwise viewed from the flywheel side of the engine Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 9 1 General remarks and safety information L LOMBARDINI SAFETY AND WARNING DECALS Important remarks and features of the text are highlighted A Caution Warning
67. he N power Oil pressure curve for LDW 2004 2204 Fig 136 The curve is obtained at the oil filter level constant engine epeed of 850 rpm in no load conditions Fig 137 The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power Oil pressure curve for LDW 2004 T 2204 T Fig 138 The curve is obtained at the oil filter level constant engine epeed of 850 rpm in no load conditions Fig 139 The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power Note The max lubrication oil temperature must be lower than the sum ambient temperature 95 C Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 C LOMBARDINI Lubrication system 6 COMPANY HL Rt DLE LACE A CUM oO OPO Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 63 7 COOLING SYSTEM LOMBARDINI A KOHLER COMPANY 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 at a standstill Coolant fluid is polluting it must therefore be disposed of in the correct way Do not litter COOLING SYSTEM LAYOUT If an electric fan is installed do not approach a hot engine since the fan itself could start up even whe
68. he manifold is not broken in any way When refitting replace gaskets B O Tighten nuts to 25 Nm Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly jl MS ad a E D a f 4 3 P d mee 9 10 V belt Danger Attention Check the belt tension only when the engine is not running Tension adjustment Loosen alternator fixing bolts C Stretch belt so that a 100 Nm load located half way between the two pulleys causes 10 15 mm flexure Pull strongly alternator externally and tighten fixing bolts C The final torque must be 40 Nm If you use the belt tension gauge type DENSO BTG 2 the correct value of tension must be from 20 to 25 kg Cooling fan Danger Attention Before disassembling the cooling fan isolate the positive battery cable to prevent accidental short circuiting and consequently activation of the starter motor Take off the fan and check that all blades are not damaged if any are damaged replace the entire fan Depending on the type ofapplication the cooling fans can be suction or blower fans and can differ in diameter Driving pulley 2 P T O The maximum torque that can be drawn from the se
69. hrust bearings The main bearing the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for LDW1503 from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004 T Pre and post modification single parts are not interchangeable Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 43 4 Disassembly Reassembly LOMBARDINI KOHLER IMPANY Grease the shoulder half rings so that they will remain in their seats during assembly Halves should be fitted with grooves A as shown in the figure 77 78 Thrust bearing thickness 2 31 2 36 mm oversize halves with thickness increased by 0 1 and 0 2 mm are available as spares Thrust bearing oversizes Grinding B according to the above table following half rings can be assembled 15 Oversize Half rings 1 and 2 on both the support sides 0 10 mm 2 Oversize Half rings 1 and 2 on one support side 0 10 mm and on the other side 0 20 mm 3 Oversize Half rings 1 and 2 on both the support sides 0 20 mm 2777 2792 28 00 28 05 1st Oversize 2797 2812 2820 2825 0 08 028 2nd Oversize 2807 2822 28 30 2835 3rd Oversize 2817 2832 2840 2845 82 Crankshaft end play After tightening main bearings measure the end play A between
70. ication diagram for tampering system adjustment screw and torque gearing device for EPA approved 84 SON aaiae Ko Ato 84 Fuel limiting device adjustments soa m iioii tetro cec done deen son bdo udo d eed eerta 84 Full speed setting in no load conditions 83 Idling speed setting in no load conditions standard emere eren 83 Injection pump delivery limiting and torque adjusting 83 Standard injection pump delivery setting without torque 83 Meer c c 84 11 ENGINE 5 retenta dti e eoe eni ieri 85 Eriglne Storage ree RR PER RE ERU ERR st RESI e 85 Preparing the engine for operation after protective emere rennen 85 Protective treatment ror dr rer RCEPM ERR ERE ERE 85 12 TORQUE SPECIFICATIONS AND USE OF SEALANT 404 0 0 2 86 87 Main itorque specifications reote eee rre eeu eee eee e e beeen 86 Table of tightening torques for standard screws coarse 87 Table of tightening torques for standard screws fine
71. ich locks the bearing to the pump body A seal is located on the shaft between the bearing and the impeller In case of worn out seal coolant leaks from hole 1 LDW 1503 1603 2004 2204 The ratio between the pump and engine rpm 1 1 2 Pump delivery at 3000 rpm is 70 liters min LDW 2004 T 2204 T The ratio between the pump and engine rpm 1 1 5 Pump delivery at 3000 rpm is 116 liters min Thermostat 1 Air valve Specifications Opening temperature 77 81 C Max stroke at 94 C 7 5 mm Coolant flow rate with thermostat and valve in closed position 15 Liters h Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 65 FUEL SYSTEM LOMBARDINI KOHLER IMPANY 147 148 150 Fuel feeding injection circuit Components 1 Tank 2 Fuel feeding pump 3 Fuel filter 4 Fuel delivery tube 5 Injector pumps overflow tube 6 Injection pump 7 High pressure tube between pump and injector 8 Injector 9 Injector return tube 10 Solenoid valve Fuel filter Components 1 Drain screw 2 Cover 3 Seal 4 Fitting 5 Cartridge Cartridge specifications Max working pressure 4 bar gt See page 22 for maintenance details Fuel feeding pump Components 1 Feeding pump 2 Push rod 3 Seal ring The fuel feedin
72. implies irreversible damages to the precombustion chamber which will have to be replaced In the assembly stage line up the dowel 1 with the reference notch 2 located in the head Driving must be carried out evenly The clearance allowance between the precombustion chamber and its bore on the cylinder head is equal to 0 05 mm Using a depth gauge check that the precombustion chamber plane protrusion does not exceed 0 04 and does not receed over 0 02 mm from the head plane level The precombustion chamber plugs ofthe CHD PLUS series engines have a different internal volume from the CHD series therefore they are not interchangeable Hydraulic tappet valve control Dimensions Clearance Limit value mm mm mm 23 000 23 021 0 040 0 046 0 10 22 960 22 975 Nota f tappet is worn out along diameter B replace it No oversize tappets are available If tappet camshaft surface is worn replace 2 Hydraulic diagram for feeding the tappets iN SADT Y 1 2 Rocker arm 1 3 Push 4 Oil drainage 5 Hydraulic tappet 35 Hydraulic tappet components a Tappet body b Plunger Non return valve d Spring e Push rod f Low pressure chamber g High pressure chamber The hydraulic tappet is a device that enables elimination of clearance between timing system components a
73. inen o ede 68 Injection pump P No 6590 249 Plunger and barrel 70 Injection timing correction by changing the pad 0 0 nnne nnne 72 Injector pin type Inj amp ctor setting nte eee e C ei ES EU p PEE ER ERR E ERE eh Instrument for equalizing injection pump em eene rennen nnne enne 69 Test data of ee acl ERR ROPA HE LEE He BUR Des eese edna Dea blero 70 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 7 Chapter index LOMBARDINI 9 ELECTRIC SYSTEM ec 73 82 Alternator type Iskra AAK3139 14V 80 75 Alternator type Iskra type AAK3570 28V 35A for 24 V emen 77 Alternator type Marelli 125 14 45 73 Alternator type Marelli AA 125 R 14V 5 74 Characteristic curves for alternator type AAK3570 28V 35A for 24 V 77 Characteristic curves for alternator type Iskra AAK3139 14V 80 75 Characteristic curves for alternator type Marelli AA
74. ith Diesel fuel and dry with compressed air Top up engine oil to the mark see below When refitting tighten nuts to 25 Nm See page 22 for periodic cleaning and oil replacement Oil bath air cleaner components Bowl Outer seal ring Lower filtering element Inner seal ring Gasket Cover Cap clamp Cap Centrifugal pre filter 10 Centrifugal pre filter clamp 11 Oil level mark 12 Upper filtering element polyurethan sponge Note Centrifugal pre filter 9 is fitted upon request Dry air cleaner Danger Attention Never clean the filtering element using solvents with a low flash point This could cause an explosion A Fitting to accomodate clogging indicator See page 22 for periodic dry air cleaner check and replacement x and the rubber intake hose air filter intake manifold Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 27 4 Disassembly Reassembly LOMBARDINI KOHLER EN DE DO V ee Dry air components 1 Main cartridge 2 Safety cartridge 6 Rubber connecting hose to the air filter manifold or compressor 3 Axial cover 7 Air filter restriction switch 4 Vacuator valve 8 Mounting for clogging indicator 5 Cap complete with clamp 9 Fastener Scave
75. ke a reference marking on the fastening flanges of the injection pumps and on the base planes of the crankcase Leave the shims for injection timing setting under each pump unchanged Each pump should be reassembled in its own housing Align the delivery reference notches located on the pump flange with those on the crankcase Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 69 LOMBARDINI KOHLER IMPANY 8 Fuel system Injection pump P No 6590 249 Plunger and barrel assembly 1 Zum Components 1 Pump body 4 gt 2 Barrel 3 Plunger 4 Plunging blade NY Note Barrel 2 forms an integral part of the pump body 1 For this reason both the barrel and plunger 3 should not be replaced Checking injection pump delivery Components 1 Delivery adjustment rod 2 Rod 1 stop position 3 Rod 1 max delivery position A 18 5 19 5 mm rod max stroke 66 rod max rotation Test data of injection pump LDW 2004 T 2204 T Delivery mm stroke Control rod Rod stroke fro Camshaft LDW 1503 2004 LDW 1603 2204 max force max delivery Delivery Delivery Newton point mm mm stroke mm stroke 70 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 L LOMBARDINI Fuel system 8 Checking low pressure injection timing for engines with hydraulic tappets
76. key of 270 in three steps 90 90 90 Assembling and tightening the cylinder head on engines with hydraulic tappets A Important Before re assembling the cylinder head the tappets must be removed from their housing and released This operation must be carried out using a pin 1 Insert pin 1 inside the tappet and open the non return valve The excess oil is released by turning the tappet upside down Rotate the crankshaft so as to position the pistons at half stroke for three cylinder engines For four cylinder engines place the piston of cylinder number one at 150 after the top dead centre in crossover stage Fit the head insert the fastening screws and tighten them in the order shown in figure 57 and to their respective torques see Cylinder Head Tightening Stage Reassemble the complete pin inserting the seats of the rocker arms on their respective rods and screw up the fastening screws of the supports by hand A Important To avoid bending the push rods or damaging the tappets the fastening screws of the rocker arm pin supports must be tightened gradually before reaching the final torque This procedure will give time for the excess oil in the tappets to drain away Each time you start to tighten up the fastening screws of the supports you can use the upper spring support cup of the valve spring as an indicator to know how far to screw them up The cup must never be compressed so much that it touches the va
77. l and get between the non return valve and its seat inside the plunger thus compromising the functioning of the tappets In this case the hydraulic tappets must be replaced Injection pump follower Introduce the follower into its housing and manually turn screw 3 until it matches with notch 2 Before locking screw 3 use your finger to check that the follower is allowed to move upwards freely Space 1 should be introduced into the pushrod with the flat surface facing upwards Note The screws 3a can be fitted without distinction in each cylinder Screw 3b however which is shorter than the others has to be fitted on the timing side of the cylinder inside the stop lever cover 38 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 35 4 Disassembly Reassembly L LOMBARDINI Cylinders 7 E Reset dial gauge with a calibrated ring Check diameter size D at 1 2 and 3 repeat the same operation at the same places after turning the dial gauge by 90 Check for wear in the X area where piston rings are located BQWW 7097 QAR VS M LI TII II DIL SSMS SS CUN T 4 SiS _ Ns F Limit value D mm mm 2 S LEN 88 00 88 01 88 100 To check clearance with the matching piston measure the diameter size at Z along the axis which runs at righ
78. licazione 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 T C LOMBARDINI SERVICE A KOHLER COMPANY 42100 Reggio Emilia Italia ITALY Via Cav del Lavoro Adelmo Lombardini 2 Cas Post 1074 rud Tel 39 0522 3891 Telex 530003 Motlom Telegr Lombarmotor UN EN cert R E A 227083 Reg Impr 10875 Cod fiscale e Partita IVA 01829970357 CEE Code IT 01829970357 E MAIL atlo lombardini it Internet http www lombardini it
79. likely anomalies and their 5 0 22 20000000 0 nemen eren EnEn nennt Ennn EnEn Ennen Ennen 12 Technical specifications M 18 3 MAINTENANCE PRESCRIBED LUBRICANT REFILLING 22 25 ACEA Regualtions ACEA Sequences sea 23 APW MIL SOGUEMCES ome halte tte semi e EL 23 cece 25 lee Bure e 25 Sr 25 Extraordinary maintenance 02 2 0 0 1 0000001 eeseaaeeee ennt 22 Fruelirecommierndatlons ur Se sas ene 25 PUG c E E 25 Fuels redire AC nerui de 25 International 2 2 eee eeee ces aeae cee TE 23 caus za aceveces 23
80. lve clearance 2 mm a 14 after S corresponding to 35 mm on the flywheel 6 after I corresponding to 15 mm on the flywheel 17 before 1 corresponding to 43 mm on the flywheel 15 before S corresponding to 38 mm on the flywheel Timing angles for operating purposes valve clearance 0 15 mm a 14 before S corresponding to 35 mm on the flywheel p 34 after I corresponding to 85 mm on the flywheel 46 before I corresponding to115 mm on the flywheel 14 after S corresponding to 35 mm on the flywheel Timing angles for checking purposes LDW 2004 T valve clearance 2 mm a 15 after S corresponding to 38 mm on the flywheel 21 after I corresponding to 52 mm on the flywheel 31 before I corresponding to 77 mm on the flywheel 13 before S corresponding to 32 mm on the flywheel Timing angles for operating purposes LDW 2004 T valve clearance 0 15 mm 12 before S corresponding to 30 mm on the flywheel 48 after I corresponding to 120 mm on the flywheel 58 before I corresponding to 145 mm on the flywheel 14 after S corresponding to 35 mm on the flywheel Timing belt operating angles with valve clearance set to zero DW 1503 under 1603 2400 r p m 2004 2204 upper 2400 r p m under upper Dw 2004 7 a 12 before 5 8 before 2400 LDW 220477 B 48 after I 4 after S a 8 before S 36
81. lve stem oil sealing ring fitted on the guide Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 39 4 Disassembly Reassembly LOMBARDINI KOHLER IMPANY 59 LDW 1503 1603 LDW 2004 2004 T 2204 2204 62 LDW 1503 2004 2004 T LDW LDW 1603 2204 2204 T 2004 T 2204 T LDW 1503 1603 2004 2204 Tightening must be carried out as shown in figure 59 Once the final torque 50 Nm is reached wait thirty minutes before manually rotating the engine to verify that the pistons do not collide with the valves if the engine turns freely start the engine normally otherwise wait another 30 minutes before repeating the operation At first start up the engine may run irregularly until all the air contained in the tappets has been drained Connecting rod N Important When remounting the big end bearings remember to thoroughly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the first time Remove oil pan and oil pump suction pipe Disconnect the connecting rod from the engine shaft and perform the subsequent checks When refitting both centering notches A and B should be located on the same side O Tighten the connecting rod big end bolts to 70 Nm Connecting rod weights Connecting rod piston and pist
82. m these simple checks before removing or replacing any part TROUBLE does POSSIBLE CAUSE consumption Engine not start Engine starts but stops No acceleration Non uniform Black smoke White smoke Too low oil pressure Overheats Inadequate performance Excessive oil High noise Obstructed fuel line Fuel filter clogged Air or water leaks in fuel system CIRCUIT The tank cap vent hole is clogged fuel Discharged battery Cable connection uncertain or incor rect Faulty starting switch Faulty starting motor SYSTEM Faulty glow plugs ELECTRIC Faulty glow plug control relay Burnt fuse on preheating spark plugs Clogged air filter Excessive idle operation Incomplete run in MAINTENANCE Overloaded engine Incorrect governor linkage adjustment Governor spring broken or unhooked Low idle speed Rings worn or sticking Worn cylinder Worn main con rod rocker arm be arings Badly sealed intake valve SETTINGS REPAIRS Damaged cylinder head gasket Defective timing system Bent rods Faulty hydraulic tappets 12 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 2 LOMBARDINI Technical information POSSIBLE CAUSE TROUBLE does Engine not start Engine starts but stops No acceleration Non unifo
83. mblies before installing them The operator must make sure that the contact surfaces are intact lubricate the coupling parts and protect those that are prone to oxidation Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely For safety and convenience you are advised to place the engine on a special rotating stand for engine overhauls Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved In order to fix assemblies and or components securely the operator must tighten the fastening parts in a criss cross or alternating pattern Assemblies and or components with a specific tightening torque must initially be fastened at a level lower than the assigned value and then subsequently tightened to the final torque RECOMMENDATIONS FOR OVERHAULS AND TUNING AN 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 dep
84. n diagram for preheating control unit Components 1 Cable cross section 2 5 mm at point 50 of the key panel 2 Cable cross section 6 mm at the fuse holder box 3 Cable cross section 1 5 at the earth 4 Cable cross section 1 mm2atthe spark plug warning light max 2 W 5 Cable cross section 6 mm at point 30 of the key panel 6 Cable cross section 1 mme at the water temperature sensor 7 Cable cross section 1 5 mm at the fuse 76 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 CL LOMBARDINI Electric system 9 Alternator type Iskra type AAK3570 28V 35 for 24 V out fits Characteristics Rated voltage 28V Rated current iieii ieiet 35A Speed of the load starting point 1140 rpm Maximum permanent intermittent speed max 15 13000 15000 rpm Front bearing wi dps 6303 2RS C3 Rear 6201 2RS Max force on the bearing 600 N Voltage 1528 RH direction of rotation di O Tighten the nut 1 to 60 70 Nm Note Lube the two bearings with high temperature grease The alternator has a W terminal for a speed indicator Charac
85. n the engine is 1 5 9 2 6 3 10 7 4 8 140 Components 1 Coolant fill cap 2 Expansion tank 3 Cylinder block 4 Circulating pump 5 Coolant temperature warning lamp 6 Thermostat 7 Fan 8 Radiator 9 Temperature sensor 10 Heat exchanger LDW 2004 T 2204T 64 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Cooling system 7 141 146 Expansion tank and cap The expansion tank is separated from the radiator and is fitted with a coolant fill cap The cap comes with vacuum valve 1 and pressure relief valve 2 The pressure relief valve opens at a pressure of 0 7 bar Checking for cooling system leaks Remove the cap from the expansion tank and check coolant level Replace the cap with one fitted with portable hand air pump coupling as shown in the figure 142 Compress air at a pressure of 1 bar for approximately 2 minutes Check that no leaks occur Caution Warning In very dusty working conditions verify and clean the outside of the radiator frequently gt Replace coolant as specified on page 22 Coolant circulating pump Impeller 3 and hub 5 are fitted to the shaft by press fit To remove the impeller screw the M 18x1 5 bolt into bore 2 To remove that shaft take 4 wh
86. nd provides the following advantages Reduces noise levels during operation Reduces wear ofthe timing system components thanks to there being no collisions at the opening with consequent breaking of 36 the oil film No maintenance 34 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 Disassembly Reassembly 4 Hydraulic tappet operation The operating principle of the hydraulic tappet is based on the incompressibility of the liquids and on controlled leakage Through push rod 1 the pressurised oil gets into the tappet in chamber A low pressure chamber maintaining a constant flow of the above chamber as wellas in the high pressure chamber B The oil can only enter chamber B through the non return valve 2 and leave through the clearance between the plunger 3 and the tappet body 4 controlled leakage Chamber B is refilled when the tappet is on the bottom of the cam base and spring 5 keeps plunger 3 pressed thus eliminating the clearance in the entire valve rocker arm push rod tappet cam 2 230 system The tappet body moves away from the plunger creating a slight vacuum in chamber B and causing the valve 2to open thus allowing the oil in chamber A to flow into chamber B re establishing the quantity of oil required for optimal running conditions 27222222222 F 922222222222 9 AN NJ SS 2
87. nging valve 4 must be positioned as in figure 4 The cartridge can be cleaned by blowing compressed air breadthways outside and inside the cartridge at a pressure not greater than 5 atmospheres or in necessity case by knocking the front of the cartridge several times against a flat surface Use a lamp to check that the filter element is not damaged or inspect it against the light while slanted In case of doubt install a new cartridge Air filter clogging indicator Important The indicator has to be tightened to mounting 4 as shown in fig 5 B Due to space requirements it can be assembled by using special fastener 3 fig A and by creating a hole of 014 15 mm in the rubber hose see fig 4 1 Air filter restriction switch 2 Turbo adapter 3 Fastener 4 Mounting for clogging indicator Note There are two types one for an aspirated engine and one for a supercharged engine Setting for aspirated engine LDW 1503 1603 2004 2204 635 mm column of water Setting for supercharged engine LDW 2004 T 2204 T 380 mm column of water Intake manifold The sealing surface should be clean smooth and free of any strains and scoring When reassembly replace gasket A O Tighten the fastening screws to 25 Nm Exhaust manifold Danger Attention Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns Verify that the seal surfaces are free of distortions and scratches and that t
88. njection advance gaskets of different thicknesses were used between the injection pump surface and the engine block surface in effect gasket A without sealing rubber border Injector pin type Components 1 Fuel inlet 7 Delivery union 2 Filter 8 Backflow union 3 Body 9 Setting shims 4 Delivery duct 10 Pressure spring 5 Pad 11 Pressure pin 6 Clamping ring nut 12 Nozzle 13 Fireproof bulkhead Whenever maintenance operations are carried out on the injector replace the seal ring 1 Introduce seal ring 1 into the injector housing with the sealing surface facing upwards see figure 171 gt See page 22 for maintenance intervals O Fix injector to the head tightening to 70 Nm Injector setting Connect the injector to a injection test stand and check that the pressure setting is 140 150 bar Adding the shims 9 increases the pressure setting reducing their number lowers it Eleven spare setting shims 9 are included their measurements range from 1 to 2 mm When spring 10 is replaced calibration must be carried out at a pressure 10 bars higher than the nominal pressure 160 bar to counterbalance bedding in the operation Check needle valve sealing by slowly moving the hand pump until approximately 120 bar 10 seconds Replace nozzle 12 in case of dripping O The torque of the injector ring nut is 70 90 Nm Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 2 LOMBARDINI KOHLER COM
89. nnection diagram for preheating control unit Components 1 Cable cross section 2 5 mm at point 50 of the key panel 2 Cable cross section 6 mm at the fuse holder box 3 Cable cross section 1 5 at the earth 4 Cable cross section 1 mm2atthe spark plug warning light max 2 W 5 Cable cross section 6 mm at point 30 of the key panel 6 Cable cross section 1 mme at the water temperature sensor 7 Cable cross section 1 5 mm at the fuse 78 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI Electric system 9 Starting Motor 12V Bosch type EV 12V 2 2 Kw RH direction of rotation Note Apply to a Bosch service center for any tipe of repair 189 Characteristic curves for starting motor type Bosch EV 12V 2 2 kW The solid lines were obtained at a temperature of 20 C the dotted lines were obtained at a temperature of 20 C Battery type 110 Ah 450A U Motor terminal voltage in Volt n Motor speed in rpm A Absorbed current in Ampere P Power in kW M Torque in Nm 190 Key switch electrical layout A 7 Accessory B Off position C On position D Starting position 191 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 79 Electric system LOMBARDINI A KOHLER 192 EH TERRE Jed M amm
90. on pin can also be weighed in a preassembled state but the difference in weigt should not exceed 14 g in order to avoid unbalance Connecting rod and piston pin The connecting rod big end shell bearings are supplied in either standard or with this value decreased by 0 25 and 0 50 mm respectively N Important The fastening screws must be tightened by hand until the beginning of the tightening stage and then pre tightened to 10 15 Nm O Final tightening is to 70 Nm 40 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 Q LOMBARD e Disassembly Reassembly 4 EMI Clearance mm Limit value mm Dimensions mm 144 98 145 02 147 98 148 02 odis od With driven and bored bearing B 28 02 28 03 With cap fitted and screws tightened to a torque of 70 Nm Connecting rod alignment Use a surface plate and a dial gauge as shown in the figure 65 Check the alignment of the axes using the wrist pin of the piston deviation A 0 02 mm limit 0 05 mm Moderate warpage may be corrected by gradually working with a press Piston cooling sprayer This is assembled on turbo engines LDW 2004 T 2204 T Blow on it with compressed air and check that there are no impurities inside Reassemble it back into place making sure you maintain axis alignment A of the spray with respect to axis B shown in the figure 67 Any
91. ools are normal workshop ones while others are special tools designed by the Manufacturer of the engine All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely 115 important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual Holes must be lined up methodically and with the aid of suitable equipment Do not use your fingers to carry out this operation to avoid the risk of amputation Some phases may require the assistance of more than one operator If so it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved Do not use flammable liquids petrol diesel etc to degrease or wash components Use special products Use the oils and greases recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to In order to minimise the impact on the environment the manu identify assess and monitor the influence of its own activities fac
92. or preheating watertemperature Thermal contact for water temperature indicator light 2 203 327 405 275 335 Thermal contact T2 features The max torque is 30 Nm 82 Workshop Manual LDW cod 1 5302 345 6 ed rev 05 C LOMBARDINI KOHLER COMPANY SETTINGS 10 Idling speed setting in no load conditions standard After filling with oil fuel and coolant start the engine and warm up for 10 minutes Adjust idling speed at 850 950 rpm by turning screw 1 then tighten lock nut Note Speed decreases when loosening screw 1 and increases when tightening it Full speed setting in no load conditions standard Before carrying out this operation make sure that the engine adjustment is standard i e corresponding to one of the power curve diagrams shown on pages 20 21 Example of adjustment of an engine at 3000 rpm After setting idle speed turn screw 2 and set full speed in no load conditions at 3200 rpm then tighten lock nut When the engine reaches the pre set power full speed stabilizes at 3000 rpm Nota Speed increases when loosening screw 2 and decreases when tightening it Standard injection pump delivery setting without torque dynamometer This adjustment must only be carried if necessary and if there is no d
93. osits or residual material Wash the components with special detergent and do not use steam or hot water Do use flammable products petrol diesel etc to degrease or wash components Use special products Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them Apply a layer of lubricant over all surfaces to protect them against oxidation Check all components for intactness wear and tear seizure cracks and or faults to be sure that the engine is in good working condition Some mechanical parts must be replaced en bloc together with their coupled parts e g valve guide valve etc as specified in the spare parts catalogue Danger Attention During repair operations when using compressed air wear eye protection 26 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Disassembly Reassembly 4 Oil bath air cleaner Danger Attention Never clean the filtering element 6 using solvents with a highly flash point This could cause an explosion A Caution Warning During repair operations when using compressed air wear eye protection Check gaskets and replace if necessary Check that flange welds are free of porosity or defective spots Carefully clean bowl and filtering element w
94. perations 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 e The engine may only be used or assembled a machine by technicians who are adequately trained about its operation and the deriving dangers This condition is also essential when it comes to routine and above all extraordinary maintenance operations which in the latter case must only be carried out by persons specifically trained by LOMBARDINI and who work in compliance with the existing documentation e 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 e 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 e Make sure that the machine is stable to prevent the risk of overturning e Become familiar with ho
95. ping when cylinder 1 tappets are in overlap position intake open exhaust closed Using the straight edge B check that rods A are at the same length Mark the idler gear with camshaft and timing gear 114 Valve timing check qe Check valve timing at the crankshaft s The values shown are checked at the flywheel circumference with ICZ SSO l flywheel diameter of 290 each degree corresponds to 2 53 mm 554 77 Set valve clearance at 0 65 0 70 mm after checking reset the 2 4 ba value to 0 15 mm SENN Set dial gauge on intake valve to a zero value by rotating the S crankshaft according to its direction of rotation you can measure 6 NN act intake valve opening advance referred to top dead center S and lt p p intake valve closing delay referred to bottom dead center I Follow the same procedure for exhaust valves checking y exhaust valve opening advance Jand 6 exhaust valve closing delay 115 54 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 2 LOMBARDINI A KOHLER COMPANY Disassembly Reassembly 4 Legend S piston at top dead centre l piston at bottom dead centre a intake valve open p intake valve closed y exhaust valve open 6 exhaust valve closed 116 Engines with hydraulic tappets Engines with mechanical tappets Timing angles for checking puposes va
96. ral Service manual aise gens een tor iens res 9 gt 1055 gt EE AE D tpe FTe 9 Safety and environmental 11 Safety and 10 oalety tegulatloris eei teet REN INUENIRI eua nU 10 DUM LL LLLI Mech c e 9 2 TECHNICAL INFORMATION no parnm e nt enm ERR a Eaa ARS REN ER 12 20 E H 14 Characteristics power torque and specific fuel consumption 20 Manufacturer and motor identification 14 Overal dimensions E 15 P 20 Possible causes and trouble shooting 5 ciae tte eine 12 Table of
97. rdini radiators please contact Lombardini directly The total volume for refilling the cooling liquid varies according to the type of engine and radiator FUEL RECOMMENDATIONS Purchase diesel fuel in small quantities and store in clean approved containers Clean fuel prevents the diesel fuel injectors and pumps from clogging Do not overfill the fuel tank Leave room for the fuel to expand Immediately clean up any spillage during refueling Never store diesel fuel in galvanized containers diesel fuel and the galvanized coating react chemically to each other producing flaking that quickly clogs filters or causes fuel pump or injector failure High sulfur content in fuel may cause engine wear In those countries where diesel has a high sufur content its is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently The regions in which diesel normally has a low sulfur content are Europe North America and Australia PRESCRIBED LUBRICANT Fuel with low sulphur content 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 speci
98. refitting it to 150 Nm Clearance Worn limit mm A B mm End play Worn limit mm A B mm 0 10 0 30 0 60 er mm o oe Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Disassembly Reassembly 4 Speed governor N Important During reassembly make sure the components are undamaged and verify they work properly Malfunctioning of the speed governor can cause serious damage to the engine and to people in the vicinity of it Components 1 Gear 2 Bell 3 Counterweights 4 Bolt 5 Throttle control rod 6 Governor spring 7 Injection pump delivery rod 8 Yoke 9 adjustement eccentric 9 Control yoke for injection pump delivery rod 10 Bushing 11 Lever 12 Adjusting screw Yoke 9 is pre set through screw 12 and eccentric 8 Do not unscrew O When refitting camshat gear 1 tighten bolt 4 to 100 Nm Dimensions for injection pump delivery control yoke adjustement Components 9 Control yoke for injection pump delivery rod 10 Bushing 11 Lever 12 Adjusting screw 13 Reference and mounting plane for support 14 14 Lever Support Dimensions mm 134mm 88 mm Note f when adjusting screw 12 is unintentionally loosened adjust yoke 9 considering the dimensions A C and D In case of replacement lever 11 is supplied complete with pre
99. refuelling e The engine must be started in compliance with the specific instructions in the operation manual of the engine and or machine itself Do not use auxiliary starting aids that were not installed on the original machine e g Startpilot Before starting remove any tools that were used to service the engine and or machine Make sure that all guards have been refitted e During operation the surface of the engine can become dangerously hot Avoid touching the exhaust system in particular e Before proceeding with any operation on the engine stop it and allow it to cool 10 Workshop Manual LDW cod 1 5302 345 6 ed rev 05 ERE et General remarks and safety information 1 Never carry out any operation whilst the engine is running e 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 en gine 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 e 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 en vironment The spongy filtering material in oil cooled air
100. rm speed Black smoke White smoke Too low oil Excessive oil consumption pressure Inadequate performance Overheats High noise INJECTION Damaged injector Injection pump valve damaged Injector not adjusted Faulty fuel feeding pump Hardened pump control rod Broken or loose supplementary start up spring Worn or damaged pumping element Incorrecttuning of injection components delivery balancing advance Cracked or broken precombustion chamber LUBRICATION CIRCUIT Oil level too high Oil level low Oil pressure valve blocked or dirty Worn oil pump Oil sump suction line clogged Faulty pressure gauge or pressure switch Blocked draining pipe Faulty spray nozzles Turbo engines only Blocked draining pipe COOLING CIRCUIT Alternator fan belt loose or torn Clogged radiator exchange surface Insufficient coolant Fault fan radiator or radiator plug Faulty thermostatic valve Blockage inside the radiator or the coolant ducts Coolant leaking from radiator hoses the crankcase or from the water pump Faulty or worn water pump Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 13 2 Technical information L LOMBARDINI A KOHLER COMPANY MANUFACTURER AND MOTOR IDENTIFICATION DATA A D
101. ry 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 Workshop Manual LDW CHD _ cod 1 5302 345 6 ed rev 05 3 LOMBARDINI KOHLER IMPANY REGISTRATION OF MODIFICATIONS TO 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 N Issue date gate Endorsed Leama 1 5302 345 50534 5 31 12 89 01 12 2009 Hews 4 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 C LOMBARD INI CHAPTER INDEX This manual gives the main instructions on how to repair LOMBARDINI diesel engines LDW 1503 1603 2004 2004 2204 2204 T fluid cooling circuit updates as of December 1 2009 INDEX 1 GENERAL REMARKS AND SAFETY nnne nnne nn nnn 9 11 General safety during operating 11 Gene
102. s portion Follow the same procedure for the timing side main bearing cap To introduce the supports complete with silicone rubber seals 2 into the crankcase place two plates C and D measuring 0 1 mm in thickness between the surfaces O Tighten the screws to 120 Nm The main bearing the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for LDW1503 from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004 T Pre and post modification single parts are not interchangeable 42 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Disassembly Reassembly LDW 1503 2004 Y 0165 75 66 25 LDW 1603 2204 2004 T 2204 T 681 65 81 90 67 15 58 25 75 76 Check clearance between main bearings and journals Use Perfect Circle Plastigage A and position it with a few drops of oil at the center of the half bearing O Tighten bolts to 120 Nm Determine clearance by measuring the squeezed portion of the plastigage with the indexed scale supplied gt For clearance between main journals connecting rod big end journals and the corresponding bearings fig 79 A Important When replacing bearings make sure that the lower half is kept separate from the upper one T
103. sealing surfaces nere deett debe dee s Leda eire aeea Lace dade tenen inodo 33 e ED ee eme mE t Par HE ERR ERR RI RUE 31 Doreir ORE 33 Valve spring idea eee 32 Valve spring check nder doe Le dette tope the be deuda oe Re ese 32 Valve timirngicheck oso ibi ree e C Eee PERDRE ERR ir egt 54 Valve timing without considering timing 54 5 Diese 58 59 Checking actuator setting Waste gate valve control rod stroke 5 59 Turbocharger uet rro rtt o top saber b PEU QE QR t Red 58 Turbocharger comporients 5 2 2 eere 58 EE 58 6 LUBRICATION SYSTEM eren 60 62 lubrication system layout imr riter eR de EEE ve E Eee eect tty 60 Oil filter cartridge s oer err RR UR ERBEN eR DAT 61 Oil pressure adjusting Valve
104. set yoke 9 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 49 Disassembly Reassembly LOMBARDINI KOHLER JOMPANY 100 101 102 103 Camshaft gear Speed governor counter weights Components 1 Camshaft gear 2 Governor weights 3 Governor weight support 4 Governor weight pin The governor weights 2 are housed inside the camshaft gear 1 The weights 2 can be of two types light or heavy depending on the speed rate and the type of application Heavy weights for engines set to run at low rpm 1500 1800 rpm and agricultural applications light weights for engines set to run at high rpm 2200 3000 rpm Speed governor counter springs Besides the weights used according to the speed rate and application type differenttypes of springs with differentfeatures are used as well Components 1 Camshaft gear 6 Speed governor springs Components 1 Limiting device torque gearing device 2 Maximum rpm adjustment screw 3 Minimum rpm adjustment screw 4 Camshaft gear 5 Governor weight 6 Speed governor spring For engines used on generating sets it is preferable to fit a single spring 6 to act against the heavy governor weights to avoid hunting with variations in the load and to achieve a more constant frequency over time Frame with idling speed governor spring Engines for
105. t angles to the driving shaft 41 Cylinder roughness N Important Do not manually hone the cylinder bore surfaces with emery cloth or other means ANN NN 1155140 N SENS N BEEN END INN nr SBD ARAN SSS N YD The inclination of the cross hatched marks left by machining should range between 115 140 they should be uniform and clearly visible in both directions Average roughness should range between 0 5 and 1 mm The cylinder surface which comes into contact with the piston rings should be machine honed with the plateau system Nw S NS NS SS E Jl NA CNN Piston Remove circlips and piston pin Remove piston rings and clean grooves Measure diameter Q at the A distance from the bottom of the skirt A 12 mm In case of diameter wear exceeding 0 05 mm of the minimum given value replace piston and rings Nota The oversizes are 0 50 and 1 00 mm The LDW TURBO piston differs from that of the NATURALLY ASPIRATED LDW in its cooling sprayer passage niche and an insert in the slot of the first ring Piston availability The pistons oversized by 0 5 and 1 0 mm have the uprating reference on the crown fig 45 46 88 00 88 01 87 960 87 967
106. teristic curves for alternator type AAK3570 28V 35A EE for 24 V outfits HH The curves have been detected with electronic voltage regulator HH after thermal stabilization at 23 5 C test voltage 13 V EE Current in Ampere ER Note The alternator rpm is equal to the rpm shown in the table EE n EE multiplied by 1000 H Ratio between engine alternator rpm 1 1 8 an LI EN LI EN LT EN LI EE T BEN EE EN EE T 0 1000 2000 3000 4000 5000 6000 1000 n g min 185 Characteristic voltage curve for regulator type AER 1528 T T LT T E E EE The electronic voltage regulator is built into the alternator 29 po The curve changes depending on temperature Ap 1 L1 14 vA 2 mm Max voltage curve 272 B Min voltage curve bro _ AAA Em VVVV A Ps EO I T ILL 1 E 2 40 30 20 10 0 90 100 110 CC 186 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 77 9 Electric system LOMBARDINI KOHLER 14 NOIR BLACK SCHWARZ 1 2 NEGRO dmm Qi ROSA NERO ROSE NOIR 9 PINK BLACK ROSA SCHWARZ ROSA NEGRO 45 54 187 WEISS BLANCO imm 1mm 15 97 NERO
107. ternator type Marelli AA 125 R 14V 65A The curves have been detected with electronic voltage regulator after thermal stabilization at 25 C test voltage 13 5 V P1 Power in kW Current in Ampere 1 7 Alternator efficiency Note The alternator rpm is equal to the rpm shown in the table multiplied by 1000 Ratio between engine alternator rpm 1 1 8 Characteristic voltage curve for regulator type RTT 119 AC The electronic voltage regulator is built into the alternator The curve changes depending on temperature A Max voltage curve B Min voltage curve 74 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Electric system 9 179 181 inn 40 20 0 20 40 60 80 100 120 CC Alternator type Iskra AAK3139 14V 80A Characteristics Rated voltage 14V Rated current eee 80A Speed of the load starting point 1350 rpm Maximum permanent intermittent speed max 15 13000 15000 rpm Front bearing 5 6303 2RS C3 Rear bearing ee teen 6201 2RS Max force on the bearing 600 N Voltage
108. the engine because a sudden increase in engine rpm could be caused by its combustion Use proper lube oil preserve your engine Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly Always use oil with the right viscosity for the ambient temperature in which your engine is being operated Use the chart when chosing your engine oil Danger Attention The used engine oil can cause skin cancer if kept frequently in contact for prolonged periods If contact with oil cannot be avoided wash carefully your hands with water and soap as soon as possible Do not disperse the oil in the ambient as it has a high pollution power LUBRICATION SYSTEM LAYOUT 1 16 8 e e 9 10 557 15 CAN AYO 5 11 YZ 12 6 13 7 14 125 Components 1 Oil fill cap 6 Oil dipstick 11 Oil pump 2 Rocker arm shaft 7 Drain plug 12 Crankshaft 3 Oil filter 8 Breather 13 Oil pressure adjusting valve 4 Main journal 9 Camshaft 14 Oil pick up screen 5 Connecting rod journal 10 Oil pressure switch 15 Hydraulic tappet 16 Turbocharger LDW 2004 T 2204 T 60 Workshop Manual LDW CHD cod 1 5302
109. tive oil while the engine is hot Pour new oil see Table of lubricants up to the maxi mum 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 A Important Maximum every 24 months of inactivity the engine must be started up by repeating all Engine Storage operations Workshop Manual LDW CHD _ cod 1 5302 345 6 ed_rev 05 85 12 TORQUE SPECIFICATIONS AND USE OF SEALANT LOMBARDINI A KOHLER MAIN TORQUE SPECIFICATIONS POSITION Reference fig N and page and pitch mm Alternator fixing bolt fig 8 pag 29 10x1 5 Diesel fuel union bolts 14x1 5 Flywheel housing 10x1 5 Preheating glow plug fig 197 pag 81 12x1 25 Roker arm cover fig 13415 pag 30 8x1 25 Main bearing cap 12x1 25 Cap vent 6x1 Intake manifold fig 6 pag 28 8x1 25 Exhaust manifold fig 7 pag 28 8x1 25 Throttle cover 6x1 Camshaft cover 6x1 Timing cover fig 93 pag 48 8x1 25 1P hydraulic pump flange cover 6x1 Hydraulic pump gear support cover
110. tside diameter F increased by 0 5 mm are available in such case valve guide bore E should also be increased by 0 5 32 Workshop Manual LDW cod 1 5302 345 6 ed rev 05 2 LOMBARDINI KOHLER COMPANY Disassembly Reassembly 4 28 Valve guide insertion after driving Press guides considering the L distance from the head plane X Dimensions Clearance Limit value mm mm mm X 7 020 7 035 Y A 0 020 0 050 0 100 Y 7 020 7 035 X A P A 3 seal in the valves guides intake and exhaust To prevent the seal 1 warping when mountig the valve guide 3 put it into the tool 2 part no 7107 1460 047 and proceed as shown in the figure 27 making sure the seal 1 reaches its stop Valve seats and bore wee 59 53 60 Valve recess and sealing surfaces Ss Sealing surface width on exhaust side Sa Sealing surface width on intake side H Valve recess with reference to the head plane Dimensions Limit value mm mm 5 5 127 1 55 2 00 Sa 1 20 1 60 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 33 4 Disassembly Reassembly L LOMBARDINI Precombustion chamber The precombustion chamber can be extracted from the head banging with a punch into the hole from the injector housing 2 This procedure
111. turer now provides a number of indications to be followed products services etc on the environment by all persons handling the engine for any reason during its Procedures for identifying the extent of the impact on the envi expected lifetime ronment must consider the following factors All packaging components must be disposed of in accor Liquid waste dance with the laws of the country in which disposal is Waste management taking place Soil contamination Keep the fuel and engine control systems and the exhaust Atmospheric emissions pipes in efficient working order to limit environmental and Use of raw materials and natural resources noise pollution Regulations and directives regarding environmental impact When discontinuing use of the engine select all compo nents according to their chemical characteristics and dispo se of them separately Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 11 2 TECHNICAL INFORMATION L LOMBARDINI POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN 1 The engine rpms suddenly increase and decrease 2 Asudden 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 perfor
112. w to adjust the rotation speed and stop the engine e 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 e The engine must not operate in places containing inflammable materials in explosive atmospheres where there is dust that can easily catch fire unles specific adequate and clearly indicated precautions have been taken and have been certified for the machine e To prevent fire hazards always keep the machine at least one meter from buildings or from other machinery e 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 e 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
113. way the correct position is ensured by the fixing screw 66 67 Connecting rod piston assemblies The three connecting rod piston assemblies should be fitted back into their original cylinders Mark them with references to avoid mistake Note The custom at LOMBARDINI is to consider the cylinder on the flywheel side as the first cylinder 69 Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 41 4 Disassembly Reassembly LOMBARDINI A KOHLER AnS 7 8 Center main bearings The main bearing caps and the crankcase have reference holes marked on them one two or three N Important In the assembly stage make sure that the number of holes on the bearings matches those on the crankcase and that they are on the same side The main bearing the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for LDW1503 from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004 T Pre and post modification single parts are not interchangeable Main bearing caps timing side flywheel side When refitting rear flywheel side main bearing cap 1 replace the rubber gaskets 2 considering that A and B should protrude 0 51 0 mm from the crankase cut any exces
114. with constand speed and variable load NA ISO 3046 1 ICXN CONTINUOUS RATING WITH OVERLOAD CAPABILITY continuous heavy duty with constant speed and constant load MN Torque curve N curve MB NB curve MA NA curve C Specific fuel consumption curve NB curve Max power tolerance is 5 Power decreases by approximately 1 every 100 m altitude and by 2 every 5 C above 25 C Engine power can be influenced by the type of coupling used with the cooling fan A Important Non approval by Lombardini for any modifications releases the company from any damages incurred by the engine Note Consult LOMBARDINI for power torque curves and specific consumptions at rates differing from those given above Workshop Manual LDW CHD _ cod 1 5302 345 6 ed rev 05 21 3 MAINTENANCE RECOMMENDED OIL TYPE REFILLING LOMBARDINI KOHLER IMPANY ROUTINE ENGINE MAINTENANCE A Caution Warning Failure to carry out the operations described in the table may lead to technical damage to the machine and or system EXTRAORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING HOURS Engine oilreplacement ORDINARY MAINTENANCE OPERATION DESCRIPTION Oil filter replacement FREQUENCY x HOURS 300 600 1200 LEVEL ENGINE LUBRICANT COOLANT LEVEL DRY AIR CLEANER OIL BATH AIR CLEANER RADIATOR EXCHANGE SURFACE BELT FAN ALTERNATO
115. ynamometric brake since this type of adjustment is very approximate Loosen delivery limiting device C by 5 turns Bring engine to max rpm in no load conditions i e 3200 rpm Tighten limiting device C until the engine rpm decreases Unscrew limiting device C by 1 1 2 turn Tighten lock nut Note f the engine at full load generates too much smoke tighten C loosen C if no smoke is observed at the exhaust and if the engine cannot deliver its full power Injection pump delivery limiting and torque adjusting device Limiting device C has the function of limiting the injection pump maximum delivery The same device acts as torque adjusting device since springs N act on lever L and thus oppose the resistance of spring M contained in the barrel The torque limiting device allows lever L to have a stroke H of 1 0 1 1 mm this increases the injection pump delivery while torque reaches its peak Note application for generating sets and motor welding units the torque adjusting device only acts as delivery limiting device without spring M and stroke H Workshop Manual LDW CHD cod 1 5302 345 6 ed rev 05 83 Settings LOMBARDINI A KOHLER MPANY 209 211 Fuel limiting device fig 208 209 When starting up the engine the fuel limiting

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