12LD 435-2 12LD 435-2/B1 12LD 475-2 12LD 475
Contents
1. How to check voltage regulator for proper operation A Caution Warning When the engine is running do not disconnect battery cables or remove the key from the control panel Keep regulator away from heat sources since temperatures above 75 C might damage it No electric welding on engine or application Check that connections correspond to the layout Disconnect the terminal from the battery positive pole Connect a d c voltmeter between the two battery poles Fit an ammeter between the positive pole and the B of the voltage regulator corresponding to ref 1 in picture 89 Start a couple of times until battery voltage drops below 13 V When battery voltage reaches 14 5 V the ammeter current suddenly drops down to almost zero Replace regulator it recharge current is zero with voltage below 14 V Starting motor type Bosch DWL 12 V 1 7 kW A Important Flywheel should not project from ring gear plane B A 29 5 31 5 mm B Ring gear plane C Flange plane 90 aa a ho Characteristic curves for starting motor type Bosch DWL 12 V 1 7 ah kW Curves were obtained at the temperature of 20 C with 88 Ah battery V Motor terminal voltage in Volt ss a a te m P Power in kW 16004 1 64 16 0 8 C Torque in N m N Motor speed in r p m woo 124 1204 8 J A Absorbed curre2. Connecting rod weight Weigh connecting rods when replacing them in order to avoid unbalance The difference in weight should not exceed 10 g Crankshaft timing gear Use tool 1 Part N 7560 4000 052 and puller 2 Part N 7271 3595 048 to remove the gear Main bearing support timing gear side Remove main bearing by means of two M8x1 25 screws with fully threa ded length of 40 mm or a puller Part N 7271 3595 048 Note To avoid deformation it is not recommended to replace the bearing bushing complete assembly s of bushing and support are available in standard 0 25 mm and 0 50 mm undersize configurations as spare parts See page 29 for dimensions Main bearing support PTO Side Remove it by means of two M8x1 25 screws with fully threaded length of 40 mm Check oil seal ring and replace if warped hardened or worn out When refitting tighten nuts to 25 Nm See page 29 for dimensions Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 27 Disassembly Reassembly LOMBARDINI 42 Wr LE 44 43 ZZA VM CRANKSHAFT Center main bearing support locating bolt Straighten plate 1 and unscrew bolt 2 before removing crankshaft When refitting tighten bolt 2 to 30 Nm
3. this is an indication of the mixture of different hydrocarbons in the fuel A high ratio of light hydrocarbons may have a negative effect on combustion Sulphur maximum 0 05 of the weight high sulphur content may cause engine wear In those countries where diesel has a high sulphur content it is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently PRESCRIBED LUBRICANT Fuel with low sulphur content API CF4 CG4 Fuel with high sulphur content API CF CD CE The countries in which diesel normally has a low sulphur content are Europe North America and Australia FUELS FOR LOW TEMPERATURES It is possible to run the engine at temperatures below 0 C using special winter fuels These fuels reduce the formation of paraffin in diesel at low temperatures If paraffin forms in the diesel the fuel filter becomes blocked interrupting the flow of fuel Fuel can be Summer up to 0 C Winter up to 10 C Alpine up to 20 C Arctic up to 30 C For all fuel types the cetane number cannot be lower than 51 AVIATION KEROSENE AND RME FUELS BIOFUELS The use of these fuels is allowed However they may condition the performance of the engine The only Aviation fuels that may be used in this engine are JP5 JP4 JP8 and JET A if 5 oil is added For more information on Aviation fuels and Biofuels RME RSME please
4. Ll fo 10 48 EN E DS l Y CNO SES c fi i A gt A ANO i Laa 2 m Te eE VA y ECO A Pia N 2 ORAR AO A 77 Injection pump mechanical speed governor timing Loosen screw 1 Move injection pump lever 2 to maximum delivery to the right Check that drive rod 3 closes the speed governor keeping lever 2 pressed to the right the drive rod should have no clearance Tighten screw 1 Injection static advance adjustment Assemble the valve lowering tool serial number 1460 285 on the cylinder head to be checked Make sure that the dial indicator tracer is correctly placed on the valve Gravity feed the injection pump Position STOP lever 3 half a stroke so that the delay supplement mark is excluded By pressing tool lever 1 pic 75 on the valve turn the flywheel using a spanner until it meets the piston and the top dead centre of the piston is reached By holding down the valve on the piston reset dial indicator 2 pic 75 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 37 Ly LOMBARDINI 6 Fuel system Fasten capillary tube 4 on the delivery union of the cylinder on which the valve lowering tool is installed Turn the flywheel and alternatively fill the capillary tube until the fuel flows out Turn the flywheel clockwise pic 77 and during the
5. Crankshaft end play When refitting crankshaft check end play be means of a feeler gauge this value should be 0 08 0 38 mm and can be set by changing the thickness of gasket A which is located on the flywheel side main bearings Gaskets with thickness of 0 30 0 50 mm can be supplied Crankshaft center main bearing support When refitting both centering notches A and B must be located on the same side Tighten screws to 25 Nm See page 29 for dimensions Crankshaft lubrication ducts Remove plugs clean duct A with a pointed tool and blow in compressed air Replace the plugs and check for sealing Crankshaft journal radius A Important When grinding main journals or crank pins restore the R value to original specification The radius R connecting journals to shoulders is 2 8 3 2 mm 28 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Disassembly Reassembly 4 48 Main bearing and connecting rod big end bearing internal diameter EN 71 981 72 000 72 070 72 090 IES 40 004 40 020 F 40 045 40 076 55 340 55 350 Gg 55 404 55 435 54 931 54 950 KN 55 000 55 020 The above dimensions refer to driven in or tightened bearings Both main bearings and connecting rod big end bearings are available with inside diameter size measuring 0 25 and 0
6. 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 oil replacement Oil filter replacement ORDINARY MAINTENANCE FREQUENCY x HOURS 125 250 500 1000 2500 OPERATION DESCRIPTION ENGINE OIL LEVEL OIL BATH AIR CLEANER DRY AIR CLEANER FUEL PIPES COOLING SYSTEM CLEANING VALVE ROCKER ARMS CLEARANCE ADJUSTMENT SETTING AND INJECTORS CLEANING RUBBER INTAKE HOSE DRY AIR CLEANER INTAKE MANIFOLD ENGINE OIL RADIATOR CLEANING ALTERNATOR AND STARTING MOTOR FUEL TANK CLEANING ENGINE OIL EXTERNAL OIL FILTER FUEL FILTER RUBBER INTAKE HOSE DRY AIR REPLACEMENT CLEANER INTAKE MANIFOLD FUEL PIPES DRY AIR CLEANER EXTERNAL C CARTRIDGE AFTER 6 CHECKS WITH CLEANING DRY AIR INTERNAL EXTERNAL CARTRIDGE AFTER 3 CHECKS WITH CLEANING PARTIAL OVERHAUL TOTAL Incase of low use every year In case of low use every 2 years The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates The air filter must be cleaned and replaced more frequently In very dusty conditions Alternately when the clogging indicator if present indicates it s necessary
7. Standards is applied on the air shroud 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 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 11 2 Technical information LOMBARDINI TECHINICAL SPECIFICATIONS Engine type 12LD 435 2 B1 GENERAL DETAILS Operating cycle Four stroke diesel Cylinders n 2 in line Bore x stroke mm 86x75 86x75 90x75 Displacements 871 871 954 Compression rate 18 0 1 18 0 1 18 0 1 Intake Oil bath air cleaner or dry air cleaner Cooling Air fan integral to the flywheel Crankshaft rotation Counter clockwise 1st P T O side Combustion sequenc Driving shaft degrees 180 Timing system side camshaft rods and rocker arms 2 per cylinder Valves n Shaft Camshaft inside the crankcase Tappets Mechanic Fuel injection Direct on piston Dry weight of engine kg 80 80 80 80 Maximum tilt while operating Momentary 35 35 35 35 Maximum tilt while operating Up to 1 hour 25 25 25 25 Combustion air volume at 3000 r p m l min 1050 1250 1150 1150 Cooling air volume at 3000 r p m l min 13300 16200 15500 15500 POWER AND TORQUE Maximum operating speed r p m 3000 3600 3000 3000 N 80 1269 CEE ISO 1585 14 0 19 0 14 7 20 0 15 8 21 5 Max powe
8. device C limits the injection pump maximum delivery It also acts as a torque setting device since spring N opposes the resistance of spring M inside the cylinder through lever L The torque setting device allows lever L to move over stroke H corresponding to 0 15 0 25 mm This consequently increases injection pump delivery with torque reaching its peak value Note In generator sets and power welders the torque setting device acts as a delivery limiter only It therefore does not feature spring M or stroke H Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 43 Settings LOMBARDINI C E 97 Injection pump delivery setting with engine at the torque dynamometer 1 Bring engine to idling speed 2 Unscrew delivery limiting device C see pic 94 3 Bring engine to the power and r p m required by the manufacturer of the device 4 Check that consumption falls within the table specifications see below If consumption is not as indicated change balance conditions at the torque dynamometer by varying the load and adjusting the governor Under stable engine conditions check consumption again 5 Tighten limiting device C until the engine r p m decreases Lock the limiting device by means of lock nut 6 Release brake completely and check at what speed the engine becomes stable Speed governor should comply with the requirements of th
9. ein ey 24 Valve seats ian MOUSINGS eii E E E 23 Valve timing without considering timing Marks ooononncnnnnccnnoncccnanoncnnonnnnnonnnnnn ono nn nro nn r cnn nr rr rra r nera n nr enn nr rr anr ne cnn nn 30 MV A e o is 23 LUBRICATION SYSTEM 32 34 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM ceecceeeeeeeceeeeeeseeeeeeeeeeaeeeeeeneeeseeseeeeeees 32 Oil filter Cartridge external spe eatsiny tebiohieas aid 33 Oil filter cartridge Internal voca at ls hen ali wee 33 Oil preassure relief Valve icono a der ahaa ee ete Teper sector a ce cia 33 Oil pressure curve at full SDE eweeddead Ei E EETA Na EEE EAE A deste E eed 34 Oil pressure curve at idliNQsSPOOd iii dni 34 a 33 FUEL SYSTEM 35 39 SA O T 35 Fuel tesding Injection Circu i int a IA ad ee ae 35 Fuel fer IMSIGS TUS TAM ies tet alto Do ae Tan eto ende e pan Do e O A ee 35 Fuel filter removed from the tank UPON request coooocccnoncccnooccononcnonanononnnnnnnnon cnn nano nono n cnn r cnn rre r nera r rre 35 How to reassemble injection PUMP COMPONENTS coooccccnncccononcnonanononannnnnnnnnn nano cnn non rr nan r erre rn rn rr ren rr rn nr enn rr rnr nn 36 Injection PUMP dera i rt it tit Ae dc 36 Injection pump mechanical speed governor TIMING oococonocccnnoccnnnoncninancnonana non nnn cnn non nn rro nn nr rre nr rr 37 Injection static advance adjustment oooccconocccononccononaconann conan corno cr nn rre 37 38 INSCIORSO INO caido 39 Injector for EPALO
10. system LOMBARDINI Tp A TZ SI ao AAA ANT 73 Injection pump Components 1 Pump body 10 Plunger 2 Fitting 11 Barrel 3 Seal ring 12 Rack rod 4 Filler 13 Sector gear 5 Shim 14 Spring 6 Spring 15 Upper retainer 7 Delivery valve 16 Lower retainer 8 Seat 17 Tappet 9 Gasket 18 Tappet roller Test data for injection pump delivery c ies Rod stroke Sue TO from max R P M Delivery Max plunger max force deliv point difference Rod stroke a rod from max Delivery n plunger max force deliv point difference mm mm3 How to reassemble injection pump components After replacing the worn out components reassemble the pump as follows Introduce sector gears into the pump body by making reference points C match with the B points on the rack Fix barrels with the eccentric screws F on the pump body Fit valves with seats springs tillers and delivery unions tightening them at 35 40 Nm Fit plungers by making reference points E match with the sector gear D points Fix retainers and springs lock tappet with special stop Check that both plungers have the same delivery by performing the necessary measurements atthe test bed it delivery is not the same set screw F 36 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 Ly LOMBARDINI Fuel system 6 eel
11. 2 EPA kw wh aie 22 elie 20 54 18 5 Ta 45 46 18 22 16 16 1 2 14 NB u MO el p 1 eae Sees E 10 12 do 8 d gikWh g CVh l d 270 195 amp 7 ee 185 ABR aE a 1800 2200 2600 3000 1 r p m 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 Continuos light duty operation with constant speed and variable load NA ISO 3046 1 ICXN CONTINUOUS RATING WITH NO OVERLOAD CAPABILITY Continuos heavy duty with constant speed and constant load MN Torque curve N curve MB NB curve MA NA curve C Specific fuel consumption curve The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 5 Power decreases by approximately 1 every 100 m altitude and by 2 every 5 C above 20 C Note Consult LOMBARDINI for power torque curves and specific consumptions at rates differing from those given above 14 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 A LOMBARDINI Technical information 2 OVERALL DIMENSIONS 12LD 435 2 435 2 B1 475 2 EPA Workshop Manual 12 LD_ cod 1 5302 460 3 ed_ rev 02 15 3 MAINTENANCE RECOMMENDED OIL TYPE REFILLING Ly LOMBARDINI ROUTINE ENGINE MAINTENANCE
12. 5 and be uniform and clear in both directions Average roughness should range between 0 5 and 1 u Piston Remove circlips and remove piston pin Remove piston rings and clean grooves Measure diameter at 2 mm from the bottom of the piston Per 12 LD 435 2 435 2B12 85 920 85 940 mm Per 12 LD 475 2 475 2 EPA 89 925 89 940 mm In case of diameter wear above 0 05 mm replace piston and piston rings Note Oversize pistons of 0 5 and 1 0 mm are available Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Disassembly Reassembly 4 24 26 27 o gt O y 28 Piston weight Weigh 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 squarely into the unworn part of the lower cylinder and measure the end gap Dimensions ES 0 030 0 050 Pistons ringis Clearance between grooves Dimensions Limit value ee ox Ps oomoo om Piston rings Fitting sequence A 1 Chromium plated ring B 2 Torsional internal tapered ring C 3 oil control ring A Important Before fitting the piston into the cylinder stagger the ring gaps at 120 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 25 Disasse
13. 50 mm less than the standard version Clearance between main journals crank pins and connecting rod bearings 0 070 0 109 0 195 0 025 0 072 0 150 0951 0095 0 190 OHD 0 050 0 089 0 180 Main bearing supports 1 PTO side Dimensions 2 Central Ret mm 3 Timing gear side A 130 000 130 020 76 980 77 020 morena ore reso ooo Main bearing housing METE e emaon Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 29 Disassembly Reassembly LOMBARDINI Dimensions of camshaft journals and housings Ref Dimensions Clearance Limit value i mm mm mm 0 040 0 085 a rss 0 040 0 080 CNI How to measure intake exhaust cam height A 1 cylinder intake cam A2 2 cylinder intake cam S 1 cylinder exhaust cam S2 2 cylinder exhaust cam Exhaust and intake cams feature the same height H H 33 62 33 65 Replace camshaft if H is 0 1 mm below the given value Camshaft timing Fit camshaft gear by making timing mark 1 coincide with timing mark 2 on the crankshaft timing gear Tighten camshaft bolt to 60 Nm Camshaft end play End play should be 0 10 0 26 mm check by means of a dial gauge pushing or pulling camshaft as required Valve timing without considering timing marks Locate piston 1 on flywheel side at the top
14. A sudden and unusual noise is heard 3 The colour of the exhaust fumes suddenly darkens 4 The oil pressure indicator light turns on while running TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation Always perform these simple checks before removing or replacing any part FUEL CIRCUIT zZ Q FR lt 9 le ira m gt l ELECTRIC NANCE SYSTEM SETTINGS REPAIR POSSIBLE CAUSE Obstructed fuel line Engine does not start Engine starts but stops No acceleration TROUBLE Non uniform Black smoke White smoke Excessive oil consumption Dripping oil and fuel from the exhaust speed Oil pressure too low Oil level increase Clogged fuel filter Air inside fuel circuit Collged tank breather Faulty feed pump Injector stuck njection pump valve damaged njector not adjusted Plunger excessive leakage Hardened pump control rod Wrong injection pump delivery setting Too high oil level Oil pressure valve blocked or dirty Worn oil pump Air inside oil suction pipe Faulty pressure gauge or switch Clogged oil suction pipe Battery discharged Wrong or inefficient cable connection Defective starter switch Defective starting motor ogged air filter Excessive idle operation Incomplete running in Engine overloaded Advanc
15. Cylinder Head A Important Do not remove it when hot to avoid deformation If cylinder head is deformed level it hot by removing a maximum of 0 3 mm When refitting tighten only if sure that rocker arm lubrication tube is well inside its holes and that both heads are in line by fitting the inlet and exhaust manifolds before tightening the cylinder head nuts Always replace copper head gasket see page 26 picture 32 for choosing the right thickness Progressively tighten nuts in the 1 2 3 4 sequence at 50 Nm Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Disassembly Reassembly 4 a t KS PS EXHAUST VALVE INTAKE VALVE 16 Valves 1 Intake valve 2 Spring seat 3 Valve stem seal 4 Spring 5 Retainer 6 Half collets Components To remove half collets firmly press down as shown in the figure A Important Valve stem seal 3 must be fitted to the intake valve only Valve guides and valve guide housings a e Components 1 Exhaust valve guide 2 Intake valve guide Te ss 140014 078 Valve guides with outside diameter increased by 0 5 mm are also available in such cases valve guide bore C should also be increased by 0 5mm 14 050 14 060 Valve guide insertion Heat cylinder head up to 160 180 C Pr
16. DINI GENERAL REMARKS AND SAFETY INFORMATION 1 WARRANTY CERTIFICATE The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24 months from the date of delivery to the first end user For engines fitted to stationary equipment working at constant load and at constant and or slightly variable speed within the setting limits the warranty covers a period up to a limit of 2000 working hours if the above mentioned period 24 months is not expired If no hour meter is fitted 12 working hours per calendar day will be considered For what concerns the parts subject to wear and deterioration injection feeding system electrical system cooling system sealing parts non metallic pipes belts warranty covers a maximum limit of 2000 working hours if the above mentioned period 24 months is not expired For correct maintenance and replacement of these parts itis necessary to follow the instructions reported in the documentation supplied with each engine To ensure the engine warranty is valid the engine installation considering the product technical features must be carried out by qualified personnel only The list of the Lombardini authorized dealers is reported in the Service booklet supplied with each engine Special applications involving considerable modifications to the cooling lubricating system for ex dry oil sump filtering system turbo charged models will require speci
17. R EEE AKENE aiia 27 Main bearing support timing gear Side rriaren a Ae een teehee Ora aeeie aE a a aa aniei 27 Main bearing SUPPOMS raient ea aer el eee a ada 29 Mechanical speed govermor iicdiccida ada 31 OilEbathalr clerical adsl dehy 20 PISTON ita idad da a a a tii a 24 PISTON FOTUING ci id enh eins 26 Piston clearance aioe o e aa a aa o TEA ia IAEA a 26 PIStON TINYQS gt mno Ro feio pi T E AETA ETET a 25 Piston rings Fitting SCQUENCE 1 5 4 cscs wed ch As enr anit tdt ia fui 25 PISTON Welt A le e ee eet a el 25 Pistons ringis Clearance between QrOOVES eeccesceeececeneeeseeeeeeeeeaeeeaeeeseeeeaeeseaeeeaeesaaeeeaeessaeeeaeeeaeseaeesiaeseaeesiaeenaeesnaeeaas 25 RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING coooccccocccccccnoncnonncnnnnconccnnncnnn nc ran cnn cnn nnran na rnccn rca 20 RECOMMENDATIONS FOR OVERHAULS AND TUNING coooocococccccccnonccnnononnnonncnnn ccoo nono ccnn cc ran ncan cc rra rar rra nc nncn 20 Rocker arm assembly iii al e be a A oaaae AE ESF 22 Spring for extra fuel supply at starting ocoocnnccnncnnnnncnncnnnccnnnnnncncncn ronca 31 Valve guide INSOMOM si cisce seuss fee a E a a a e a a a tiene araa a aa a Ea a aa a A a Aa Ea AE aa Aaa aiae TERE EEE a es 23 Valve guides and valve guide NOUSINGS ccesscceeeseseeseeeeeeeeeeeeeeeeeeeneeeneseneessaeeeseseeenessaeeeneaseseseeeessaeeeseneesesneeneniseeess 23 Valve Rocker arm cle arancelaria e dai 21 Valve seat A Gordie de ea eee eer deed ete
18. WORK SHOP MANUAL 12LD Series engines cod 1 5302 460_3 ed 12LD 435 2 12LD 435 2 B1 12LD 475 2 12LD 475 2 EPA SERVICE LOMBARDINI 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 pody code N Issue date date Endorsed PREFACE Every attempt has been made to present within this service manual accurate and up to date technical information However development on the LOMBARDINI series is continuous Therefore the information within this manual is subject to change without notice and without obligation The information contained within this service manual is the sole property of LOMBARDINI As such no reproduction or replication in whole or part is allowed without the express written permission of LOMBARDINI Information presented within this manual assumes the following 1 The person or people performing service work on LOMBARDINI series engines is properly trained and equipped to safely and professionally perform the subject operation 2 The person or people performing service work on LOMBARDINI series engines possesses adequate hand and LOMBARDINI special tools to safely and professionally perform the subject service operation 3 The person or people performing service work on LOMBARDINI series engines has read the pertinent information regar
19. al written warranty agreements Within the above stated periods Lombardini Srl directly or through its authorized network will repair and or replace free of charge any own part or component that upon examination by Lombardini or by an authorized Lombardini agent is found to be defective in conformity workmanship or materials Any other responsibility obligation for different expenses damages and direct indirect losses deriving from the engine use or from both the total or partial impossibility of use is excluded The repair or replacement of any component will not extend or renew the warranty period Lombardini warranty obligations here above described will be cancelled if Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected and altered Lombardini engines are not used according to the instructions reported in the Use and Maintenance booklet supplied with each engine Any seal affixed to the engine by Lombardini has been tampered with or removed Spare parts used are not original Lombardini Feeding and injection systems are damaged by unauthorized or poor quality fuel types Electrical system failure is due to components connected to this system which are not supplied or installed by Lombardini Engines have been disassembled repaired or altered by any part other than an authorized Lombardini agent Following expiration of the above stated w
20. anual 12 LD _ cod 1 5302 460 3 ed_ rev 02 A LOMBARDINI FUEL SYSTEM 6 Fuel feeding injection circuit Components 1 Tank 2 Filter 3 Fuel feeding tube 4 Fuel feeding pump 5 Injection pump 6 Injection line 7 Injector 8 Injector leak off line and self bleeding system Fuel filter inside fuel tank Components 1 Spring 2 Disc 3 Ring 4 Cartridge 5 Gasket 6 Gasket 7 Cap 8 Ring 9 Bolt 68 1 Fuel filter removed from the tank upon request EE ae 1 Bleeding screw 2 2 Holder on 3 Cartridge 4 Rubber ring 3 5 Filtering element Lae NaS aa 4 Characteristics H Filtering paper oo eects eeeeees PF 905 Filtering Surface cooocicicinonocnn 2400 cm e 5 Filtering capacity ococococoncncconninnonos 2 3 i j i Maximum operating pressure 4 bar DA For maintenance see page 16 69 Fuel feeding pump The fuel feeding pump is of the diaphragm type operated by a 2 camshaft eccentric through a drive rod It features an external lever for manual operation Components 1 Drive rod shelf 1 470 2 070 mm 2 Gasket S Y 3 41 3 Camshaft eccentric Characteristics when the control eccentric rotates at 1500 r p m minimum delivery is 90 h while self regulation pressure is 0 5 0 7 bar 70 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 35 Fuel
21. arranty 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 2 All data presented are in metric format Failure to use genuine Lombardini parts could result in That is dimensions are presented in millimeters mm sub standard performance and low longevity torque is presented in Newton meters Nm weight is presented in kilograms kg volume is presented in liters or cubic centimeters cc and pressure is presented in barometric units bar Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 7 1 General remarks and safety information Q LOMBARDINI GLOSSARY AND TERMINOLOGY For clarity here are the definitions of a number of terms used Cylinder number one is the first piston viewed from the recurrently in the manual 18 P T O side of the engine Rotation direction anticlockwise viewed from the 1 P T O side of the engine SAFETY AND WARNING DECALS Important remarks and features of the text are highlighted A Caution Warning using symbols which are explained below This indicates that itis necessary to take proper precautions to prevent any risk to the health and safety of i
22. ck 1 Spacers h 40mm 1460 285 2 Dial gauge indicator 3 Dial gauge extension High preassure pump for static injection timing check 1460 273 Static timing tool 1460 024 Tool for valve stem O ring assembly 1460 108 Valve ring assembly tool 1460 009 Tool for valve cotters assembly disassembly 1460 113 Flywheel puller 1460 119 Valve guide seal installation tool 1460 047 48 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 AN LOMBARDINI 42100 Reggio Emilia Italia ITALY Via Cav del Lavoro Adelmo Lombardini 2 Cas Post 1074 Tel 39 0522 3891 Telex 530003 Motlom I Telegr Lombarmotor R E A 227083 Reg Impr RE 10875 Cod fiscale e Partita IVA 01829970357 CEE Code IT 01829970357 E MAIL atlOlombardini it Internet http www lombardini it La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione Lombardini se reserve le droit de modifier a 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 Angaben jederzeit zu ver ndern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicaci n
23. compression phase turn it slowly Stop as soon as the fuel starts moving inside the capillary tube Press the valve by turning lever 1 until it meets the piston and using dial indicator 2 read the piston position in millimetres before the TDC Use the transformation chart to find out the correspondence between the millimeters measured with dial indicator 2 and the degrees i Advance Piston lowering Engine type 12LD435 2 B1 3600 12LD475 2 3000 12LD475 2 EPA 3000 Injector for standard engines 9 SKS a Components 3 1 Intake fitting 8 Needle valve 4 2 Nozzle holder 9 Fixing flange 5 3 Shim 10 Taper pin 6 4 Spring 11 Gasket fle 5 Pressure rod 12 System duct 7 Hp 6 Intermediate flange 13 Sump j 7 Nozzle 8 __ 38 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Fuel system 6 Injector for EPA engines Components 1 Injector housing 7 Nozzle 2 Intake fitting 8 Cup 3 Shim 9 Needle valve 4 Spring 10 Sump 5 Pressure rod 11 System duct 6 Taper pin 12 Overflow pipe When refitting tighten ring 8 nut at 50 Nm Injector setting Connect injector to a hand pump and check that setting pressure is 210 220 bar 258 270 bar for EPA engines make the required adjustments if any by changing the shim over the spring When replacing the spring setting should be performed at a 10 bar
24. contact the Lombardini applications department Capacities standard fuel tank Litres 15 As for filters tanks and special crankcases please refer to LOMBARDINI instructions Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 19 4 DISASSEMBLY REASSEMBLY LOMBARDINI RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING A Important To locate specific topics the reader should refer to the index Besides disassembly and reassembly operations this chapter also includes checking and setting specifications dimensions repair and operating instructions Always use original LOMBARDINI spare parts for proper repair operations The operator must wash clean and dry components and assemblies before installing them The operator must make sure that the contact surfaces are intact lubricate the coupling parts and protect those that are prone to oxidation Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely For safety and convenience you are advised to place the engine on a special rotating stand for engine overhauls Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved In order to fix assemblies and or components securely the operator must tighten the fastening parts in a criss
25. 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 A Important To locate specific topics the reader should refer to the index Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine Before carrying out any operation clean the assemblies and or components thoroughly and eliminate any deposits or residual material Wash the components with special detergent and do not use steam or hot water Do not use flammable products petrol diesel etc to degrease or wash components Use special products Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them Apply a layer of lubricant over all surfaces to protect them against oxidation Check all components for intactness wear and tear seizure cracks and or faults to be sure that the engine is in good working condition Some mechanical parts must be replaced en bloc together with their coupled parts e g valve guide valve etc as specified in the spare parts catalogue A Danger Atte
26. dead center Position two small cylinders A of the same height onto the tappets Rotate camshaft stopping when cylinder 1 tappets are in overlap position intake open exhaust closed By means of ruler B check that tappets are at the same height Engage camshaft gear with crankshaft gear Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Disassembly Reassembly NATA s N a o a PUN 3 lt lt a Wyrm SSN ay a ri X i AR Lee Hydraulic pump p t o 1P 1 Seal ring 2 Centering ring 3 Coupling 4 Half coupling 5 Flange 6 Gear 7 Bracket 8 Thrust washer 9 Stop ring 10 Cover The maximum torque is 27 Nm corresponding to 7 64 kW at 3000 r p m Mechanical speed governor Components 1 Gear 6 Lever 2 Fly weight 7 Drive rod 3 Sliding bell 8 Governor spring 4 Stop ring 9 Rack control lever 5 Yoke Weights are moved to the periphery by the centrifugal force and thus axially shift a mobile bell connected to the injection pump rack control lever by a linkage A spring placed under tension by the accelerator control offsets the weights centrifugal force Balance between the two forces keeps speed at an almost constant level in spite of load variations See picture 52 for timing Governor springs with rocker arm Components 1 Rocker arm for spring anchoring 2 Governor spr
27. ding the subject service operations and fully understands the operation at hand This manual was written by the manufacturer to provide technical and operating information to authorised LOMBARDINI after sales service centres to carry out assembly disassembly overhauling replacement and tuning operations Aswellas 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 2 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 A LOMBARDINI CHAPTER INDEX This manual contains pertinent information regarding the repair of LOMBARDINI air cooled direct injection Diesel engines type 12 LD 435 2 435 2 B1 475 2 475 2 EPA updated 05 03 2007 TABLE OF CONTENTS 1 GENERAL REMARKS AND SAFETY INFORMATION P 7 9 GENERAL SERVICE MANUAL NOTES 0 coord dead 7 GLOSSARY AND TERMINOLOGY poria aenn aaan rio inte dla lt lili ide 8 SAFETY REGULATIONS oiocariii iaa aiii roda aie E dieta 8 9 WARRANTY CERTIFICA T Escort a ee ee eee ees 7 2 TECHNICAL INFORMATION 10 15 MANUFACTURER AND MOTOR IDENTIFICATION DATA coococccccccnocconnnoncnnnnoncnnnnonnno cnn cnn n cnn n tae cnn n
28. e class indicated by the manufacturer of the device 7 Stop the engine 8 Check valve clearance when the engine has cooled down Required settings most requested A Power Engine kW HP Time sec g kWh per 100 cm3 g HPh N 13 97 19 74 76 290 282 213 208 12LD435 2 3000 NB 13 72 17 3 91 93 259 254 191 186 12LD435 2 B1 3600 12LD475 2 3000 Stop setting 1 Completely turn lever C counterclockwise and keep it in this posi tion Retainer F should not be in contact with lever C 2 Unscrew nut G and bring retainer F in contact with lever C 3 Push retainer F so that lever C is moved backwards clockwise by 1 0 1 5 mm 4 Lock retainer F by screwing nut G Note Under these conditions no damage can be caused to the injection pump rack rod stops by sudden impacts due to the available electric stops 44 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 A LOMBARDINI STORAGE 9 When the engines are not used for more than 3 months they have to be protected by performing the operations described STORAGE Internal engine protection Start the engine and heat it Stop the engine Remove the drain plug and let the oil flow completely Replace the oil filter with a new one screw manually the new filter Clean the oil drain plug and after having assembled a new gasket tighten it Carry out the oil refilling to the upper level of the rod usin
29. ed injection timing Retarded injection timing Incorrect governor linkage adjustment Governor spring broken or unhooked Too low idle speed setting Worn out or stuck piston rings Worn cylinders Worn valve guides Valves sticking or damaged Worn out bearings Non sliding speed governor leverage rankshaft not turning freely Damaged cylinder head gasket 10 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 QZ LOMBARDINI Technical information 2 MANUFACTURER AND MOTOR IDENTIFICATION DATA BA D SA02E0 te Co 475 2 A LOMBARDINI IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO U S EPA REGULATIONS LARGE COMPRESSION IGNITIO 2 Te 2005 1 3 954 cc RATED POWERI3 20 kW 4 EPA FAMILY ID 4LBDL 954127 DFI FUEL TYPE 2D DIESEL JUIVALE TUNEUP SPECIFICATION 3 INJECTION TIMING Oe Eee 6 iNUECTOR OPENING PRESSURE 290 10 bar VALVE CLEARANCE 0 20 mm 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 The data plate for EPA
30. er cartridge external Maximum operating pressure bar 7 Maximum combustion pressure bar 20 Filter capacity u 15 By pass valve setting bar 1 5 1 7 Filtering surface cm 730 Oil filter cartridge internal Maximum operating pressure bar 4 5 Filter capacity um 70 By pass valve setting bar 0 60 0 75 ELECTRICAL SYSTEM Alternator Internal Standard nominal voltage V 12 5 Alternator Internal Optional nominal voltage 12 Alternator Internal Standard nominal current 14 Alternator Internal Optional nominal current 18 Starter motor power Bosh GF 1 7 see Alternator battery charger curve pages 40 41 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 13 2 Technical information LOMBARDINI PERFORMANCE DIAGRAMS 12 LD 435 2 12 LD 435 2 B1 KW CV KIM um E 5 AG Trelis das 4 40 16 14 18 i 2 Ne 12 16 Na 10 14 8 12 gh 10 TVs g kWh amp 6 200 270 260 6 de 240 RPNiioo 400 1800 2200 2600 3090 RAM 1800 2000 2400 2805 52006 3600 12 LD 475 2 12 LD 475
31. ess guides considering the A and B distances from the head piane a 30 80 31 20 OB 24 80 25 20 Note If guides are seated with stop ring C first locate the ring in place and then position guides without considering A and B Valve seats and housings CS A Ref Cc Press valve seats into the housings and cut a at 45 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 23 Disassembly Reassembly LOMBARDINI Valve seat grinding After cutting grind valve seats with fine emery paste in oil suspension The sealing surface S should not exceed 2 mm Valve recess after grinding D 0 75 1 25 mm maximum worn limit 1 65 mm Cylinder Measure diameter size between two diametrically opposed points at three different heights Per 12 LD 435 2 435 2B12 86 00 86 02 mm Per 12 LD 475 2 475 2 EPA 90 00 90 02 mm In case wear exceeds 0 10 mm bore the cylinder and fit oversize piston and rings In case of less wear replace piston rings only Cylinder roughness The cylinder should show no blowholes or porosities check for leakage by sealing both ends of the cylinder and preassurizing with compressed air at 4 bar and immerging it in water for 30 seconds Fins must be intact Cross hatch pattern polishing must range between 45 5
32. etely Reinsert the drain plug Carry out motor oil refilling to the upper level of the rod using the oil recommended by the manufacturer for a normal engine operation Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 45 10 TORQUE SPECIFICATIONS AND USE OF SEALANT LOMBARDINI Table of tightening torques for the main components Picture Diam and pitch N mm Connecting rod 35 8X1 25 Injection pump union 71 73 18X1 5 Rocker arm cover 5 8X1 25 Central support collar 42 8X1 25 Intake manifold 8X1 25 Exhaust manifold 8X1 25 Air conveyor 6X1 0 Throttle cover 6X1 0 Oil sump 8X1 25 Oil filter 6X1 0 Oil filter internal 6X1 0 Hydraulic pump coupling flange 8X1 25 Camshaft gear 10X1 5 Oil pump gear 10X1 5 Starting Motor 10X1 5 Rocker arm shaft 8X1 25 Air conveyor baffle Engine foot Fuel feeding pump Injection pump Oil pump Injector nozzle holder Crankshaft timing side support Crankshaft P T O side support Crankshaft central side support Hydraulic pump gear holder R p m counter holder Fuel tank support Cylinder head Flywheel POSITION Use of sealant POSITION Type of sealant Tank bracket vibration dampers Loctite 270 Oil pump nut or union Loctite 270 Oil pump gear threading Loctite 270 Oil filter cartridge nipple Loctite 270 Oil filter center plate nipple Loctite 270 Head
33. g AGIP RUSTIA C for Countries in which this product is not available find an equivalent product on the market Start for about 10 minutes and verify any possible oil leakage then stop the engine Injection systems protection Empty the fuel tank Replace the fuel filter with a new one Carry out the filling of fuel using 10 of AGIP RUSTIA NT special additives After having performed the air bleeding start the engine verify any possible fuel leakage then stop the engine External engine protection Clean the cooling fins of the cylinders and heads Protect the external non painted surfaces with AGIP RUSTIA 100 F Seal with adhesive tape the intake and exhaust systems Coat the engine with a nylon or plastic sheet Keep in a dry place If possible not in direct contact with the ground and away from high voltage electric lines PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE Remove all protections and coverings Remove the rust preventer from the external part of the engine by means of adequate products solvent or degreaser Disassemble the injectors and introduce by means of a bowl motor oil on the piston crown no more than 2 cc for every cylinder Remove valve covers and spray motor oil on the valves then turn the crankshaft manually for a few revolutions Start the engine and heat it for about 10 minutes Remove the drain plug and let the protective oil flow compl
34. greater pressure 220 230 bar for standard engines 268 280 bar for EPA engines to allow for bedding during operation Check needle valve sealing by slowly moving hand pump until approximately 180 bar Replace nozzle in case of dripping Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 39 ELECTRIC SYSTEM LOMBARDINI Girit 1200 1600 2000 2400 2800 3200 3600 Tpm 1400 1800 2200 2600 3000 3400 T min Usmin 85 Electrical starting layout with battery charging light Components Alternator Starting motor Voltage regulator Battery Pressure switch Oil pressure warning light Key switch Battery charging light ONOahWAN Note Battery which is not supplied by Lombardini should feature 12 V voltage and capacity not below 70 Ah 12 5 V 14 A Alternator Features a fixed armature winding mounted on the air shroud bracket The rotating permanent magnet inductor is located in the fan spindle Dimensions mm a 158 80 159 20 B 27 50 27 90 Note Clearance between armature winding and inductor air gap should be 0 48 0 60 mm Alternator battery charger curve 12 5 V 14A The curve was obtained at room temperature of 25 C with 12 5 V battery voltage 40 Work
35. he engine must be started in compliance with the specific instructions in the operation manual of the engine and or machine itself Do not use auxiliary starting aids that were not installed on the original machine e g Startpilot Before starting remove any tools that were used to service the engine and or machine Make sure that all guards have been refitted During operation the surface of the engine can become dangerously hot Avoid touching the exhaust system in particular Before proceeding with any operation on the engine stop it and allow it to cool Never carry out any operation whilst the engine is running The coolant fluid circuit is under pressure Never carry out any inspections until the engine has cooled and even in this case only open the radiator plug or expansion chamber with the utmost caution wearing protective garments and goggles If there is an electric fan do not approach the engine whilst it is still hot as the fan could also start operating when the engine is at a standstill Only clean the coolant system when the engine is at a standstill When cleaning the oil cooled air filter make sure that the old oil is disposed of in the correct way in order to safeguard the environment The spongy filtering material in oil cooled air filters must not be soaked in oil The reservoir of the separator pre filter must not be filled with oil The oil must be drained whilst the engine is hot oil T 80 C Part
36. hine lt The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and the deriving dangers This condition is also essential when it comes to routine and above all extraordinary maintenance operations which in the latter case must only be carried out by persons specifically trained by Lombardini and who work in compliance with the existing documentation Variations to the functional parameters of the engine adjustments to the fuel flow rate and rotation speed removal of seals demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve Lombardini from all and every liability for deriving accidents or for failure to comply with the laws in merit On starting make sure that the engine is as horizontal as possible unless the machine specifications differ In the case of manual start ups make sure that the relative actions can take place without the risk of hitting walls or dangerous objects also considering the movements made by the operator Pull starting with a free cord thus excluding self winding starting only is not permitted even in an emergency Make sure that the machine is stable to prevent the risk of overturning Become familiar with how to adjust the rotation speed and stop the engine Never start the engine in a closed place or where there is insufficient ventilation Combustion creates carb
37. icular care is required to prevent burns Do not allow the oil to come into contact with the skin Make sure that the drained oil the oil filter and the oil it contains are disposed of in the correct way in order to safeguard the environment Pay attention to the temperature of the oil filter when the filter itself is replaced Only check top up and change the coolant fluid when the engine is off and cold Take care to prevent fluids containing nitrites from being mixed with others that do not contain these substances since Nitrosamine dangerous for the health can form The coolant fluid is polluting and must therefore be disposed of in the correct way to safeguard the environment During operations that involve access to moving parts of the engine and or removal of rotating guards disconnect and insulate the positive wire of the battery to prevent accidental short circuits and to stop the starter motor from being energized Only check belt tension when the engine is off Only use the eyebolts installed by Lombardini to move the engine These lifting points are not suitable for the entire machine in this case the eyebolts installed by the manufacturer should be used Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 9 2 TECHNICAL INFORMATION Zy LOMBARDINI TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN 1 The engine rpms suddenly increase and decrease 2
38. ings 3 Plate 4 Link 5 Lever Spring for extra fuel supply at starting Components 1 Extra fuel spring 2 Injection pump control yoke 3 Governor spring The device is operated automatically when the engine is stopped spring 1 acts on injection pump control yoke 2 providing maximum fuel delivery until the engine starts and the governor controls the injection pump rack Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 31 5 LUBRICATION SYSTEM Ls LOMBARDINI LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM A Danger Attention The engine can be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed Use suitable oil in order to protect the engine Nothing more than lubrication oil can influence the performances and life of an engine Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston rings to jam and will lead to rapid wear on the cylinder liner the bearings and all other moving parts Engine life will also be notably reduced The oil viscosity must suit the ambient temperature in which the engine operates A Danger Attention Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time Wear protective gloves to avoid t
39. mbly Reassembly LOMBARDINI Piston Refitting Connect piston to connecting rod in a way that the combustion chamber center b is at right angle under nozzle tip a Lubricate piston pin and introduce it into the piston by exerting pressure with your thumb Check that both circlips are well inside their seats Piston clearance A Piston clearance 0 65 0 70 mm 0 55 0 60 mm for EPA engines B Copper head gasket A is determined by placing the piston at top dead center and measuring with a feeler gauge and straight edge the distance the piston is below or above the cylinder face A copper gasket B available in various thicknesses is then selected to ensure the clearance is correct Gaskets are available in the following thicknesses 0 45 0 50 0 55 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 1 00 Connecting rod small end bushing Dimensions and clearance mm EN 117 95 118 05 22 015 22 025 with machine bushing in place za 21 995 22 005 0 01 0 03 C D o Connecting rod big end bearing Both centering notches A and B must be on the same side when refitting Tighten bolts to 40 Nm See page 29 for dimensions Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Disassembly Reassembly 4
40. n cnn nan n nan nnn anna nana 11 OVERALL DIMENSIONS aisian iiaae tal rllo dde tiran iania aaaea Egoa ads Oaa deca date tats 15 PERFORMANCE DIAGRAMS ivcoco norenicias tit pt td ni eet eee di cee ee ete 14 TEGHINIGAL SPECIFICATIONS coso id eek Bee ee ee Ss nn ee 12 13 TROUBLE SHOOTING ic tad ie 10 3 MAINTENANCE RECOMMENDED OIL TYPE REFILLING 16 19 ACEA Regulations ACEA Sequences ccocccccncconcocononcnnnnonnncnnco nn cnn 17 APIA MIL Sequences cities E dd 17 FUEL SPECIFIGATIONS coin A iced eave Peddie 19 International specifications sico iii ai iia 17 EUBRIGAN Tera erste ln ett liada ae a aeaa dle ti dren cool eee 17 PRESCRIBED CUBRICANT aotearoa lap aa eee ae 18 ROUTINE ENGINE MAINTENANCE wise ceed eee cies ered A aba 16 SAE GlIASSINCAtI OM aatesadcasasacictasceataacuan seseeiindee cseiaadaasasiapcnioteadesaassaaners 17 4 DISASSEMBLY REASSEMBLY 20 31 Altern atorado il ol 21 Camshaft end playa A ib tipa as alicatado lia aba id pa o a 30 Camshaft UM A a A A evened 30 Center main bearing support locating bolt oococinccnnnccinnicnnccnnccnnnnnnnnncnnn conan corn cr nn cnn rra 28 Clearance between main journals crank pins and Connecting rod bearings oooccoicincccnnccnnccnnnccnnccnn nan n arc corran 29 Gompression release optional a os 22 Gonnecting TOA big end bearing eiii E di da 26 Gon ecting rod small end DUSNINO 243 ccs seccescseicatenhesancesdeneuceschaaadbagicens cnan epucesda aauescnadaaicesscoter
41. nQINGS iii ica 39 Injector for standard Engines foil talioeealoiies 38 Test data for injection PUMP delivery oocoonnncccnnnncnnncconnsrccnnncnnn cren 36 ELECTRIC SYSTEM 40 42 Alternator battery charger curve 12 V 18 A ncnnccononccinnncncnonnnnnnoncnnnnnn conan cnn nr 41 Alternator battery charger Curve 12 5 V TA oonocincccnnonccononnnononcnnnnno no nonn cnn nr 40 Alternator 12 1 BAN in A so e ari 41 Alternator 12 5 V TA AY italia theta sks ta cai ella feds dedicada 40 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Chapter index Characteristic curves for starting motor type Bosch DWL 12 V 1 7 KW iiiincninnnnncinnnccnncnnnnncnncnnanc conc narcnnncnnnns Page 42 Electrical starting layout with battery Charging liQht cee ee eeseeeeeseeeeeneeeeeeneeeeeaeeeeeaeeessnaeeeeaeeeseaeeessaaeesenaeeeneaeeeesaaes 40 How to check voltage regulator for proper operation ooooncccnnoccononcccnnooncnnnnnnn nan nnn nn nn rra nn nr rre rre 42 OPTIONAL ELECTRIC EOU RME N ei ce aaa ae aa a a aA a N a E Ta succes ise tuadantestetssae eausianietasd gaaqerseees 41 Starting motor type Bosch DWL 12 V 1 7 KW ceceeececeeeeeeeeeeeeeeeeeeaeecaeeseaeeeaeessaeesaeesaeeceaeeeaeesaaeseaeseaeeseeeeeeeeneeeeaees 42 Voltage regulator ss sittin ahh dele he a ida 41 8 SETTINGS 43 44 Full speed setting in no load conditions Standard ooooconccc nonicnnonanononnnnnoncnonann non orn nn nnnr nn
42. ndividuals A A and avoid financial damage anger Attention This indicates situations of grave danger which if ignored may seriously threaten the health and safety of individuals Important This indicates particularly important technical information that should not be ignored SAFETY REGULATIONS Lombardini Engines are built to supply their performances in a safe and long lasting way To obtain these results it is essential for users to comply with the servicing instructions given in the relative manual along with the safety recommendations listed below The engine has been made according to a machine manufacturer s specifications and all actions required to meet the essential safety and health safeguarding requisites have been taken as prescribed by the current laws in merit All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined by Lombardini which thus declines all liability for any accidents deriving from such operations The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine operation in particular along with the relative routine maintenance work The user must read these instructions carefully and become familiar with the operations described Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of the mac
43. nr rra 43 Idling speed setting in no load conditions oooooconnccnnonccononaccnananononnno nano corn nr nr narrar rre rre rr 43 Injection pump delivery limiting and extra fuel device oooococonoccccnncccnnoncncnannnonannnn nano nc nano cnn nor nn rro ner 43 Injection pump delivery Set Ng ceci ba 43 Injection pump delivery setting with engine at the torque dynamometer eee eeseeeeeneeeeeeeeeeeaeeeeeneeeeeneeeeseeeeneneees 44 STOP SONO a a 44 9 STORAGE 45 External engine Protections citas id iaa cai 45 Injection Systems protection srining gie a oe 45 ItOrMal SNIE PLENA te ert 45 PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE cocococcccccocccnonononcnoncononcnancnnnnccnn cnn nn ran cnnnncrnnccnos 45 STORAGE citada ac aia a 45 10 TORQUE SPECIFICATIONS AND USE OF SEALANT 46 47 Table of tightening torques for standard screws Coarse thread cococonccononccononcccnnocnnnannconono corno ono nnn ocn rn r nn rn rr rra rra 47 Table of tightening torques for standard screws fine thread o ocoonccnnonicononaconancnonanannnnnn cnn nano no nano norris 47 Table of tightening torques for the Main COMPONENTS ooocccnoncccnoncncnannnonannnon non no nnnn cnn nono ren rene rre 46 Use f sealant iii AA eee Ae eat 46 11 SPECIAL TOOLS 48 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 5 Chapter index LOMBARDINI Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBAR
44. nt in Ampere 400 044 4 0 2 H 5 91 o SA 200 400 600 800 1000 1200 1400 1600 42 Workshop Manual 12 LD_ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI SETTINGS og SZ J ON gt T je A NS 7 AE Settings 1 Idling speed setting in no load conditions After filling with oil and fuel start the engine and let it warm up for 10 minutes Adjust idling speed at 1200 1300 r p m by turning setscrew 1 then tighten lock nut 2 Full speed setting in no load conditions standard After setting idle speed turn screw 2 and set full speed in no load conditions at 3200 r p m then tighten lock nut Note When the engine reaches the preset power full speed stabilizes at 3000 r p m Injection pump delivery setting This setting should be performed at the torque dynamometer if not setting is only approximate The following steps are required Loosen delivery limiting device C by 5 turns Bring engine to full speed in no load conditions i e 3200 r p m Tighten limiting device until the engine shows a drop in r p m Unscrew limiting device C by 1 turn Tighten lock nut Note If the engine under full load generates too much smoke tighten C if no smoke is observed at the exhaust and the engine cannot reach its full power unscrew C Injection pump delivery limiting and extra fuel device Limiting
45. ntion During repair operations when using compressed air wear eye protection Oil bath air cleaner Check gaskets and replace if necessary Check that flange weld is free of porosity or defective spots Carefully clean bowl and filtering element with Diesel oil and blow through with compressed air Top up with engine oil to the mark When refitting tighten nuts at 25 Nm See page 16 for periodic maintenance details Components 1 Bowl 5 Internal seal ring 2 Oil level mark 6 Cover 2 3 Filtering element 7 Clamp 4 Seal ring 8 Prefilter 20 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Disassembly Reassembly 4 Dry air cleaner 1 Hand wheel 2 Cover 3 Cartridge 4 Seal ring 5 Bracket 6 Clogging indicator A Important Replace cartridge immediately when indicator shows that it s clogged Flywheel Remove flywheel with puller part N 7271 3595 048 Check starter ring gear and tapered crankshatt mating surfaces Unscrew bolt 1 clockwise when refitting tighten bolt to 180 Nm Note To replace starter ring gear heat it up to 200 250 C and rapidly drive it onto the flywheel Alternator Remove stator and place it inside the rotor to prevent metal particles from being attracted by the magnets When refitting tighten rotor screws and s
46. on monoxide an odourless and highly poisonous gas Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death 8 Workshop Manual 12 LD_ cod 1 5302 460 3 ed_ rev 02 Z LOMBARDINI General remarks and safety information 1 The engine must not operate in places containing inflammable materials in explosive atmospheres where there is dust that can easily catch fire unles specific adequate and clearly indicated precautions have been taken and have been certified for the machine To prevent fire hazards always keep the machine at least one meter from buildings or from other machinery Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation Fuel is inflammable The tank must only be filled when the engine is off Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil Make sure that no soundproofing panels made of porous material are soaked in fuel or oil Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil Fully tighten the tank plug each time after refuelling Do not fill the tank right to the top but leave an adequate space for the fuel to expand Fuel vapour is highly toxic Only refuel outdoors or in a well ventilated place Do not smoke or use naked flames when refuelling T
47. ouching used oil If contact with the oil is unavoidable you are advised to wash your hands with soap and water as soon as possible Dispose of old oil in the correct way as it is highly polluting 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 L 58 Components 1 Oil pressure switch 2 Breather 3 Connecting rod big and bearing 4 Crankshaft main bearing gear side 5 Oil preassure relief valve 6 Fitting for preassure gauge 7 Cartridge filter 8 Oil pump 9 Oil fill plug 10 Rocker arm shifts 11 Pushrod protection tube 12 Hydraulic pump gear 13 Camshaft journal on flywheel side 14 Oil dipstick 15 Drain plug 16 Internal filter 32 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Lubrication system 5 62 N RRR Aa 63 64 Oil Pump Check that gear teeth are intact and that clearance between gear edge and pump body does not exceed 0 15 mm Further more check that control shaft is free to rotate with end float not exceeding 0 15 mm Oil pump delivery at 3000 r p m is 9 liters min Oil filter cartridge internal Through engine serial n 4877736 Components 1 Plug 2 Seal ring 3 Spring 4 Cartridge Features Filtering Capacity secen 70 um By pass valve opening press
48. our engine oil AN 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 18 Workshop Manual 12 LD_ cod 1 5302 460 3 ed_ rev 02 A LOMBARDINI Maintenance Recommended oil type Refilling 3 FUEL SPECIFICATIONS 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 To achieve optimum performance of the engine use good quality fuel with certain characteristics Cetane number minimum 51 indicates the ignition quality A fuel with a low cetane number may cause problems when starting from cold and have a negative effect on combustion Viscosity 2 0 4 5 centistokes at 40 C this is the resistance to flow and performance may decline if not within the limits Density 0 835 0 855 Kg litre alow density reduces the power of the engine and density that is too high increases performance and opacity of the exhaust Distillation 85 at 350
49. p Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 17 3 Maintenance Recommended oil type Refilling QQ LOMBARDINI PRESCRIBED LUBRICANT AGIP SUPERDIESEL ee Aras MULTIGRADE specifications MITE me E aE 10W40 Es In the countries where AGIP products are not available use oil API SJ CF for Diesel engines or oil corresponding to the military specification MIL L 4165 D E For a temperature of 10 C an oil with a 5W40 viscosity is recommended For a temperature of 15 C an oil with a OW30 viscosity is recommended 435 2 12 LD ENGINES OIL CAPACITY 435 2 B1 OIL VOLUME AT MAX LEVEL OIL FILTER INCLUDED Litres OIL VOLUME AT MAX LEVEL WITHOUT OIL FILTER Litres A Danger Attention The engine may be damaged if operated with insufficient lube oil Itis also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion Use proper lube oil preserve your engine Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly Always use oil with the right viscosity for the ambient temperature in which your engine is being operated Use the chart when chosing y
50. r NB ISO 3046 IFN kW CV 12 7 17 2 13 2 18 0 14 8 20 1 14 8 20 1 NA ISO 3046 ICXN 11 4 15 5 12 0 16 3 13 5 18 3 13 5 18 3 Maximum torque NB power Nm kgm 49 0 5 0 49 0 5 0 57 0 5 8 48 0 4 9 Maximum torque 3 P T O Nm kgm 25 0 2 5 25 0 2 5 25 0 2 5 25 0 2 5 Axial load allowed on crankshaft Kg 300 300 300 300 CONSUMPTION AT MAXIMUM POWER ane g kWh g CVh 260 191 280 206 245 180 257 189 0 020 0 020 0 025 0 025 Specific fuel onsumption Oil consumption kg h i 2000 rpm for 435 2 e 435 2 B1 engines 2100 rpm for 475 2 engines 2200rpm for 475 2 EPA engines i At 3600 rpm RE At NB power 12 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 A LOMBARDINI Technical information 2 Engine type 12LD 435 2 B1 FUEL SUPPLY CIRCUIT Fuel type Automotive diesel fuel minimum cetane 51 Fuel supply Mechanical fuel lift pump diaphragm type Fuel filter internal Filtering surface cm 2400 Filter capacity H 223 Maximum operating pressure bar 4 Fuel filter external Filtering surface cm Filter capacity H LUBRICATION CIRCUIT Type of lubrication Completely forced Circuit supply Gear pump Maximum oil quantity Including filter 1 2 7 2 7 Maximum oil quantity Excluding filter 1 2 5 2 5 Oil pressure at min speed oil temperature 120 C bar 0 6 0 6 Oil filt
51. safeesneadagpiastetisansisasecdascensaend 26 Connecting rod Weight Tenri doll aaa ie 27 GRANKSHAPT Data tn oa lada leia ie 28 29 Crankshaft center main bearing SUpport comccncccnccnnnoniccnnocnnnnnnnnn crac ronca rr 28 Grankshattiend play cusco aaa adi liaib da 28 Crankshaft journal radils ida lt o 28 Crankshaft I brication JUGS eeni e a A a a t 28 Crankshaft timing gear cessano en cece ees AE A NE A E E EE AE ET ne ide ieee ened 27 TAO PE E A T T A A A 24 C linderHead ienne it io a a a Ad cane cde a aa a a a a 22 GylindeF RONEN 0 AVET A a ida E E E E AT 24 Dimensions of camshaft journals and NOUSINGS oooccoocccnnoncccnonanonananonanrnnnnnr cnn ronca nr rre rre 30 Dial e EEEE EA AET A iii 21 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 3 Chapter index LOMBARDINI AAE E E T A E E tect ot ois Aste A E E bad lat page 21 Governor springs with rocker atM aeit e a da ceed tee 31 How to measure intake exhaust CAM height eee eesceeeeeeeeeneeeeeeaeeeesaeeeeeneeeeeeaeeseaeeeseaeeeeeaaeeseaeeessaeeeeeaaeeseneeeeenaeeeeas 30 Aydraulic pumpup t 02 NS 31 Injector Projection iia BG da ik inh ain dagen patna 22 Main bearing and connecting rod big end bearing internal diameter o ooooncccnoncconnnaccnanancnnnonn crono conan nr nnrn cnn non cnn nn 29 Main bearing housing uicirt ne Aaa ai Bei Rie Sia el ee ee eds 29 Main bearing Suppe PTOS lO ciao vac E e r ag aa rr cand aA Ea a Ta a aa AAA a
52. shop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Electric system 7 Giri 1 1200 1600 2000 2400 2800 3200 3600 ram 1400 1800 2200 2600 3000 3400 T min U min 87 OPTIONAL ELECTRIC EQUIPMENT 12 V 18A Alternator Only two yellow cables are at output CEES e 158 159 20 27 50 27 90 Note Clearance between armature winding and inductor air gap must be 0 48 0 60 mm Alternator battery charger curve 12 V 18 A This curve is obtained at 25 C with 12 5 V battery voltage Voltage regulator Type LOMBARDINI supplied by SAPRISA and DUCA TI Voltage 12 V max current 26A References for SAPRISA connections with the cor responding DUCATI connections SAPRISA DUCATI To avoid wrong connections 3 different sizes are supplied Connection size mm SAPRISA DUCATI f Width Thickness 0 8 OA 00 R 960 12 B aso L The voltage regulator fits to both circuits with and without battery charging light in the latter case connections LE SAPRISA and L DUCA TI are not used Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 41 Electric system LOMBARDINI
53. so as to be considered qualified and in conformity to the regulations set for each lubrication kind A P l American Petroleum Institute MIL Engine oil U S military specifications released for logistic reasons ACEA European Automobile Manufacturers Association Tables shown on page 53 are of useful reference when buying a kind of oil Codes are usually printed out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics Usually a specification showing a following letter or number is preferable to one with a preceding letter or number An SF oil for instance is more performing than a SE oil but less performing than a SG one ACEA REGULATIONS ACEA SEQUENCES PETROL HEAVY DUTY DIESEL ENGINES ALow viscosity for frictions reduction ETEZOBS LETE A2E Standard ASiZHigh performances E2 Standard E3 Heavy conditions Euro 1 Euro 2 engines LIGHT DUTY DIESEL ENGINES E4 Heavy conditions Euro 1 Euro 2 Euro 3 engines Bi Low viscosity for frictions reduction E5 High performances in heavy conditions Euro 1 Euro 2 B2 Standard Euro 3 engines B3 High performances indirect injection B4 High quality direct injection API MIL SEQUENCES DIESEL PETROL NAS ANA Mx AN EE BE eM 04 L 21 D E CURRENT ORSOLETE Worksho
54. stud Loctite 270 Main bearing support fixing stud bolt flywheel side Loctite 270 Crankcase stud bolt Loctite 270 Fuel feeding pump stud bolt Loctite 270 Blower housing stud Loctite 270 Tank bracket gasket Loctite IS 495 46 Workshop Manual 12 LD_ cod 1 5302 460 3 ed_ rev 02 LOMBARDINI Torque specifications and use of sealant 10 Table of tightening torques for standard screws coarse thread Resistance class R Quality Dimensions R gt 400N mm R gt 500 R gt 600N mm R gt 800N mm R gt 1000N mm R gt 1200N mm Nm Nm Nm Nm Nm Nm Nm 0 5 0 7 0 6 1 1 4 1 9 2 3 1 1 1 5 1 4 2 2 2 9 4 1 4 9 2 3 3 2 8 6 8 5 10 3 8 5 4 7 10 14 17 9 4 13 12 25 35 41 18 25 23 49 69 83 32 43 40 86 51 68 63 79 98 Diameter Quality Dimensions R gt 400N mm R gt 500 R gt 600N mm R gt 800N mm R gt 1000N mm R gt 1200N mm Diameter Nm Nm Nm Nm Nm Nm Nm 10 14 13 20 27 38 45 21 28 26 42 56 79 95 20 26 24 39 52 73 88 36 48 45 71 95 38 45 42 68 90 56 75 70 84 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 47 11 SPECIAL TOOLS LOMBARDINI SPECIAL TOOLS Special tools and equipment for maintenance DESCIPTION Valve lowering tool for static injection timing che
55. tator bolts at 10 Nm See pages 40 and 41 for alternator characteristics Valve Rocker arm clearance A Caution Warning Setting should be performed when the engine is cold Remove rocker arm cover and check gaskets for breakage Bring each cylin der piston to top dead center on the compression stroke and set clearance A at 0 15 0 20 mm When refitting tighten cover screws to 20 Nm Workshop Manual 12 LD_ cod 1 5302 460 3 ed_ rev 02 21 Disassembly Reassembly LOMBARDINI Compression release optional Bring piston to top dead center on the compression stroke Unscrew rocker arm cover side plug and measure clearance A which must be 0 30 0 40 mm For setting purposes remove rocker arm cover unscrew lock nut C and set clearance A by adjusting the screw B Rocker arm assembly Components 1 Bore 2 Lubrification tube Dimensions mm A 18 032 18 050 B 17 989 18 000 If clearance A B exceeds 0 135 mm replace shaft and rocker arms When refitting check that lubrication tube perfectly matches with the journal bore Tighten screws to 25 Nm Injector projection The end of nozzle A should project 3 0 3 5 mm 2 00 2 50mm for EPA engines from the cylinder head plane Adjust injector projection by means of copper shims B measuring 1 5 and 1 00 mm in thickness
56. to replace the filter 16 Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 ZY LOMBARDINI Maintenance Recommended oil type Refilling 3 LUBRICANT SAE Classification In the SAE classification oils differ on the basis of their a viscosity and no other qualitative characteristic is taken 40 35 30 25 201510 5 0 5 10 15 20 25 30 35 40 45 50 into account SAE 10W The first number refers to the viscosity when the engine is 7 cold symbol W winter while the second considers SAE 20W viscosity with the engine at r gime SAE 30 The criteria for choosing must consider during winter the SAE 40 lowest outside temperature to which the engine will be SAE 10W 30 subject and the highest functioning temperature during SAE 10W 40 SUMME i SAE 10W 60 Single degree oils are normally used when the running RE 15W40 temperature varies scarcely _ _ _ gt Multi degree oil is less sensitive to temperature SAE 15W 40 changes SAE 20W 60 SAE 5W 30 SAE 5W 40 SAE 0W 30 Mineral base SAE Grade Semi synthetic base Synthetic base International specifications They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis
57. ure 0 60 0 75 bar Max working pressure l es 4 5 bar Oil filter cartridge external Starting from engine serial n 4877736 Components 1 Gasket 5 Filtering element 2 Steel shroud 6 Bypass valve 3 Gommino 7 Spring 4 Spring Characteristics Maximum operating pressure eee 7 bar Maximum blast pressure scce 20 bar Filtering capacity eee 15H By pass valve Settidg ooooomoocccinnnnnoccccnnnnnn 1 5 1 7 bar Total filtering surface l enn 730 cm Oil preassure relief valve Only for engines with internal oil filter Through egine serial n 4877736 Details 1 Piston 2 Washer 3 Valve housing 4 Spring 5 Snap ring Operating preaSSUre oooocccnnocccinocccnononcnnno 5 bar Workshop Manual 12 LD _ cod 1 5302 460 3 ed_ rev 02 33 Lubrication System LOMBARDINI Oil pressure curve at idling speed bar 5 The curve is obtained at the oil filter level with constant engine speed of 1200 r p m in no load conditions and at a room temperature of 25 4 Pressure is given in bar and temperature in centigrade 3 2 5 60 70 80 90 100 120 C Oil pressure curve at full speed bar p j 5 The curve is obtained at the oil filter level with engine working at 3000 r p m at a room temperature of 25 C and at 25 84 HP 4 Pressure is given in bar and temperature in centigrade 3 2 1 5 60 70 80 90 100 120 C 34 Workshop M
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