Lombardini 3LD 450 Workshop Manual
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Lombardini 3LD 450 Workshop Manual

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3/4 LD, CODE1-5302-556 ENGINE SERIES
TECO/ATL AUTHOR
BOOK CODE
1-5302-556
WORKSHOP
MANUAL
3LD 450
3LD 510
3LD 450/S
3LD 510/S
4LD 640
4LD 705
4LD 820
rd
edition
3
SERVICE
MODEL No.
DATE OF ISSUE
50839
01-94
DATE
A P P R O V A L
02
REVIEW
30.11.2001
1

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  • Page 1 WORKSHOP MANUAL 3/4 LD, CODE1-5302-556 ENGINE SERIES 3LD 450 3LD 510 3LD 450/S 3LD 510/S 4LD 640 4LD 705 4LD 820 edition SERVICE TECO/ATL AUTHOR MODEL No. DATE OF ISSUE BOOK CODE DATE A P P R O V A L...

  • Page 2: Table Of Contents

    This handbook provides the main information concerning the repair of the following LOMBARDINI Diesel engines 3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S, 4LD 640, 4LD 705, 4LD 820, which are air-cooled, provided with direct injection and revised on the 30-11-2001.
  • Page 3 REGISTRATION CODE AND IDENTIFICATION DIESEL LOMBARDINI Engine group number Displacement CC Engine serial number Customer's code Approval code Customer's code Engine serial number Engine grup number LOMBARDINI DIESEL Displacement CC Approval code TECO/ATL AUTHOR MODEL No. DATE OF ISSUE BOOK CODE...
  • Page 4 These powers are reduced of abt. 1% every 100 m height and of 2% for every 5°C exceeding 25°C. C (NB): Specific fuel consumption at NB power : Torque at N power : Continuous service field of use. For any purpose out of this field of use, please contact company LOMBARDINI. TECO/ATL AUTHOR BOOK CODE MODEL No.
  • Page 5 MIL -L-2104 C and MIL -L-2104D military specifications. Air filter oil bowl = 0.3 For special filters, tanks and oil sumps, please follow LOMBARDINI instructions. RATING SAE 10W SAE 20W/20 SAE 30 SAE 40 °C...
  • Page 6 TROUBLE SHOOTING This table shows some possible causes concerning malfunctions that could arise during the machine running. Always, systematically carry out simpler checks before any disassembly or replacement. TROUBLE PROBABLE CAUSES Clogged pipings Clogged fuel filter Presence of air in the fuel circuit Clogged tank breather Faulty fuel pump Blocked injector...
  • Page 7 Check that the starter ring gear, when it is present, and the conic surface of the driving shaft coupling hole are intact. While reassembling, tighten the screws 1 at 170 Nm for 3LD 450, 3LD 451/S, 3LD510, 3LD 510/s and at 350 Nm for 4LD 640, 4LD 705, 4LD 820.
  • Page 8 1 moved back at ( 45°) according to the rotation direction of the engine, as per picture 4 and 5 . Tighten the screws at 35 Nm for 3LD 450, 3LD 451/S, 3LD510, 3LD 510/S, at 40 Nm for 4LD 640, 4LD 705, 4LD 820.
  • Page 9 Always replace the copper gasket, see picture 34 for the choice of thickness. Gradually tighten the nuts according to the following order 1, 3, 2, 4, at 50 Nm for 3LD 450, 3LD 451/S, 3LD 510, 3LD510/S, and at 80 Nm for 4LD 640, 4LD 705, 4LD 820. Injector, projection...
  • Page 10 A and B. Valve guide dimensions and clearances 3LD 450, 3LD 451/s, 3LD 510, 3LD 510/S (mm): D = 7.030 ÷ 7.050 E = 6.985 ÷ 7.000 (D-E) = 0.030 ÷ 0.065 (D-E) limit= 0.13 4LD640, 4LD 705, 4LD 820 D = 8.030 ÷...
  • Page 11 After milling, grind with fine emery paste in engine oil bath. The S sealing surface shall not exceed 2 mm. Embed valves D after grinding for 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S = 0.55 ÷ 1.05 mm; for 4LD 640, 4LD 705, 4LD 820 = 0.45 ÷...
  • Page 12 C = 0.07 ÷ 0.09 D = 0.06 ÷ 0.08 Piston ring assembly order 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S, picture 30 A = slot for first piston ring (chromium plated) B = slot for piston ring segment (torsional)
  • Page 13 B = Head gasket The thickness B head gasket determines the clearance volume which shall be 0.75 ÷ 0.90 mm for 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S and 0.80 ÷ 1.00 mm for 4LD 640, 4LD 705, 4LD 820.
  • Page 14 The axial clearance A shall be: A = 0.20 ÷ 0.60 mm 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S. A = 0.15 ÷ 0.65 mm for 4LD 640, 4LD 705, 4LD 820. Adjust the clearance by changing the gasket thickness between the distributor port (if it is assembled) or bell 1 and the base;...
  • Page 15 820 have the same camshaft; it differs in 3LD 451/S and 3LD 510/S left-handed engines. Camshaft intake and exhaust cam timing For 3LD 450, 3LD 510, 4LD 640, 4LD 705, 4LD 820, see picture 48. Clockwise rotation. TDC = Top dead centre of the piston...
  • Page 16 DISASSEMBLY/REASSEMBLY Camshaft pin and housing dimensions (mm) A = 18.000 ÷ 18.018 (housing on the base) B = 17.945 ÷ 17.975 C = 18.000 ÷ 18.018 (housing on the port) D = 17.945 ÷ 17.975 A-B and C-D = 0.025 ÷ 0.073 Worn limit = 0.13 Camshaft intake and exhaust cam height.
  • Page 17 - Close the governor (move the mobile bell 3 towards the operator, picture 55). - Place lever 1 at A distance, picture 56 (22 mm for 3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S and 28 mm for 4LD 640, 4LD 705, 4LD 820).

  • Page 18: Lubrication Circuit

    LUBRICATION CIRCUIT Lubrication circuit Details: 1 Intake pipe 2 Oil pump 3 Oil filter 4 Pressure switch 5 Crankshaft bearing 6 Pressure adjusting valve 7 Tappet rod protection pipe 8 Vent and oil filler plug. Oil pump Make sure that the gear teeth are intact and check that the clearance between the gear periphery and the pump case does not exceed 0.15 mm and that the drive shaft can easily turn with an axial clearance not exceeding 0.15 mm.
  • Page 19 By-pass valve setting: 1÷ 1.4 Total filtering surface: 750 cm Oil pressure regulating valve It is housed in the flywheel side main bearing For 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S, see picture 63 1 Support 4Sheet metal 2 Valve...

  • Page 20: Vii Fuel/Injection Circuit

    The projection A of rod 3 is 0.8 ÷ 1.2 mm; it shall be adjusted with the following supplied gaskets having a thickness of 0.50; 0.80 and 1.0 mm. Rod length = 65.4 mm for 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S and 75.2 mm for 4LD 640, 4LD 705, 4LD 820. Injection pump...
  • Page 21 170 bars. In case of dripping, replace the nozzle. Tighten the injector to the head at 15 Nm for 3LD 450, 3LD 451/S, 3 LD 510, 3 LD 510/S and at 20 Nm for 4LD 640, 4LD705, 4LD 820.

  • Page 22: Viii Electric Circuit

    Note: The batteries, which are not supplied by Lombardini, shall have a 12 V voltage and the following capacity: 3LD 450, 3lD 451/S, 3LD 510, 3LD 510/S = 45 Ah 4LD 640 = 55 Ah 4LD 705 = 66 Ah 4LD 820 = 70 Ah 12.5 V 14 A alternator...
  • Page 23 Avoid any electric welding either on the engine and on the equipment. Bosch DW (L) 12 V 1, 1 KW type, starting motor For 3LD 450, 3LD 510 Anticlockwise rotation direction (seen from the flywheel side) A = 29.5 ÷ 31.5 mm (rim surface and motor flange distance)

  • Page 24: Ix Electric Equipment

    ELECTRIC EQUIPMENT Characteristic curves for Bosch DW(L) 12V 1.1 kW type, starting motor Bosch JF(L) 12V 2.5 kW type, starting motor For 4LD 640, 4LD 705, 4LD 820 Anticlockwise rotation (seen from the pinion side) A = 23 ÷ 25 mm Characteristic curves for Bosch JF(L) 12V 2,5 kW type starting motor TECO/ATL AUTHOR...
  • Page 25 ADJUSTMENTS Minimum rpm adjustment at idle running (standard) After filling the engine with oil and fuel, start and warm up the engine for 10 minutes. Actuating the adjusting screw 1, set the idling at 1150 rpm; then fasten the lock nut. Peak rpm adjustment at idle (standard) After adjusting the minimum rpm, set the screw 2 and adjust the peak rpm at 3200 rpm at idle;...

  • Page 26: X Adjustments

    8) When the engine is cold, check the valve clearance again. Required adjustments (the most demanded) Specific fuel consumption * Time secs Engine r/kW.h power for 100 cc. 140-146 3LD 450 3000 272-283 N 7,5 143-149 3LD 450 3600 285-299 NB 7 117-122...
  • Page 27 UPKEEPING UPKEEPING The engines to be stored for more than 30 days shall be prepared as follows: Temporary protection (1÷ 6 months). · Start the engine at idle and at a minimum rpm for at least 15 minutes. · Fill the sump with protection oil MIL -1-644-P9 and operate for 5 ÷...

  • Page 28: Xii Technical Data

    TECHNICAL DATA TECO/ATL AUTHOR BOOK CODE MODEL No. DATE OF ISSUE DATE APPROVAL REVIEW 1-5302-556 50839 01-94 30-11-2001...
  • Page 29 XIII MAIN DRIVING TORQUES 3LD 450 - 3LD 510 - 3LD 451/S - 3LD 510/S MAIN DRIVING TORQUES REFERENCE Dia. /Pitch Torque POSITION ( Picture NO. ) ( mm ) ( Nm ) Injection pump union 18x1.5 Connecting rod 8x1.25 Clutch bearing bell bolt 14x1.5...

  • Page 30: Xiv Use Of Sealant

    USE OF SEALANT USE OF DOPE FOR 3LD 450 - 3LD 510 - 3LD 451/S - 3LD 510/S TYPE OF SEALANT POSITION Clutch bearing bell and embedded hexagonal-head screws LOCTITE 270 Control pin threading LOCTITE 270 Coupling nipple for oil filter cartridge...
  • Page 31 DRIVING TORQUES DRIVING TORQUES FOR STANDARD SCREWS NAME R ≥ ≥ ≥ ≥ ≥ 1000 N/mm² R ≥ ≥ ≥ ≥ ≥ 800 N/mm² R ≥ ≥ ≥ ≥ ≥ 1200 N/mm2 Dia. per pitch (mm) 4x0.70 0.37 0.52 0.62 11.9 5x0.80 0.72...
  • Page 32 GENERAL ALPHABETICAL INDEX Adjustments Starting pulley Advanced injection Temporary protection Advanced injection reference on conveyor and Timing system Air filter Timing system without considering any reference Alternator Upkeeping Battery characteristic curve Valve clearance housings Bosch DW(L) starting motor Valve guide clearance dimensions Bosch JF(L) starting motor Valve guide insertion Camshaft...
  • Page 33 Tel. (0522) 3891 - Telex: 530003 Motlom I Telegr: Lombarmotor - Telefax (0522) 389465 La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione. Lombardini se réserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication.

This manual is also suitable for:

3ld 5103ld 4513ld 451/s4ld 7054ld 6404ld 820 ... Show all

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