Lombardini LDW 422 SERIES Workshop Manual
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Lombardini LDW 422 SERIES Workshop Manual

Lombardini LDW 422 SERIES Workshop Manual

4 speed - euro 2 version
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WORKSHOP
MANUAL
LDW 422 engines-
4 Speed - EURO 2 Version
code 1-5302-662
LDW 422
1st Edition
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
DATE
ENDORSED
00
1
REVISION
18-10-2004
18-10-2004
1-5302-662
51092

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Summary of Contents for Lombardini LDW 422 SERIES

  • Page 1 WORKSHOP MANUAL LDW 422 engines- 4 Speed - EURO 2 Version code 1-5302-662 LDW 422 1st Edition COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...
  • Page 3 FOREWORD We have done all in our power to give up to date and accurate technical information in this manual. Lombardini engines are, however, constantly developing thus the data in this publication may be liable to modification without prior notice.

  • Page 4: Table Of Contents

    INDEX This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled, indirect injection Diesel engines type LDW 422: updated October 18, 2004. TABLE OF CONTENTS SAFETY DECALS - SAFETY INSTRUCTIONS ................Pag. TROUBLESHOOTING ......................... " 10-11 MAINTENANCE ........................... "...
  • Page 5 INDEX Assembly play - Piston rings ............................63 Assembly play - Piston - Piston pin ..........................64 Assembly play - Piston slots - piston rings ........................64 Assembly play - Small end bush - wrist pin ........................64 Assembly play - Connecting rod small end bush ......................64 Assembly play - Crankshaft - big end ..........................
  • Page 6 INDEX Fuel pump - Disassembly ............................... 47 Fuel pump – Characteristics and components ......................104 Fuel pump - Reassembling ............................104 Gear assembly measure check ............................78 Gear cluster ball bearing and drive shaft d.c. roller bearing ..................84 Gearbox .................................... 80 Gearbox shaft ...................................
  • Page 7 Tappet cover disassembly .............................. 46 Tappets - Disassembly ..............................46 Then check injection advance tining as follows - A....................... 112 Thermostat – Assembly ..............................101 Thermostat - Disassembly ............................. 44 Timing belt cover - Assembly ............................105 Timing belt cover, air shroud and stator support ......................32 Timing gear and speed gear control box - Disassembly.
  • Page 8 SAFETY INSTRUCTIONS • 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.
  • Page 9 • 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.

  • Page 10: Itroubleshooting

    TROUBLE SHOOTING POSSIBLE CAUSES AND TROUBLE SHOOTING 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. FAULT FINDING REMEDIES STARTING PROBLEMS Faulty fuel pump Check and, if necessary, replace Presence of air inside the injection system Purge by operating the fuel pump lever...
  • Page 11 TROUBLE SHOOTING REMEDIES FAULT FINDING WHITE EXHAUST SMOKE Cold engine Heat the engine for few minutes at low speed Faulty injector Check and, if necessary, replace High oil level Restore the level BLACK EXHAUST SMOKE Air filter clogged Replace Incorrect injection pump delivery Check and restore Faulty injector Clean and, if necessary, replace...

  • Page 12: Maintenance

    MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system LDW 422 ENGINE - SPECIAL MAINTENANCE OPERATION COMPONENT after the first after the first 1000 Km 5000 Km Dry-type air filter...

  • Page 13: Maintenance- Recommended Oil Type - Refilling

    MAINTENANCE - RECOMMENDED OIL - FUELS AND LUBRICANTS The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed. Use a suitable oil in order to protect the engine. The lubrication oil influences the performances and life of the engine in an incredible way.

  • Page 14: Model Number And Identification

    MODEL NUMBER AND IDENTIFICATION Lombardini r.p.m. Diesel Customer's code Water cooled Displacement (cc) Engine serial number COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 15: Technical Data

    TECHNICAL DATA LDW 422 ENGINE MAIN SPECIFICATIONS - 4-stroke single cylinder engine - Indirect-injection Diesel-cycle type - Liquid cooling system with axial fan - Differential gear and gearbox assembly on rear axle - OHC axle driven by toothed belt - Lubrication is made through a lobe pump controlled by driving-shaft chain - Injection system by immersed-type pump, fed by diaphragm fuel pump - Dry-type cartridge air filter - Oil filter with cartridge...

  • Page 16: Vi Lubrication System

    LUBRICATION SYSTEM COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 17: Lubrication System

    LUBRICATION SYSTEM LDW 422 OIL CIRCUIT DIAGRAM OIL PICK UP OIL PUMP OIL FILTER PRESSURE VALVE VALVE FOR CYLINDER CRANKSHAFT PISTON COOLING CONROD CYLINDER HEAD CAMSHAFT OIL SUMP CAMSHAFT SUPPORT GOVERNOR REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004...

  • Page 18: Water Cooled System Description

    COOLING SYSTEM FORCED LIQUID COOLING SYSTEM WITH AXIAL FAN Details: 1) Cooling liquid level 8) Thermostat 2) Overflow pipe 9) Liquid circulating pump 3) Plug with calibrated pressurizing valve 10) Engine outlet-radiator inlet hose 4) Compensation tank 11) Radiator outlet-engine inlet hose 5) Breathing pipe 12) Radiator 6) Pipe for the connection to the expansion vessel...

  • Page 19: Cooling System

    COOLING SYSTEM Cooling liquid features It is recommended to use cooling liquids according to the recommended percentages, because besides lowering the freezing point as well as the pressure determined by the plug (radiator or expansion vessel), it determines the rise of the liquid boiling point inside the circuit.

  • Page 20: Cooling Liquid Circulating Pump

    COOLING SYSTEM Cooling liquid circulating pump Components: 1 Water pump case 2 Snap ring 3 Water pump bearing 4 Water pump sealing 5 Water pump impeller 6 Pulley 7 Shaft Checks on water pump Water pump is provided with two drain channels located in the upper part to the purpose of unveiling possible liquid leakages thus indicating an incipient failure of the pump seal.

  • Page 21: Check Of The Coolant Temperature Switch

    COOLING SYSTEM Sensor for cooling liquid temperature indicator light Features: Circuit: ........... Unipolar Supply voltage: ......6/24 V Voltage: .......... 6/24 V Absorbed power: ......3 W Operating temperature: 110 ± 3° C The following operation must be performed with the utmost attention.

  • Page 22: Fuel System

    VIII FUEL SYSTEM FUEL SUPPLY CIRCUIT WITH QUICK STOP DEVICE ( QSD ) This device stops electrically the diesel engines, equipped with immersed-type injection pumps of type Q and K. The device operation is based mainly on a special electronically-controlled slide valve integrated in the fuel filter. During the stop phase of the engine, fuel is sucked from the injection pump thanks to the suction vacuum of the fuel pump.

  • Page 23: Qsd Behaviour With De-Excited Electromagnet

    FUEL SYSTEM VIII Running engine (excited electromagnet) CAPTION: 1 – Fuel tank 5 – Special union for QSD ( valve closed ) 2 – Fuel filter with QSD 6 - Injector 3 – Fuel supply pump 7 – Fuel return pipe to tank 4 –...

  • Page 24: Fuel Circuit Air Bleeding

    VIII FUEL SYSTEM Fuel circuit air bleeding Should you empty the fuel circuit completely, bleed it carefully by using the indicated screw A. This operation is to be carried out once the fuel refilling is over and with the engine running at idle speed. QSD WIRING DIAGRAM COMPILER TECO/ATI REG.

  • Page 25: Timing Diagram

    TIMING DIAGRAM Timing diagram Data concern 1 mm. cold play between tappets and valves REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 26: Xpreheating System

    PREHEATING SYSTEM Preheating system The preheating system is made up of: a key switch, a gear case with built-in temperature sensor, a glow plug, a preheating indicator light. By turning key 1 to the ON position on switch 2 the preheating indicator lamp 3 turns on indicating the waiting time, which depends on the ambient temperature detected by the sensor located inside the gear case 7.

  • Page 27: Distraction Time Diagram

    PREHEATING SYSTEM Preheating time diagram according to ambient temperature ( 11V ) A) Preheating indicator lamp on and glow plug heated B) (Tolerance) Indicator lamp off and glow plug heated (for the time needed to start the engine) Distraction time diagram C) Switch-key turned from ON to OFF position before the set preheating- time is over –...
  • Page 28 NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 29: Muffler - Disassembly

    Apart from disassembly and reassembly operations, this handbook also includes checks, setting up, dimensions, repairs and running instructions. It is necessary to use LOMBARDINI original spare parts for a correct repair. During repair operations, when using compressed air, wear eye protection.

  • Page 30: Air Shroud, Cooling Fan - Disassembly

    DISASSEMBLY/REASSEMBLY Air shroud, Cooling fan - Disassembly Loosen the 9 fastening screws to disassemble the air shroud on the radiator side (see picture 6). Use a short cross-head screwdriver to loosen the 3 lower screws (see picture 5). Loosen the 4 M6x20 fastening socket head screws to disassemble the cooling fan (see picture 8).

  • Page 31: Cooling Fan Support - Disassembly

    DISASSEMBLY/REASSEMBLY Cooling fan support - Disassembly Loosen the 5 M 6x20 socket head screws (see picture 13) to disassemble the liquid cooling fan support of the radiator from the flywheel. Flywheel - disassembly tool 981075.414 Place tool 981075.414 onto the starting motor housing (see picture 15) to lock the flywheel, remove the flywheel retaining screw using the 22 mm socket wrench (...

  • Page 32: Internal Alternator

    DISASSEMBLY/REASSEMBLY Timing belt cover, air shroud and stator support After removing the timing belt cover (see picture 23), loosen the 6 screws and remove the air shroud and stator support (Fig. 24), and remember to remove the clamp from the alternator cable (Fig. 25). Internal alternator Components: 1 Stator...

  • Page 33: Internal Alternator - Features

    DISASSEMBLY/REASSEMBLY Internal alternator - features 3-phase magnet flywheel Max rpm ......... 5000 rpm Rotor poles ........12 Stator poles ........18 Operating temperature ....-10° C ÷ + 110° C Battery recharge curve REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI...
  • Page 34 DISASSEMBLY/REASSEMBLY Alternator-voltage regulator connecting cable Tree-phase alternator and voltage regulator wiring diagram COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...
  • Page 35 DISASSEMBLY/REASSEMBLY REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 36: Clutch Cover, Clutch Pack - Disassembly

    DISASSEMBLY/REASSEMBLY Clutch cover, clutch pack - Disassembly Loosen the 6 M 6x45 hex bolts to disassemble the entire clutch cover ( fig. 30-31 ). Extract the snap ring using pliers then remove the thrust plate ( fig. 32-33 ). Place the stop device 985110.039 (see picture 34) and unscrew the fastening nut (see picture 35). Place the puller 981075.419 and loosen the middle screw to remove the clutch pack (see picture 37-38).

  • Page 37: Camshaft Timing

    DISASSEMBLY/REASSEMBLY Timing system Before starting to disassemble the timing belt, camshaft and crankshaft timing is necessary. Camshaft timing Remove the screw plug from the camshaft support (see picture 41). Turn the timing gear until hole 3 on the camshaft is aligned with the hole on the support from which screw plug 1 has been removed (see picture 43).

  • Page 38: Crankshaft Timing

    DISASSEMBLY/REASSEMBLY Crankshaft timing Place tool 5900.217 (see picture 46 ) on the crankshaft replacing the previously disassembled clutch pack, by using the key. By means of the same fastening nut used for the clutch, tighten the tool to 120÷140 Nm. Then fit timing pin 8430.124 (see picture 46) and screw it on the clamping hub so that it corresponds to the hole on the clutch housing pan (see picture 48).

  • Page 39: Toothed Timing Belt - Disassembly

    DISASSEMBLY/REASSEMBLY Toothed timing belt - Disassembly Once the relevant parts – i.e. crankshaft and camshaft – have been set in timing phase following to the procedures explained before, the toothed timing belt can be disassembled. First loosen the belt tightener fastening nut (fig. 51), then push the tightener upwards until it lays against the cover and lock it in this position by retightening the nut.
  • Page 40 DISASSEMBLY/REASSEMBLY Then tighten again the belt tightener fastening nut to a 40÷44 Nm torque (fig. 57). Tighten the fastening nut of the camshaft toothed pulley to 70 Nm (fig. 58). Close the safety lock onto the camshaft fastening nut (fig. 59). Now remove both timing pins to allow the camshaft and the crankshaft to rotate (fig.

  • Page 41: Injector, Fireproof Bulkhead - Disassembly

    DISASSEMBLY/REASSEMBLY Once the correct tension of the toothed timing belt has been set, remove the timing tool from the crankshaft by using a multi- purpose puller as shown in fig. 66, then reassemble the clutch (fig. 67). Injector, fireproof bulkhead - Disassembly Disassemble the hose connecting the injection pump to the injector (fig.

  • Page 42: Glow Plug - Disassembly

    DISASSEMBLY/REASSEMBLY Glow plug - Disassembly Thermoelectric specifications Connection: ......1 pole Nominal voltage: ....11 Volt Operating voltage: ....9 ± 1 Amp Temperature: ....... 850° C = </= 6.5 sec. Maximum temperature: </= 1150° C Glow plug - Check Remove the glow plug from the cylinder head and connect it through two cables to the poles of a 12 V battery.

  • Page 43: Injection Pump - Disassembly

    DISASSEMBLY/REASSEMBLY Injection pump - Disassembly Remove inspection plug (fig. 79). To disassemble the injection pump from the camshaft support, unscrew the two M8 nuts and remove them together with the relevant spring washers (fig. 80). Disengage the injection pump control rod (fig. 81). Extract the injection pump by paying particular attention to the seals inserted between the pump and the cover surfaces.

  • Page 44: Complete Governor Assembly - Disassembly

    DISASSEMBLY/REASSEMBLY Thermostat - Disassembly After removing the three M6X25 bolts, disassemble the cover (fig. 86) to reach the thermostatic valve (fig. 87). To avoid air intake, check the seal ring and replace it if necessary. The thermostatic valve is to be assembled properly: the bleeding hole should face upwards (fig. 88). Complete governor assembly - Disassembly Unscrew the 5 bolts and remove the complete governor assembly (fig.

  • Page 45: Belt Tightener - Disassembly

    DISASSEMBLY/REASSEMBLY Injection pump control cam Disassembly Remove the snap ring by using pliers for internal snap rings (Fig. 95), extract the shoulder washer (Fig. 96) and extract the injection cam . Belt tightener - Disassembly After unscrewing the flanged fastening nut, remove the safety washer, the belt tightener and the tensioner spring (Fig.

  • Page 46: Camshaft Extraction

    DISASSEMBLY/REASSEMBLY Tappet cover disassembly Unscrew the four M6x20 hex screws to disassemble the tappet cover, check the seal ring and replace it - if necessary - before reassembly (fig. 101). Camshaft extraction Turn the shaft and bring the cam lobe to coincide with the opening provided for (Fig. 102). Repeat the procedure on the second cam to extract the shaft completely (Fig.

  • Page 47: Camshaft Support - Disassembly

    DISASSEMBLY/REASSEMBLY Fuel pump - Disassembly To disassemble the fuel pump, unscrew both fastening nuts (fig., 108), then remove the spacer with the cam driven rod controlling the pump (fig. 110). Always check and replace the two seal rings if necessary (fig. 109). Camshaft support - Disassembly Use a proper wrench to unscrew the four M6x20 cheese screws for the anchoring to the head (fig.

  • Page 48: Oil Dipstick Case - Disassembly

    DISASSEMBLY/REASSEMBLY Water pump - Disassembly Unscrew the 4 fastening bolts of the water pump and disassemble it (fig. 116-117). Every time the water pump is to be disassembled, we advise you to replace the two seal rings (fig. 118). Should the water pump not work properly, it cannot be repaired but only replaced. Oil dipstick case - Disassembly Unscrew the two HH M6x20 hex screws and disassemble the oil dipstick case.

  • Page 49: Driving Shaft Gear

    DISASSEMBLY/REASSEMBLY Ring gear - Disassembly Disassemble the clutch housing pan by removing the single nut and the 10 screws (Fig. 123), then use the provided tool 981075.412 (Fig. 124) to lock the ring gear and unscrew the fastening bolt (Fig. 125). As you disassemble the clutch housing pan (fig.

  • Page 50: Oil Pressure Regulating Valve - Disassembly

    DISASSEMBLY/REASSEMBLY Oil pump driving gear and oil pump - Disassembly Lock the oil pump control gear using a screwdriver in order to unscrew the retaining bolt (Fig. 132), and then remove the chain (Fig. 133). Unscrew the two bolts securing the oil pump (Fig.

  • Page 51: Cylinder - Piston - Wrist Pin - Disassembly

    DISASSEMBLY/REASSEMBLY Cylinder – Piston – Wrist pin - Disassembly After extracting the cylinder (Fig. 139), remove the retaining snap rings from their seat by using a screwdriver (Fig. 140÷141) then extract the wrist pin (Fig. 142) and disassemble the piston. Timing gear and speed gear control box - Disassembly.

  • Page 52: Crankshaft - Reverse Shaft - Gearbox Shaft - Multiple Gear - Differential Gear Assembly

    DISASSEMBLY/REASSEMBLY Separation of the housing halves Unscrew the 15 union screws (Fig. 100), position the engine horizontally as shown in the figure (Fig. 146) and separate the two housing halves by hitting with a mallet. When reassembling, the shoulder washers which are located between drive shaft and flywheel-side housing should be placed with the 4 lubrication marks turned towards...

  • Page 53: Clutch-Side Housing Half - Gearbox Shaft Roller Case And Multiple Gear Ball Bearing - Disassembling

    DISASSEMBLY/REASSEMBLY Flywheel-side housing half – Roller case, multiple gear and roller case, gear - Disassembly Remove the two gearbox shaft roller cases by using a crop end as a punch, with an external Ø of 24 mm (Fig. 154) for the roller case of the multiple gear “A”...
  • Page 54 DISASSEMBLY/REASSEMBLY NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...
  • Page 55 DISASSEMBLY/REASSEMBLY NOTE REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 56: Fuel Flow Governor Description

    DISASSEMBLY/REASSEMBLY FUEL FLOW GOVERNOR DESCRIPTION From figures 1 and 2 one can see the essential components and the functioning of the governor. The mass holder (1) is driven in rotation by its own shaft driven in turn by the camshaft. In to the mass holder (1) there are 4 centrifugal counterweights (2) that act on the push rod (3) .
  • Page 57 DISASSEMBLY/REASSEMBLY The governor main functions are the following: - Engine low idling speed adjustment - Engine maximum RPM limitation - Delivery increase during start up FIG. 1 FIG. 2 REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004...

  • Page 58: Delivery Regulator - Disassembly

    DISASSEMBLY/REASSEMBLY - Disassembly Delivery regulator Remove the cover by way of the 6 retaining screws (Fig. 160).Remove retainer A (Fig. 161), cap B and idling spring C (Fig. 162).Set adjustment lever 13 (Fig. 162) towards the outside, extract supplementary spring D, extract retainer E and remove pump control rod 6 (Fig.

  • Page 59: Delivery Regulator - Reassembly

    DISASSEMBLY/REASSEMBLY Remove the snap ring from its slot using the pliers which are provided (Fig. 169) then extract the shaft and the weights holder shaft (Fig. 170). Now unscrew the two retaining nuts A (see Figg. fig. 171÷172), then remove the metal plate and disassemble the magnet holding the lever in extra fuel position (Figg.

  • Page 60: Governor's Working Description - Engine Standing Or At Starting

    DISASSEMBLY/REASSEMBLY GOVERNOR'S WORKING DESCRIPTION ENGINE STANDING OR AT STARTING In these conditions the governor flyweight are completely closed, due to the slider thrust on which acts the minimum and the extra-fuel springs (see fig. 3) . The control lever, pushed at one end by the minimum spring, reacts on the regulation screw. The control rod lever, pushed by the relative extra-fuel spring, puts the pump control rod in the maximum fuel flow position and therefore in the engine start position.
  • Page 61 DISASSEMBLY/REASSEMBLY ENGINE AT PARTIAL LOAD From the minimum position, by acting on the accelerator lever, the minimum spring is completely pre-loaded; after that, the cup. Is push directly on the regulation lever carrying the pump connection rod toward greater fuel flow positions partially closing the governor flyweight.
  • Page 62 DISASSEMBLY/REASSEMBLY ENGINE AT MAX SPEED When the engine reaches the maximum working speed the governor flyweights centrifugal force exceede the reaction of the maximum speed regulating spring; the expanding flyweights move the regulating lever and the pump connecting rod towards a position of lower fuel flow.

  • Page 63: Assembly Play - Cylinder-Piston

    DISASSEMBLY/REASSEMBLY Assembly play Pistons and cylinders supplied by the Factory as spares are marked with letters of the alphabet. In cases where a cylinder or a piston is to be substituted, it should be replaced with the same letter as the mating component. In case of a rebored cylinder, the dimension “E”...

  • Page 64: Assembly Play - Piston - Piston Pin

    DISASSEMBLY/REASSEMBLY Piston slots - piston rings Part name Part name Clearance -A- (mm) piston slot 2,160÷2,190 (Ø80) Piston ring, upper 2,095÷2,075 (Ø80) 0,065÷0,115 piston slot 2,040÷2,060 Piston ring, lower 1,990÷1,970 0,050÷0,090 piston slot 3,020÷3,040 Scraper ring 2,990÷2,975 0,030÷0,065 Piston - Piston pin Piston “A”...

  • Page 65: Assembly Play - Crankshaft - Big End

    DISASSEMBLY/REASSEMBLY Crankshaft - big end Part name Dimension (mm) Big end “A” 51,333 - 0 + 0,013 Con-rod bearing, half “C” 1,535÷1,526 Crankshaft “B” 48,288 - 0,02 +0 Valve guide - valve stim Part name Dimension (mm) Valve guide “A” 8,015÷8,033 Valve stim exh.

  • Page 66: Assembly Play - Tappet

    DISASSEMBLY/REASSEMBLY Tappet Tappet dia. “A” 35,000÷35,025 Tappet seat dia. “B” 34,975÷34,995 Clearance on assy “C” 0,005÷0,050 Valves caps Thickness “A”: 3,25 - 3,30 - 3,35 - 3,40 - 3,45 - 3,50 - 3,55 - 3,60 - 3,65 - 3,70 - 3,75 - 3,80 - 3,85 - 3,90 - 3,-95 - 4,00 - 4,05 - 4,10 - 4,15 - 4,20 - 4,25 - 4,30 - 4,35 - 4,40 - 4,45 - 4,50 - 4,55 - 4,60 Tolerance...

  • Page 67: Cranckcase - Bearings - Clutch Side Multiple Gear Ball Bearing

    DISASSEMBLY/REASSEMBLY CRANCKCASE - BEARINGS CLUTCH SIDE MULTIPLE GEAR BALL BEARING Bearing external diameter Ø 62,000÷61,987 Seat diameter Ø 61,979÷61,949 Assemble interference gap 0,008 mm interf. 0,051 mm NEEDLE BEARING HOUSING Seat diameter for multiple gear needle bearing flyweel side Ø 25,979÷26,000 Seat diameter for gear needle bearing clutch side Ø...

  • Page 68: Injection Pump

    DISASSEMBLY/REASSEMBLY Injection pump : "MICO" type F 002 F 10 006 Test conditions Pumping element dia.: 6 mm L.H. helix pitch: 12 mm Test Oil: SHELL S 93 65 Test Oil temperature: 40°C±2° Pump inlet pressure: 0,2 Kg/cm Pumping element prelift: 2÷3 mm Features of the pump on the bench Adjusting lever in reference to central position:...

  • Page 69: Injector Setting

    DISASSEMBLY/REASSEMBLY Injector : MICO F 002 C 6 Z 396 Caption: 1- High pressure delivery pipe ( Ø 6 - Ø 1,75x168 ) 2- Nut for connection to the delivery pipe 3- Pressure duct 4- Pressure setting shim 5- Pressure spring 6- Pressure pin 7- Nozzle MICO DNO SD 287 8- Nozzle clamping ring nut...

  • Page 70: Cylinder Head

    DISASSEMBLY/REASSEMBLY Cylinder head Caption: 1- Cotters 2- Valve spring upper collars 3- Valve spring 4- Valve guide sealing rings 5- Valve spring lower collars 6- Precombustion chamber 7- Exhaust valve 8- Intake valve Dismantling values Compress valves springs (fig. 192) by using a valve lifting clamp as shown in fig. 191 ( the tool was not included in the special tool set as it is commercially available), take away cotters (fig.

  • Page 71: Valves Grinding

    DISASSEMBLY/REASSEMBLY Valves grinding Carefully remove carbon deposit without notching the metal and wash with cleaning liquid. Inspect valves seats: they shouldn’t present indentations or scorings, but they must have a uniform surface so as to assure a perfect valve seal. Otherwise carry out valves seat grinding. This operation must be performed as follows with the best attention: smear valves with fine emery, introduce the valve in its guide and fix wrench “O”...

  • Page 72: Reassembly Of Valves

    DISASSEMBLY/REASSEMBLY Reassembly of valves Prior to valve reassembling, which is done in reverse sequence as to disassembling, always replace the two sealing rings (fig. 195) on the valve guides using punch 986290.109 (fig. 197-198). Important - Before reassembling valves lubricate guides and stems. punch 986290.109 COMPILER TECO/ATI REG.
  • Page 73 DISASSEMBLY/REASSEMBLY NOTE REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 74: Precombustion Chamber – Disassembly And Reassembly

    DISASSEMBLY/REASSEMBLY Precombustion chamber – disassembly and reassembly To extract the precombustion chamber, top the injector seat with a purch (Fig. 204) from the injector seat.This expulsion method causes damages to the precombustion chamber, therefore it must be replaced every time it is extracted.Before assembling the new precombustion chamber, the depth of the seat inside the head shall be measured (Fig.

  • Page 75: Oil Pump

    DISASSEMBLY/REASSEMBLY Oil pump Clean all parts and check : - that the union surfaces are flat. - Replace the faulty parts in case of deformation - The side play of the rotors and the radial play between the two rotors If the desired values are not found, replace the faulty parts delivery intake...

  • Page 76: Connecting Rod

    DISASSEMBLY/REASSEMBLY Drive shaft and connecting rod 1- Connecting rod shaft 2- Connecting rod cap fastening screw 3- Connecting rod half bearings 4- Breech plug 5- Crankshaft 6- Connecting rod cap fastening nuts 7- Connecting rod cap 8- Oil pump gear Connecting rod Remove the two retaining nuts and the connecting rod.

  • Page 77: Caption Gearbox Shaft 4Th Speed Gear

    DISASSEMBLY/REASSEMBLY Caption Gearbox shaft 4th Gearbox shaft 4th speed gear: speed gear: 1- Gearbox shaft with differential gear control coil 2- Speed coupling spider 3- Spacer 4- 4th speed gear 5- 3rd speed gear 6- 2nd speed gear 7- 1st speed gear 8- Reverse gear 9- Clearance ring 10- Stop ring...

  • Page 78: Gear Assembly Measure Check

    DISASSEMBLY/REASSEMBLY Reassembling the gearbox shaft: tightening the spider clamping ring nut. Apply Loctite 270 (fig. 221a) on the thread of the spider clamping ring nut. Insert ring nut into the gearbox shaft (fig. 221b) on the differential gear control coil side.
  • Page 79 DISASSEMBLY/REASSEMBLY NOTE REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 80: Gearbox

    DISASSEMBLY/REASSEMBLY Gearbox After unscrewing the gearbox coupling screws, disengage the gear speed control stem from the selector switch sliding block and disassemble the gearbox. Caption: 1- Lever pin with P.I. 2- O-ring 3- Sliding block 4- Selector switch 5- Elastic pin 6- Lock ring 7- Ball 8- Spring...

  • Page 81: Differential Case

    DISASSEMBLY/REASSEMBLY Differential gear box Caption: 1- Differential gear ring 2- Screws 3- Differential gear pin 4- Differential gear box 5- Differential gear side pinions 6- Clearance ring 7- Snap ring 8- Differential gear crown wheel 9- Differential gear pin check squares 10- Washers Differential case Take away the 6 bolts “E”, side pinions pin retaining brackets “F”...

  • Page 82: Electrical Diagram

    DISASSEMBLY/REASSEMBLY Starting motor 4-pole permanent-magnet-type starting motor. It is controlled by a remote control allowing pinion clutch and power supply enabling. The starting motor is battery powered and controlled by a key switch. It is connected to the engine by means of the pinion and of the ring gear on the flywheel. Main features of electrical starter .
  • Page 83 DISASSEMBLY/REASSEMBLY Characteristic curve of the 12 V 1.6 kW starting motor REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 84: Clutch-Side Housing Half

    DISASSEMBLY/REASSEMBLY Crankcase, half, flywheel side Drive shaft and gear cluster d.c. roller bearings: place crankcase half on a base plate and fit, by using the specific punches 986290.106 d.c. roller bearing “A” of drive shaft and 986290.104 d.c. roller bearing “B” of gear cluster. Position on crankcase, half, duly greased on housing face, to avoid fall during assembling operations, shoulder bearing “C”...

  • Page 85: Drive Shaft, Reverse Gear Shaft, Multiple Gear, Gearbox Shaft And Differential Gear

    DISASSEMBLY/REASSEMBLY Drive shaft, reverse gear shaft, multiple gear, gearbox shaft and differential gear Insert the differential gear (Fig. 241) assembly, the multiple gear (Fig. 242), the gearbox shaft (Fig. 243), the reverse gear (Fig. 244), the drive shaft (Fig. 245), the oil filter “G” , the pipe “N” and the sealing ring “I” (Fig. 246÷247), as indicated in the figure.

  • Page 86: Oil Pump Gear And Oil Pump - Reassembling

    DISASSEMBLY/REASSEMBLY Oil pump gear and oil pump - reassembling When reassembling the oil pump, always replace the seal with a new one. Reassemble the oil pump paying attention to the correct assembly direction (suction and delivery). We advise you to fill the pump case with oil before the assembly.

  • Page 87: Engine Gear

    DISASSEMBLY/REASSEMBLY Engine gear Assemble the gear “L”, the clearance shim “M” and the snap ring “N” by using the pliers for internal snap rings. Use the tool 986782.034 provided with a dial indicator on the housing pan and verify that the gear axial endfloat is mm 0.04÷0.1.

  • Page 88: Clutch Assembly

    DISASSEMBLY/REASSEMBLY Clutch assembly To replace the duct disk no particular tools are required, simply remove the 6 bolts “B” and remove the duct disk. When reassembling, before locking bolts “B” , assemble the clutch assembly on the drive shaft to help centering the duct disk, then place washer “C”, secure nut “D”...

  • Page 89: Piston And Cylinder

    DISASSEMBLY/REASSEMBLY Speed gear control box Rotate the drive shaft and bring the gears in a position such to allow stem “A” the maximum protusion, position upper lever in 2nd gear; spread with seal paste (Loctite 510) speed-gear control box union surface, engage sliding bloc of 3rd and 4th gears lever, then the one of reverse, bottom and 2nd gears.

  • Page 90: Measurement To Determine The Thickness Of The Head Gasket

    DISASSEMBLY/REASSEMBLY Measurement to determine the thickness of the head gasket. Use the dial indicator on the tool 981075.417 (fig.284) and set it to zero on a surface plate. Assemble the tool on the cylinder by using the 2 head and cylinder clamping stud bolts, set the piston to the top dead centre and measure on the dial indicator the piston protrusion beyond the zero (fig.285).

  • Page 91: Camshaft And Tappet Support

    DISASSEMBLY/REASSEMBLY Cylinder head installation - Reassembly Fit the cylinder head and after lubricating washers, studs and the 4 nuts, in order to carry out a perfect locking act as follows, by bearing in mind that for each tightening stage the sequence pointed out below must be performed according to the diagram in fig.

  • Page 92: Camshaft - Reassembly

    DISASSEMBLY/REASSEMBLY Camshaft - Reassembly Insert the camshaft into the support (fig. 295), assemble ther shoulder washer “A” and the retaining snap ring “B” (fig. 296). Use the dial indicator on the tool 981075.417 (fig. 297), assemble it on the support and check that the camshaft axial endfloat is mm 0.15÷0.20 (fig.

  • Page 93: Oil Dipstick Case - Assembly

    DISASSEMBLY/REASSEMBLY Toothed camshaft timing pulley - Assembly Fit the camshaft clamping pin (fig.302), assemble the toothed timing pulley (fig.303), then tighten the bolt to a 70÷75 Nm torque as specified (fig.304), fit again the brake washer (fig.305). Toothed crankshaft timing pulley - Assembly Taking care that the key remains in its housing, reassemble the toothed pulley on the crankshaft (fig.306).
  • Page 94 DISASSEMBLY/REASSEMBLY NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...
  • Page 95 DISASSEMBLY/REASSEMBLY NOTE REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 96: Cooling Liquid Circulating Pump - Assembly

    DISASSEMBLY/REASSEMBLY Cooling liquid circulating pump - Assembly At every disassembly replace the sealing rings A and B (fig.308). Insert the cooling liquid circulating pump in its housing in the cylinder (fig.309-310) and fix it by tightening the screws at 15 Nm (fig. 311). Toothed timing belt tensioner - Assembly Insert the calibrated spring for the toothed timing belt tensioning inside the tensioner (the spring can be assembled only in one direction).

  • Page 97: Centrifugal Weights Assembly - Assembling

    DISASSEMBLY/REASSEMBLY Injection pump control cam – Assembling Insert the injection pump control cam on the timing shaft (fig. 313), then insert the shoulder washer and assemble the snap ring by means of pliers for internal snap rings (fig.314). Centrifugal weights assembly - Assembling Insert the centrifugal weights assembly taking care to insert the pins of the weights “L”...

  • Page 98: Description Of The Injection Advance Regulator

    DISASSEMBLY/REASSEMBLY Injection advance variator Caption: 1- Injection advance variator fastening screw 2- Washer 3- Calibrated spring cases 4- Lock rings 5- Centrifugal weights 6- Lock rings 7- Lock rings 8- Counterflange 9- Snap ring for shafts 10- Washer 11- Cam for injection pump with P.I. Description of the injection advance regulator When starting, and at a low idling speed the correct value of injection advance is 11°...
  • Page 99 DISASSEMBLY/REASSEMBLY When the RPM increases, the centrifugal weights force becomes higher than the spring load, the weights move and through the pins D (fig. 323) engaged into the slots rotating the injection cam. At 3500 R.P.M. the weights are completely open, see fig. 323 and the injection advance is 24°...

  • Page 100: Clearance Check

    DISASSEMBLY/REASSEMBLY Clearance Check Rotate the crankshaft and bring the piston to the TDC at explosion level. Using a thickness gauge, check that clearance is 0.30 mm for the intake valve and 0.40 mm for the exhaust valve, when the engine is cold (fig. 324÷325). If clearance does not match these measurements, proceed as follows: Turn the crankshaft backwards of about 40°...

  • Page 101: Fireproof Bulkhead And Injector - Assembly

    DISASSEMBLY/REASSEMBLY Fireproof bulkhead and injector - Assembly Insert the fireproof bulkhead A into the seat on the head (fig. 332), place the copper seal B (fig. 333) on the injector, screw the injector into its seat and tighten it to a 70 Nm torque (fig.

  • Page 102: Glow Plug - Assembling

    DISASSEMBLY/REASSEMBLY Glow plug - Assembling The glow plug must be tightened with the torque wrench to the indicated torque, because inside the head there is no limit stop and the glow plug threading is conical. An incorrect tightening would irreparably damage the cylinder head 15 Nm (fig. 336). Injection pump - Assembling Insert the injection tappet with the relevant collar inside its housing on the camshaft support (fig.

  • Page 103: Adjustment Of Pump Control Rod

    DISASSEMBLY/REASSEMBLY INJECTION EQUIPMENT DESCRIPTION AND FUNTIONING FUEL INJECTION In the Diesel engine the fuel is injected towards the end of the compression process into the precombustion chamber via the injection pump and relative injector. The quantity of fuel injected for each cycle is regulated by a function of the power/capacity required through the rotation of the pumping element of the injection pump that is carried out by the regulation rod.

  • Page 104: Feeding Pump

    DISASSEMBLY/REASSEMBLY -------------------- Fuel pump – Characteristics and components The diaphragm type fuel pump 1 is operated by a camshaft eccentric 2 through a rod 3. It is equipped with an external lever for the manual priming 4. A spacer 5 is inserted between the surface of the head and the surface of the fuel pump.

  • Page 105: Fuel Exhaust Pipe - Assembly

    DISASSEMBLY/REASSEMBLY Tappet cover - Assembly After replacing the rubber sealing ring 1 (fig. 351), reassemble the tappet cover and tighten the four M 6x20 fixing screws at 8 a torque of Nm (fig. 351-352) Fuel exhaust pipe - Assembly Use the special pliers to connect the pipe (RILSAN) to the injector and, on the opposite end, to the two-way banjo.

  • Page 106: Air Shroud, Cooling Fan - Radiator Shroud - Assembly

    DISASSEMBLY/REASSEMBLY Flywheel and cooling fan support - Assembly Reassemble the flywheel onto the crankshaft and then fasten it with the cone and the fastening bolt. Use tool 981075.414 to lock the flywheel, thus allowing the fastening bolt to be tightened at 180÷200 Nm. Assemble the cooling fan support onto the flywheel and fasten it by tightening the five screws at 12÷15 Nm (fig.

  • Page 107: Muffler - Assembly

    DISASSEMBLY/REASSEMBLY Oil filter - Assembly Lubricate and oil the seal between the oil filter and the support surface on the half casing using engine oil (fig. 361÷362). Then screw and tighten the cartridge manually (fig. 363). Muffler - Assembly Insert the exhaust manifold by placing the seal between head and manifold. Tighten the fastening nuts at 19÷21 Nm.

  • Page 108: Injection Static Advance Timing

    DISASSEMBLY/REASSEMBLY Injection static advance timing Set the camshaft in timing phase and fix it with appropriate pin, serial number 8430.123 (fig. 367÷368). Disassemble the whole speed governor support and remove the Oldham union (fig. 369). Unscrew the injection advance variator fixing screw (fig. 371) and remove the injection advance variator weights with the proper puller (fig.
  • Page 109 DISASSEMBLY/REASSEMBLY Disassemble the dial indicator holder and replace it with tool 1460.192 (timing gauge) (fig. 377). If the previously measured difference with dial indicator was null (i.e. equal to given value 53.2 mm), insert four 0.1-mm shims (fig. 378-379) between the tool base plane and the guard base plane.
  • Page 110 DISASSEMBLY/REASSEMBLY Screw the tool fixing upper screw manually without tightening (fig. 385) Turn the tool anti-clockwise (fig. 386). It will time the advance variator in the correct position with the injection cam, in perfect contact with injection tappet. Once the timing is completed, two operations are required: turn the proper knob anti-clockwise and simultaneously tighten the screw that fixes the tool and all parts connected and timed (injection advance variator, injection cam, camshaft and injection tappet) (fig.
  • Page 111 DISASSEMBLY/REASSEMBLY NOTE REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...

  • Page 112: Then Check Injection Advance Tining As Follows - A

    DISASSEMBLY/REASSEMBLY Then check injection advance tining as follows - A. 1) Connect delivery pipe “C” of the proper hand pump (for inst. BOSCH Type) to the feed union of injection pump and insert suction pipe into a container filtered and full of gas oil and plug the hole of gas oil recovery “D”...

  • Page 113: Injection Advance Dynamic Control - B

    DISASSEMBLY/REASSEMBLY Injection advance dynamic control - B The dynamic control of the injection advance is made through a suitable equipment - stroboscopic gun - according to the following: 1) Clean carefully the injection pipe and check that the sensor coupling zone “V” is free from scoring signs 2) Install the sensor “V”...
  • Page 114 DISASSEMBLY/REASSEMBLY P.M.S 4) If the conditions described at point 3 are not satisfied, and the injection timing is advanced or delayed, replace or increase the gaskets under the injection pump, following the instructions given in Injection pump and checking the static injection advance relevant to the engine static timing.

  • Page 115: Min. And Max R.p.m. Regulation

    DISASSEMBLY/REASSEMBLY Min. and max r.p.m. regulation The operations of min. and max r-p.m. must be carried out with a warm engine, as follows: act after unlocking the lock nut, on screw “F” of accelerator lever position so as min. r.p.m. result 1200 and lock again lock nut. loosen the lock nut of screw “G”, gradually accelerate the engine until 4150 r.p.m.
  • Page 116 NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...
  • Page 117 TOOLS LOMBARDINI LOMBARDINI DRAWING DESCRIPTION DRAWING CODE PART CODE 8430.124 5900.217 5900.217 Timing reference tool and Pin for camshaft part. 8430.124 part. 8430.124 timing Pin for camshaft 8430.123 8430 123 timing Differential box 1460.170 981075.411 extraction tool Primary gear 1460.169 981075.412...
  • Page 118 TOOLS LOMBARDINI LOMBARDINI DRAWING DESCRIPTION DRAWING CODE PART CODE Head seal 1460.163 981075.417 identification tool 1460.162 Flywheel extraction 981075.418 tool Clutch extraction 1460.181 981075.419 tool 984651.457 981075.420 1460.180 Flywheel cone extraction tool 984651.457 1460.179 Anticipation 981075.421 1460.156 extraction tool 1460.177 Engine support tool 981075.422...
  • Page 119 TOOLS LOMBARDINI LOMBARDINI DRAWING DESCRIPTION DRAWING CODE PART CODE 981075.424 981075.424 Valve plates 1460.161 + replacement tools 984620.319 + 984620.319 1460.182 + 1460.183 + 985620.320 985620.320 984651.457 981075.425 1460.178 Bearing extractor 1460.179 984651.457 Bearing extractor 981075.426 1460.167 Double fork to check the P-NP differential 1460.158...
  • Page 120 TOOLS LOMBARDINI LOMBARDINI DRAWING DESCRIPTION DRAWING CODE PART CODE Punch for roller box for elbow shaft on 1460.189 986290.106 flywheel side Punch for roller box 986290.107 1460.188 diam35 Differential bearing 1460.175 986290.108 punch Punch to install 986290.109 1460.160 sealing ring on the...
  • Page 121 TOOLS TOOLS LOMBARDINI LOMBARDINI DRAWING DESCRIPTION DRAWING CODE PART CODE Calibrated tool for injection cam 1460.192 1460.192 positioning Positioning tool for 1460.193 1460.193 injection cam advance variator REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004...
  • Page 122 XIII MAIN TORQUE SPECIFICATIONS MAIN TORQUE SPECIFICATIONS Diam. and pitch Torque POSITION ( mm ) ( Nm ) Connecting rod cap fixing nut M 10x1 Flywheel fixing screws M 14x1,5 180÷200 Clutch – fixing screws 120÷140 M 22x1,5 Alternator rotor fixing screws 12÷15 Clutch disk pusher fixing screw Primary ring gear of gear box fixing screw...
  • Page 123 MAIN TORQUE SPECIFICATIONS XIII STANDARD BOLT TORQUE SPECIFICATIONS DESCRIPTION R ≥ 800 N/mm2 R ≥ 1000 N/mm2 R ≥ 1200 N/mm2 Diameter x pitch (mm) 4x0,70 0,37 0,52 0,62 5x0,80 0,72 1,01 11,9 1,22 6x1,00 1,23 1,73 20,4 2,08 7x1,00 19,8 2,02 27,8...
  • Page 124 NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 18-10-2004 18-10-2004 1-5302-662 51092...
  • Page 125 NOTE REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 18-10-2004 18-10-2004 1-5302-662 51092...
  • Page 126 E-MAIL: atl@lombardini.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 rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication. Data reported in this issue can be modified at any time by Lombardini.

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