Lombardini LDA 422 Workshop Manual
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Lombardini LDA 422 Workshop Manual

Lombardini LDA 422 Workshop Manual

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WORKSHOP
MANUAL
LDA 422 engines, code 1-5302-596
LDA 422
1st Edition
REG. CODE
MODEL N°
COMPILER TECO/ATI
DATE OF ISSUE
DATE
ENDORSED
00
1
REVISION
1-5302-596
50881
15-05-2003
15-05-2003

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  • Page 1 WORKSHOP MANUAL LDA 422 engines, code 1-5302-596 LDA 422 1st Edition REG. CODE MODEL N° COMPILER TECO/ATI DATE OF ISSUE DATE ENDORSED REVISION 1-5302-596 50881 15-05-2003 15-05-2003...
  • 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 LDA 422: updated May 15, 2003. TABLE OF CONTENTS SAFETY DECALS - SAFETY INSTRUCTIONS Pag. TROUBLESHOOTING " MAINTENANCE- RECOMMENDED OIL TYPE - REFILLING "...
  • Page 5 INDEX Cylinder-Piston ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
  • Page 6 INDEX Reassembling the gearbox shaft ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
  • Page 7 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 8 • 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 9 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. REMEDIES FAULT FINDING 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 10: Itroubleshooting

    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 11: Maintenance- Recommended Oil Type - Refilling

    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 LDA 422 ENGINE MAINTENANCE INTERVAL KM OPERATION COMPONENT after the first 1000 2000...

  • Page 12: Model Number And Identification

    MODEL NUMBER AND IDENTIFICATION Lombardini r.p.m. Diesel Customer's code Air cooled Displacement (cc) Engine serial number COMPILER TECO/ATI REG. CODE MODEL N° DATE DATE OF ISSUE ENDORSED REVISION 1-5302-596 50881 15-05-2003 15-05-2003...

  • Page 13: Technical Data

    TECHNICAL DATA LDA 422 ENGINE MAIN SPECIFICATIONS - 4-stroke single cylinder engine - Indirect-injection Diesel-cycle type - Forced air-cooling system - 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...

  • Page 14: Vfeed Induction Diagram

    FEED INDUCTION DIAGRAM Components : 1) Air cleaner (paper filtering cartridge) 9) Fuel return pipe from injector 2) Induction duct 10) Return pipe to tank of exceeding fuel 3) Induction valve 11) Preheating plug 4) Fuel tank 12) Piston 5) Fuel feed pump 13) Cylinder 6) Fuel filter 14) Camshaft...

  • Page 15: Lubrication System

    LUBRICATION SYSTEM REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 1-5302-596 50881 15-05-2003 15-05-2003...
  • Page 16 LUBRICATION SYSTEM LDA 422 OIL CIRCUIT DIAGRAM OIL PICK UP OIL PUMP OIL FILTER PRESSURE VALVE VALVE FOR CYLINDER CRANKSHAFT PISTON COOLING CONROD CYLINDER HEAD CYLINDER OIL VALVE HEAD CAMSHAFT CAMSHAFT OIL SUMP SUPPORT GOVERNOR COMPILER TECO/ATI REG. CODE MODEL N°...

  • Page 17: 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 1-5302-596 50881 15-05-2003 15-05-2003...

  • Page 18: Engine-Differential Unit

    VIII ENGINE-DIFFERENTIAL UNIT Components: 1) Starting motor 14) Dipstick 2) Cylinder 15) Tappet 3) Preheating plug 16) Timing belt 4) Injector 17) Induction valve 5) Injection pump 18) Piston 7) Accelerator lever 19) Belt tensioner 9) Delivery control 20) Starting crown gear 12) Feed pump 21) Starting pinion 13) Camshaft...
  • Page 19 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 20 DISASSEMBLY/REASSEMBLY Cooling fan flywheel Place tool 981075.414 onto the starting motor (Fig. 9) housing to fix the flywheel, remove the flywheel retaining screw using a 22 mm socket wrench and extract the cone and remove the flywheel (Fig. 11) using extractor 981075.420 (equipped with component 984651.457).

  • Page 21: Assembly And Disassembly Of Timing Belt And Oil Dipstick

    DISASSEMBLY/REASSEMBLY Assembly and disassembly of timing belt and oil dipstick Before disassembling the timing belt . Turn the camshaft gear and fit timing pin 8430.123 into its housing on the support ( see figure 20 ) so that it coincides with the hole that can be found on the shaft ( the pin must rest against the boss surface). pin 8430.123 Loosen the belt tensioner and clamp it up high as shown, remove the timing belt (Fig.

  • Page 22: Belt Assembly

    DISASSEMBLY/REASSEMBLY Belt assembly Clamp the belt tensioner in the minimum load position, then fit the belt on the drive shaft pulley and next on the camshaft pulley (Fig. 28). Unscrew the idler nut to tension the belt. Then tighten the belt tensioner nut with a 40÷40,4 Nm torque (Fig. 29). Tighten the camshaft pulley to 70 Nm, then fit again the safety washer on the bolt (Fig.

  • Page 23: Belt Tensioning Check

    DISASSEMBLY/REASSEMBLY Belt tensioning check Use the DENSO tool to measure the belt tension, carefully place the denso on the belt tooth as shown in figure 36. The belt tension should be between 25 and 28 Nm, see Fig. 37. If this is not the case loosen the idler, let it slide downwards and tighten it again to the rated torque, then re-check the tension. When removing the timing belt you must replace it even though its scheduled life spar is not over.
  • Page 24 DISASSEMBLY/REASSEMBLY Injection pump - Remove the inspection plug. - Disengage the injection pump control rod and extract the pump. - Remove the injection tappets with the related collar housed inside it (Fig. 45÷46). Governor assembly Unscrew the 5 bolts (Fig. 47) and remove the governor assembly (Fig.

  • Page 25: Camshaft Extraction

    DISASSEMBLY/REASSEMBLY Injection pump control cam Extract the key from its slot (Fig. 52), remove the snap ring (use pliers for internal snap rings), extract the shoulder washer and extract the cam (Fig. 53). Timing pulley and camshaft sealing ring Straighten the retaining washer, unscrew the bolt and remove the timing pulley (Fig. 54). Remove the sealing oil ring (use a screw driver) (Fig.

  • Page 26: Camshaft Support

    DISASSEMBLY/REASSEMBLY Tappet disassembling Mark the tappets and the adjustment shims, making sure that they are reassembled in the same position. The collar surface on which the shim identification code is indicated shall be assembled facing the tappets socket. Camshaft support Disassemble the fuel supply pump, the plastic support, and the fuel supply pump control rod.
  • Page 27 DISASSEMBLY/REASSEMBLY Cylinder head Unscrew the 4 retaining nuts (Fig. 67), extract the cylinder head assembly (Fig. 68) and remove the gasket (Fig. 69). When reassembling always replace the cylinder head gasket with a new one REG. CODE MODEL N° DATE OF ISSUE DATE COMPILER TECO/ATI ENDORSED...
  • Page 28 DISASSEMBLY/REASSEMBLY Clutch - Disassemble the cover (Figg. 70÷71)and place the stop key 985110.039 - Using pliers extract the snap ring then remove the clutch pressure plate. - Unscrew the nut (Figg. 73-74), use extractor 981075.419 and extract the clutch by turning the central screw (Fig. 76). stop key 985110.039 puller 981075.419 Ring gear disassembling...
  • Page 29 DISASSEMBLY/REASSEMBLY Using tool 981075.425 together with component 984651.457 extract the cone (Fig. 81) and remove the ring gear (Fig. 82). 984651.457 puller 981075.425 Drive shaft gear First remove the snap ring using the specific pliers, then remove the clearance shim (Fig. 83) and the camshaft gear (Fig. 84÷85).
  • Page 30 DISASSEMBLY/REASSEMBLY LUBRICATION SYSTEM DESCRIPTION The oil contained in the engine sump is deaerated through the labyrinth (1) and filtered by the filter (2) before it is sucked by the pump (3) through the suction duct (4). From the pump the oil is pushed towards a circuit machined in the cylinder head in proximity to particular points to be cooled (5).
  • Page 31 DISASSEMBLY/REASSEMBLY Oil pressure regulating valve Remove the snap ring, extract the spring and the by-pass valve.Check for possible dirt build up in the ducts and for good spring condition. Piston – wrist pin After extracting the cylinder (Fig. 94) remove the snap rings from their seat by means of a screwdriver (Fig.

  • Page 32: 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 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 33 DISASSEMBLY/REASSEMBLY Flywheel-side housing half – Roller case, multiple gear and roller case, gear Remove the two gearbox shaft roller cases by using a crop end as a punch, with an external Ø of 24 mm for the roller case of the multiple gear “A”...
  • Page 34 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 35 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 1-5302-596 50881...
  • Page 36 DISASSEMBLY/REASSEMBLY Delivery regulator: Remove the cover by way of the 6 retaining screws.Remove retainer A, cap B and idling spring C.Set adjustment lever 13 towards the outside, extract supplementary spring D, extract retainer E and remove pump control rod 6. Remove the snap ring, extract pin 7, disassemble the adjustment lever, rod control lever 4, spacers F and shim washers G which are located between the two levers;...
  • Page 37 DISASSEMBLY/REASSEMBLY Remove the snap ring from its slot using the pliers which are provided (see Fig. 124) then extract the shaft and the weights holder shaft (Fig. 125). Now unscrew the two retaining nuts A (see Fig. 126 ÷ 127), then remove the metal plate and disassemble the magnet holding the lever in extra fuel position (Fig.
  • Page 38 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 39 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 40 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 41 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 42 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 43 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 44 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 45 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 46 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 47 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 48 DISASSEMBLY/REASSEMBLY Cylinder head Caption: 1- Cotters 2- Valve spring upper collars 3- Internal valve spring 4- External valve spring 5- Valve guide sealing rings 6- Valve spring lower collars 7- Precombustion chamber 8- Exhaust valve 9- Intake valve Dismantling values Compress valves springs by using a valve lifting clamp as shown in fig.
  • Page 49 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 50 DISASSEMBLY/REASSEMBLY Precombustion chamber – disassembly and reassembly To extract the precombustion chamber, top the injector seat with a purch (Fig. 159) 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 51 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 52 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 53 DISASSEMBLY/REASSEMBLY Caption: 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 11- Speed control stem Gear assembly measure check After reassembling the gears, the spacer “R”...
  • Page 54 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 55 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 56 DISASSEMBLY/REASSEMBLY Remote control switch By means of a Screwdriver unscrew the 3 screws “D”, disconnect cable “E” and remove remote control switch “R” complete with movable element. Replacement of the brushes After removing cap unscrew both nuts “F” take away cir-clip “G” and remove cover.
  • Page 57 DISASSEMBLY/REASSEMBLY Main features of electrical starter Type MAICO Rated voltage Rated output 1,1 kW Direction of rotation Left hand Connection with engine with pinion and crown gear on the flywheel-fan Warning: Values within brackets are specific for the test with 66 Ah battery. 1) No-load test: maximum input of no-loaded starter: 7.5 A by feeding voltage of 11.5 (12) V r.p.m.
  • Page 58 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 59 DISASSEMBLY/REASSEMBLY Drive shaft, reverse gear shaft, multiple gear, gearbox shaft and differential gear Insert the differential gear (Fig. 196) assembly, the multiple gear (Fig. 197), the gearbox shaft (Fig. 198), the reverse gear (Fig. 199), the drive shaft (Fig. 200), the oil filter “G” , the pipe “N” and the sealing ring “I” (Fig. 201÷202), as indicated in the figure.
  • Page 60 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 61 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 62 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 63 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 64 DISASSEMBLY/REASSEMBLY Measure execution for determination of cylinder head gasket thickness Use the dial indicator on the tool 981075.417 and set it to zero on the surface plate. Assemble the tool on the cylinder by using the 2 head clamping stud bolts , set the piston to the top dead centre and measure on the dial indicator the piston protrusion beyond the zero.
  • Page 65 DISASSEMBLY/REASSEMBLY Cylinder head installation 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 66 DISASSEMBLY/REASSEMBLY Camshaft Insert the camshaft into the support, assemble ther shoulder washer “A” and the retaining snap ring “B”. Use the dial indicator on the tool 981075.417, assemble it on the support and check that the camshaft axial endfloat is mm 0.15÷0.20. If the right axial endfloat is not obtained, replace the shoulder washer with one of a higher or lower size as required until the...
  • Page 67 DISASSEMBLY/REASSEMBLY Timing pulley Fit the camshaft clamping pin, assemble the timing pulley, then tighten the bolt as torque specified, refit again the retorning washer WARNING Assembly of toothed belt and timing The assembly, timing and tension adjustment of the timing drive toothed belt have already been described from page 21 to page 23.
  • Page 68 DISASSEMBLY/REASSEMBLY Advance variator Position injection pump control cam with lobe opposed to regulator hub key and insert centrifugal weights unit making sure that pins of centrifugal weights “L” engage the slots “M”. Working on the side opposed to the one shown in the figure, keep the timing gear locked and clamp the weight-holder hub along with the related bolt by tightening it to a 25÷28 Nm torque.
  • Page 69 DISASSEMBLY/REASSEMBLY Description of the injection advance regulator When starting, and at a low idling speed the correct value of injection advance is 11° before P.M.S.. This value increases in accordance with the engine RPM, attains 24° at 3500 R.P.M., then renains constant. The advance variation is obtained through the injection advance regulator, see fig.
  • Page 70 DISASSEMBLY/REASSEMBLY Check of tappets clearance Rotate the engine and put the piston at T.D.C. in compression stroke. With a thickness gauge check that tappets clearance is 0.30 mm for inlet valve and 0.40 mm for the exhaust valve, with the engine cold. If such a clearance doesn’t occur act as follows: 1) Rotate backwards the engine about 40°...
  • Page 71 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 72 DISASSEMBLY/REASSEMBLY Injection pump and check static injection advance Insert the tappet in its housing equipped with cap, position the shims and the injection pump making sure, before the locking, that pin is correctly inserted into the control rod and reference dowel into its housing. Then check injection advance tining as follows.
  • Page 73 DISASSEMBLY/REASSEMBLY Injection advance dynamic control 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 74 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 75 DISASSEMBLY/REASSEMBLY Fireproof bulkhead and injector Insert the fireproof bulkhead A into the seat on the head, place the copper seal B on the injector, screw the injector into its seat and tighten it to a 70 Nm torque, as specified. Then fit the rubber cap with the elastic self-tightening clamp on the injector waste union.
  • Page 76 DISASSEMBLY/REASSEMBLY Reassembling – Oil filter – Injection pump inspection cover – Fuel supply pump – High pressure pipe – Tappets cover Screw the oil filter on the appropriate union, screw or the injection pump inspection plug, fit the fuel supply pump control rod, then reassemble the pump, fixing it with the appropriate nuts to a 20 Nm torque, as specified.
  • Page 77 DISASSEMBLY/REASSEMBLY Reassembling – Oil level rod - Starting motor - Flywheel – Fan scroll together with the stator – Belt cover - Exhaust manifold – Cooling covers – Fan scroll cover - Muffler - etc.. Complete the engine with the above mentioned details REG.
  • Page 78 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 79 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 80 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 1460.179 984651.457 Anticipation 1460.156 981075.421 extraction tool 1460.177 Engine support tool 981075.422...
  • Page 81 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 1460.178 981075.425 Bearing extractor 984651.457 1460.179 Bearing extractor 981075.426 1460.167 Double fork to check the P-NP differential 1460.158...
  • Page 82 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 83 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 – flywheel fixing screws 120÷140 M 22x1,5 Fan – alternator rotor fixing screws Clutch disk pusher fixing screw Primary ring gear of gear box fixing screw 120÷140...
  • Page 84 TORQUE SPECIFICATIONS 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 2,84 3,40...
  • Page 85 NOTE REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED COMPILER TECO/ATI REVISION 1-5302-596 50881 15-05-2003 15-05-2003...
  • Page 86 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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