However, development on the Lombardini series is continuos. 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.
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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.
INTRODUCTION This manual contains the most important information for the repair of LOMBARDINI air cooled, direct injection Diesel engines type 11LD535-3, 11LD625-3 e 11LD626-3. This information is current upto April 17.04.2003 . TABLE OF CONTENTS TROUBLESHOOTING Page SAFETY DECALS - SAFETY INSTRUCTIONS "...
POSSIBLE CAUSES AND TROUBLE SHOOTING POSSIBLE CAUSES AND TROUBLE SHOOTING The following table contains the possible cause of some failures hich may occur during operation. Always perform the simplest checks before removing or replacing any part. TROUBLE POSSIBLE CAUSE • Clogged pipings •...
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.
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• 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.
MODEL NUMBER AND IDENTIFICATION MODEL NUMBER AND IDENTIFICATION 11LD535-3 11 LD 625-3 11LD626-3 Engine group number LOMBARDINI N° Cilynders Diesel R.P.M. COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE REG. CODE ENDORSED REVISION 17.04.2003 1-5302-296 50510 01.89...
TECHNICAL DATA 11LD 11LD 11LD ENGINE TYPE 625-3 626-3 535-3 Number of cylinders Bore Stroke Cm³ Displacement 1870 1870 1605 Compression ratio 17:1 17:1 17:1 R.P.M. 3000 3000 3000 N DIN 70020 30,8/42 28/38 25,4/33,3 Power kW/HP NB DIN 6270 28,6/39 26/35,4 22/30...
) : Specific fuel consumption at N power. : Torque at N : Range of application for continuous operation. Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above. COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE REG.
Includes checking cylinders, piston rings, guides, springs, grinding valve seats, de-carboning heads and cylinders as welle as checking injection pump and injectors. CAPACITIES (LITERS) Standard fuel tank: LITERS As for filters, tanks and special crankcases please refer to LOMBARDINI instructions. COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE REG.
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MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING 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.
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NOTE COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE REG. CODE ENDORSED REVISION 17.04.2003 50510 01.89 1-5302-296...
Besides disassembly and reassembiy operations this chapter also includes checking and setting specifications, dimensions, repair using compressed air, wear eye and operating instructions. Always use original LOMBARDINI spare protection. parts for proper repair operations. Do not blow the paper filter element with compressed air to clean.
VIII DISASSEMBLY/REASSEMBLY Intake manifold Check flange surface for warpage and correct if necessary. Before refitting check that heads are in line. Replace gaskets. Tighten nuts at 2.5 Kgm. Note: In case of low temperature starting we can supply a manifold with provision for a glow plug for air preheating.
DISASSEMBLY/REASSEMBLY VIII Before demounting the cooling fan, disconnect the positive battery cable to prevent accidental short-circuits which could consequently energize the starter motor. Blower assembly Data plate and voltage regulator are fixed outside the blower housing. A 14 A or 21 A alternator is housed inside the stator. See Page 56-57 and 60 for the alternator technical data.
DISASSEMBLY/REASSEMBLY VIII Crankshaft pulley Components: 1 Nut 2 Washer 3 Puller, Part No. 7271-3595-048 Loosen the nut by turning clockwise and remove the pulley using the puller. The pulley has reference marks for the top dead center (See Page 51). Tighten the bolt at 300 Nm. Note: The crankshaft end play can be checked only after tightening the pulley.
DISASSEMBLY/REASSEMBLY VIII During the demounting phases, pay particular attention to prevent the flywheel from dropping as this could seriously injure the operator. Wear protective goggles when removing the flywheel ring. Flywheel Loosen the bolts which fix the flywheei to the crankshaft. To replace starter ring gear heat it up to 300°C for 15÷20 minutes.
DISASSEMBLY/REASSEMBLY VIII Rocker arm assembly Components: 1 Bore 2 Lubricatíon tube Dimensions: A = 18.032÷18.050 B = 17.989÷18.000 lf (A-B) clearance exceeds 0. 135 mm replace pin and rocker arms. When refitting check that lubrication tube 2 perfectly fits into centering bore 1 Tighten screws at 2.5 Kgm.
DISASSEMBLY/REASSEMBLY VIII Vatves Components: 1 Intake valve 2 Spring seat 3 Valve stem oil seal 4 Spring 5 Retainer 6 Half collets Te remove half collets firmly press down as shown ìn the figure. Note: Valve stem oil seal, 3 must be fitted to the intake valve only. Valve springs Measure free length with a gauge.
DISASSEMBLY/REASSEMBLY VIII Valve guides and cylinder head housìngs Intake and exhaust valve guides are both made of phosphoric cast iron. Components: 1 = Exhaust valve guide 2 = Intake valve guide Dimensions (mm) A = 42.00 B = 48.5 C = 14.000÷14.018 D = 14.050÷14.060 Valve guides with outside diameter increased by 0.5 mm are also available;...
DISASSEMBLY/REASSEMBLY VIII Valve seats and housings Dimensions (mm.): A = 40.000÷40.016 (intake valve housing dia.) B = 40.120÷40.140 (intake valve seat dia.) C = 34.000÷34.016 (exhaust valve housìng dia.) D = 34.120÷34.140 (exhaust valve seat dia.) Press valve seats into the housings and cut a at 45°. Valve seat lapping After cutting, lap valve seats with fine emery paste in oil suspension.
DISASSEMBLY/REASSEMBLY VIII CYLINDER Measure diameter sìze between two diametrically opposed points at three different heights. For 11 LD535-3 Ø = 88.00÷88.03 mm. For 11 LD625-3 and 11 LD626-3 Ø = 95.00÷95.03 mm. In case wear exceeds 0.10 mm, bore the cyIinder and fit oversize piston and ríngs.
DISASSEMBLY/REASSEMBLY VIII 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 (mm) Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap.
DISASSEMBLY/REASSEMBLY VIII Lubricate the following parts with oil before mounting: the piston pin, the piston, the cylinder and the big-end bearing Piston - Refitting Connect piston to connecting rod in a way that the combustion chamber center b is under nozzle tip a. Lubricate piston pin and introduce it into the piston by exerting pressure with your thumb.
VIII DISASSEMBLY/REASSEMBLY Connecting rod alignment Check alignment of small end and big end bearing bores using fitted mandrels; axial mis-alignment A = 0.02 mm; maximum limit 0.05 mm. Moderale warpage may be corrected by gradually working with a press. Connecting rod weight Weigh connecting rods when replacing them in order to avoid unbalance.
DISASSEMBLY/REASSEMBLY VIII Camshaft gear Remove nut 1 and washer 2. Then remove camshaft gear 3. The cylindrical type of coupling makes gear removal easier since no puller is required. Tighten nut 1 at 25 Kgm. See Page 38 for timing. Oil pump gear Remove nut 1 and washer 2.
DISASSEMBLY/REASSEMBLY VIII Main bearing support, flywheel side Loosen nuts and extract main bearing support using two M 8x1.25 screws with fully threaded length of 40 mm. Check oil seal ring and replace if warped, hardened or worn-out. When refitting tighten nuts at 2.5 Kgm. See Page 36 for dimensions CRANKSHAFT Center main bearing support, locating bolts.
VIII DISASSEMBLY/REASSEMBLY During repair operations, when using compressed air, wear eye protection. Crankshaft lubrication ducts Remove plugs, clean ducts A, B and C with a pointed tool and blow in compressed air. Screw plugs back in place and check for sealing. Crankshaft journal radius The radius R connecting journal to shoulders is 2.8÷3.2 mm.
DISASSEMBLY/REASSEMBLY VIII Use an inside micrometer to measure the inside diameter of main bearings. Main bearing and connecting rod big end bearing inside diameter Dimensions (mm): E = 80.870÷80.890 F = 45.548÷45.578 G = 55.430÷55.460 H = 55.000÷55.020 (see Note on Page 32) The above dimensions refer to driven in or tightened bearings.
VIII DISASSEMBLY/REASSEMBLY Main bearing supports 1 Flywheei side 2 1st central 3 2nd central 4 Gear side Dimensions (mm) 85.785÷85.815 L= 152.000÷152.020 M= 60.000÷60.020 N = 150.000÷150.020 (with tightened bearing) 0 = 148.000÷148.020 (with tightened bearing) P= 77.990÷78.010 Main bearing housings Dimensions (mm): A = 152.000÷152.020 B = 150.000÷150.020...
DISASSEMBLY/REASSEMBLY VIII CAMSHAFT Camshaft removal To pull out the camshaft simply remove bell 1, gear 2, fuel feeding pump 3, injection pumps 4 and tilt the engine; in this position the cam followers is not in contact with the camshaft thus making its removal possible.
DISASSEMBLY/REASSEMBLY VIII Valve timing check Check valve timing at the crankshaft. The value shown are checked at the flywheel circumference (with flywheel of 291 mm. diameter each degree corresponds to 2.5 mm). Set valve clearance at 0.65÷0.70 mm (after checking restore the value al 0.15÷0.20 mm).
DISASSEMBLY/REASSEMBLY VIII Hydraulic pump p.t.o. A hydraulic pump of group 1 or 2 can be installed on the gear side A, 3rd p.t.o. A group 1 hydraulic pump can be installed at the 4th p.t.o. B. Hydraulic pump 3rd p.t.o., group 2 Components: 1 Gear 2 Gear support...
DISASSEMBLY/REASSEMBLY VIII MECHANICAL SPEED GOVERNOR The governor (with weights) is housed inside the crankcase and is controlled by a camshaft gear. To remove speed governor 1 remove camshaft bell 2 and speed governor control gear 3. Mechanical speed governor components (standard) 1 Drive rod 2 Stop ring 3 Bearing...
DISASSEMBLY/REASSEMBLY VIII Mechanical speed governor components for special generating sets 1 Spring anchoring rocker arm 2 Governor springs 3 Journal 4 Governor control lever 5 Governor control lever ball bearing 6 Lever 7 Bearing 8 Plate Note: Two types of governor springs (2) are available: one for full speed regulation at 1500 r.p.m.
DISASSEMBLY/REASSEMBLY VIII ELECTRONIC SPEED GOVERNOR (optional) A = Actuator S = r.p.m. sensor T = Electromagnet An electronic speed governor can be fitted upon request. The crankcase features a hole for sensor S introduction. Electronic speed governor 1 Injection pump 2 Delivery control lever 3 Actuator A mounting flange 4 Mobile retainer...
DISASSEMBLY/REASSEMBLY VIII Starting with electronic speed governor (see lay-out on page 43) In position 0 the engine is not working and no part is energized. The rack rod is in stop position (retained by two springs 10 inside actuator A). By rotating key C to position 2 the electromagnet withdraws allowing the rack rod to reach ìts highest delivery being connected to the actuator at its max.
LUBRICATION SYSTEM 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.
LUBRICATION SYSTEM Oil pump Check that gear teeth are intact and that clearance between gear edge and pump body is 0.041÷0.053 mm with limit value 0.10 mm. Furthermore check that control shaft is tree to rotate with end float of 0.040÷0.090 mm with limit value of 0.170 mm.
LUBRICATION SYSTEM Oil pressure curve at idling speed The curve is obtained at the oil filter level with constant engine speed of 1200 r.p.m. in no-Ioad conditions and at a room temperature of + 25° C. Pressure is given in bar and temperature in centigrades. Oil pressure curve at full speed The curve is obtained at the oil filter level with engine working al 3000 r.p.m.
The Bosch injection system consists of three pumps each feeding one cylinder. The pumps mounted on the crankcase, corresponding to their proper cylinder, are directly operated by the camshaft. Injection pump type LOMBARDINI - OMAP For 11LD625-3 and 11LD626-3 Components: 1 Rack rod lock...
FUEL SYSTEM Plunger For injection pump type LOMBARDINI-OMAP mounted on 11 LD626-3 For injection pumps type Bosch and LOMBARDINI-OMAP mounted on 11 LD535-3 and 11 LD625-3. Dimensions (mm): 1.000÷1.100 7.445÷7.455 7.500 3.000÷3.025 7.225÷7.275 7.000 3.000 10.250 How to check plunger and barrel for internal leakage This operation is only diagnostic since pressure changes depend on the pumping speed.
FUEL SYSTEM Test data for injection pump delivery at the test bed - Pump type LOMBARDINI-OMAP 1 Rack rod lock to be removed after pump fitting to the engine 2 Injection pump axis Test data Rod stroke from Camshaft Control rod pump axis r.P.M.
Whern replacing the crankcase or the camshaft preserve the same distance A between D, injection pump support, and C, injection cam radius; add shims on D to obtain the right A value if required. LOMBARDINI-OMAP injection pump replacement 1 Rack rod lock 2 White, green or blue reference mark A = 82.80 mm...
FUEL SYSTEM (STATIC) INJECTION TIMING Disconnect injection line on cylinder 1 making sure not to loosen the pump delivery union. Attach the timing tool shown below. Injection timing checking device Components: 1 Union 2 Tube 3 Sleeve 4 Transparent body, serial No. 7271-9727-003 This device allows for immediate monitoring of the fuel flow through its transparent portion.
FUEL SYSTEM Injection timing reference marks on crankcase and flywheel A = Piston reference mark al the top dead centre B = Injection timing reference mark compared to A (A - B) = Distance in mm. C = Piston reference mark in injection tíming position. α...
6 Oil pressure warning light 7 Key switch 8 Battery charging light Note: Battery, which is not supplied by Lombardini, should feature a 12V voltage. When choosing battery capacity please consider environmental conditions: 66 Ah are recommended down to -10°C and 88 Ah are recommended below -15°C;...
ELECTRIC SYSTEM Alternator battery charger curve (12.5 V, 14A) The curve was obtained at room temperature of + 25°C with 12.5V battery voltage. Note: The r.p.m. shown in the table refers to the engine. 12 V, 21 A Alternator Features a fixed armature winding housed in the bell inside the blower stator.
Using an ohmmeter check for continuity between the red cable and the two yellow ones. Furthermore, check that they are insulated from the ground. VOLTAGE REGULATOR Type LOMBARDINI, supplied by SAPRISA and DUCATI: Voltage 12 V, max. current 26A. References for SAPRISA connections with the corresponding DUCATI connections. SAPRISA DUCATI To avoid wrong connections 3 different sizes are supplied.
The voltage regulator fits to both circuits with and without battery charging light; in the latter case connections LE (SAPRISA) and L (DUCATI) are not used. The voltage regulator shown in the picture is LOMBARDINI-DUCATI. Connections for LOMBARDINI-DUCATI voltage regulator How to check voltage regulator for proper operation Check that connections correspond to the layout.
ELECTRIC SYSTEM Alternator type Bosch Gl 14 V, 33 A The alternator is ot the claw-pole rotor type with built-in voltage reguiator. The rotating motion is conveyed by the engine through a 'V' belt and sheave. Features: 12V rated voltage. Max. current 33A at 7000 alternator r.p.m..
ELECTRIC SYSTEM STARTING MOTOR Bosch tipo JF (R) 12 V, class 2.5 RH direction of rotation A = 23÷24 mm B = Ring gear plane C = Flange plane Warning: The flywheel should not project from ring gear plane B. Note: Apply to Bosch Service Centers for any type of repair.
SETTINGS SETTINGS 1) ldling speed setting in no-load conditions (standard) After filling with oil and fuel, start the engine and let it warm up for 10 minutes. Adjust idling speed at 800÷900 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.;...
SETTINGS Injection pump delivery setting with engine at the torque dynamometer 1) Bring engine to idling speed 2) Unscrew delivery limiting device C (see page 59) 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).
XIII STORAGE STORAGE Prepare engines as follows for storage over 30 days: Temporary protection (1÷6 months). • Let engine work at idling speed in no-load conditions for 15 minutes. • Fill crankcase wíth protection oil MIL-1-644-P9 and let engine run al 3/4 full speed for 5 - 10 minutes.
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NOTE COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE REG. CODE ENDORSED REVISION 17.04.2003 1-5302-296 50510 01.89...
MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS MAIN TORQUE SPECIFICATIONS Diameter and pitch Torque COMPONENT ( mm ) Connecting rod Injection pump delivery valve union 18x1,5 Rocker arm cover 8x1,25 8x1,25 Center main bearing support Intake manifold 8x1,25 8x1,25 Exhaust manifold Air shroud 8x1,25 Throttle control cover...
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STANDARD BOLT 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...
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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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