Table of Contents
Related Manuals for Lombardini LGW 523 Series
Summary of Contents for Lombardini LGW 523 Series
- Page 1 WORKSHOP MANUAL Series LGW 523-627 and LGW 627 GPL engines code 1-5302-509 LGW 523 LGW 627 1st Edition SERVICE COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE REG. CODE ENDORSED REVISION 10.06.99 1-5302-509 50778 10.06.99...
- Page 2 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 3 WARRANTY CLAUSE Lombardini S.r.l., guarantees its engines for a period of 12 months from the date of delivery to the first user, and no later than 24 months from the date of delivery to the manufacturer or building site. Of the two alternatives, the one that occurs first shall be considered valid.
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Page 4: Table Of Contents
TABLE OF CONTENTS This manual contains information on how to repair LOMBARDINI LGW 523, LGW 627 gasoline fuelled engines and LOMBARDINI LGW 627 LPG fuelled engines and is up to date as of 10.06.1999. TABLE OF CONTENTS TROUBLESHOOTING Page 9 SAFETY DECALS - SAFETY INSTRUCTIONS "... - Page 5 TABLE OF CONTENTS LGW 523 bleed ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
- Page 6 TABLE OF CONTENTS COOLING CIRCUIT Page 48 Cooling circuit ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
- Page 7 TABLE OF CONTENTS Battery recharging curve for 12V 30A alternator ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
- Page 8 TABLE OF CONTENTS MAIN DRIVING TORQUES Driving torques for standard screws ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
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Page 9: Troubleshooting
TROUBLESHOOTING PROBABLE CAUSES AND THEIR REMEDIES The table gives the causes of some of the faults that may occur during operation. Proceed systematically with the simplest inspections before removing or replacing any parts. FAULTS PROBABLE CAUSE · Clogged tubes · ·... -
Page 10: Safety Decals - Safety Instructions
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 11 · 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.
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Page 12: Code And Identification
CODE AND IDENTIFICATION Max speed setting Type of engine (r/min) Serial N° N° of version (K modulus) Performance approval Exhaust approvals Note: The Performance Approval and Exhaust Approvals are only stamped for Diesel engines REG. CODE COMPILER TECO/ATI MODEL N° DATE OF ISSUE DATE ENDORSED... -
Page 13: Technical Specifications
TECHNICAL SPECIFICATIONS LGW 523-627 SPECIFICATIONS SELF-DRIVING POWER: Discontinuous service at variable rate and load. CONT. OVERLOADABLE POWER: Continuous heavy-duty service at constant rate and load. LGW 627 LGW 523 COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99... -
Page 14: Vcharacteristic Curves
LGW 627 will involve a variation in the carburation. Optimizing must be checked beforehand in the Lombardini test departments. Failure of Lombardini to approve this type of modification relieves the same from all liability for any damage the engine may sustain. -
Page 15: Overall Dimensions
OVERALL DIMENSIONS LGW 523 LGW 627 Note : The values are in mm COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99 10.06.99 1-5302-509... -
Page 16: Maintenance- Recommended Oil - Coolant Fluid - Fuels And Lubricants
MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system LGW 523 ENGINE MAINTENANCE FREQUENCY HOURS OPERATION PART 10 50 80 100 175 250 350 500 1000 2000 5000 SUMP OIL LEVEL RADIATOR FINS ALTERNATOR BELT TENSION... - Page 17 MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - 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.
- Page 18 MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS The fluid coolant circuit is pressurized. Inspections must only be made when the engine has cooled and even in this case, the radiator or expansion chamber plug must be unscrewed with the utmost caution. If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the engine is at a standstill.
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Page 19: Disassembly/Reassembly
Always use genuine LOMBARDINI spares to correctly repair the engines. LGW 523 Dry air filter The dry air filter of engine LGW 523 consists of a single unit (casing and cartridge) which cannot be separated. -
Page 20: Exhaust Manifold
The carburation must be tested beforehand in the Lombardini test department. Failure of Lombardini to approve this type of modification shall relieve the same of all liability for deriving operating faults and any damage to which the engine may be subjected. -
Page 21: Cooling Fan
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. Cooling fan Thoroughly clean the cooling fan and make sure that all its blades are in a good condition. Replace the fan if even only one of its blades is damaged. -
Page 22: Driving Pulley
VIII DISASSEMBLY/REASSEMBLY Transmission pulley Remove the pulley by taking out screw 1 of fig. 12. Components: 1 Screw 6 Ball bearing 2 Washer 7 Spacer 3 Centering bush 8 Ball bearing 4 Pulley 9 Circlip 5 Circlip Note: To remount, thoroughly clean the thread of screw 1 and torque to 25 Nm. -
Page 23: Belt Tightening Guide Pulley
VIII DISASSEMBLY/REASSEMBLY If the timing belt is removed, it must be replaced even though it has not terminated its forecast period of use. Always make sure that the battery + is well disconnected. Removing the timing belt Unscrew the screw of the tightening pulley 1 and remove the belt by pulling it from the timing pulley on the camshaft. -
Page 24: Timing Pulley - Timing System Tuning Reference Marks
VIII DISASSEMBLY/REASSEMBLY Timing pulley - Timing system tuning reference marks 1 Timing system tuning reference mark for LGW 523 and LGW 627 2 Timing system tuning reference mark for LGW 523 3 Timing system tuning reference mark for LGW 627. Only remove the timing belt from its protective casing just before assembly. -
Page 25: Operative Timing System Tuning Angles (Valve Clearance = 0.26 Mm) For Lgw 523
DISASSEMBLY/REASSEMBLY VIII Tuning the timing system - Inspection A = Intake valve B = Exhaust valve Move piston N° 1 (the one on the flywheel side) to top dead center. Make sure that intake and exhaust valves A and B are balanced by setting the touch probes of the two dial gauges on the valve caps. -
Page 26: Lgw 627 Speed Governor
VIII DISASSEMBLY/REASSEMBLY LGW 627 speed governor the speed governor is a mechanical type with centrifugal weights. It is installed behind aluminium support A fig. 30 and is driven directly by the camshaft. Components: 1 Support with 4 weights 2 Sliding sleeve 3 Axial needle bearing 4 Thrust plate LGW 627 speed governor components... -
Page 27: Demounting The Oil Pump
DISASSEMBLY/REASSEMBLY VIII Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil is unavoidable, you are advised to wash your hands with soap and water as soon as possible. -
Page 28: Lgw 627 Rocker Cap
DISASSEMBLY/REASSEMBLY VIII LGW 627 rocker cap Many of the more important engine components are on the cylinder head. The rocker cover houses part of the camshaft lubrication duct, that of the rockers and part of the engine bleeding system. External parts of the rocker cover: 1 Screw to fix the rocker cover to the cylinder head 2 Pressure switch (the only point where the engine oil pressure can be gauged) -
Page 29: Lgw 523 - Lgw 627 Valve/Rocker Clearance
DISASSEMBLY/REASSEMBLY VIII LGW 523 rocker cover Components : 1 Camshaft and rocker rod lubrication ducts 1a Camshaft and rocker rod lubrication routes 2 Rocker cover without labyrinth for oil vapour 3 Seal for rocker cover without hole for oil vapour access 4 Hole to drain oil from the cylinder head The rocker cover seal ensures that the rocker pivot camshaft lubrication circuit is tight. -
Page 30: Rocker Shaft
VIII DISASSEMBLY/REASSEMBLY Rocker shaft Unscrew the nuts from the supports that fix the rocker shaft to the cylinder head. Tighten them to a 40 Nm torque when they are remounted. The shaft is hollow inside to allow for lubrication and is closed at both ends by two plugs. -
Page 31: Cam Height Inspection
DISASSEMBLY/REASSEMBLY VIII Camshaft, demounting Before removing the camshaft, demount the rocker shaft as indicated in fig. 43 Slacken off the screws and remove the cover 1. Make sure that the retention ring 2 is in a perfect condition. Remove the rod from the fuel pump. Remove the camshaft by pulling and turning, paying particular attention since the cam turns directly on the cylinder block without the aid of bushes. -
Page 32: Cylinder Head, Removal
VIII DISASSEMBLY/REASSEMBLY Intake, exhaust cam height LGW 523 A1 = 1st cylinder intake S1 = 1st cylinder exhaust A2 = 2nd cylinder intake S2 = 2nd cylinder exhaust H = 30.78 to 30.718 mm (intake and exhaust cam height) LGW 627 A1 = 1st cylinder intake S1 = 1st cylinder exhaust A2 = 2nd cylinder intake... -
Page 33: Lgw 523 - Lgw 627 Valve Springs
DISASSEMBLY/REASSEMBLY VIII Valve springs Measure the free length with a gauge. For LGW 523 - Free length A = 39.8 mm. Replace the spring if the length value is less than 37.3 mm. For LGW 627 - Free length A = 45.6 mm Replace the spring if the length value is less than 43.1 mm. -
Page 34: Oil Sump, Removal
DISASSEMBLY/REASSEMBLY VIII Valve seats and housings Dimensions (mm) A = 34.020 to 34.045 B = 34.106 to 34.115 C = 30.020 to 30.041 D = 30.108 to 30.116 a a a a a = 44°53' to 45° a a a a a 1 = 59°53' to 60°... -
Page 35: Demounting And Remounting The Pin Stop Rings
DISASSEMBLY/REASSEMBLY VIII Piston Remove the big-end cap. Remove the piston connecting-rod assembly. Piston, demounting and inspection Remove the circlips and take out the pin, see fig. 77. Take out the piston rings and clean the slots. Measure diameter Q at dimension A from the base of the skirt (A = 9 mm). -
Page 36: Piston Rings - Distance Between The Tips
VIII DISASSEMBLY/REASSEMBLY Pistons, weight To prevent imbalance, the pistons must be weighed before they are replaced. The difference in weight must not exceed 4 g. Piston rings - Distance between the tips Fit each piston ring into the cylinder and measure the distance between tips A in the operating zone. -
Page 37: Head Gasket
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 Couple the piston to the connecting-rod by inserting the pin (after it has been lubricated) and simply pressing with the thumb. Fit in the two circlips that hold the pin in place and make sure that they are well housed in their seats;... -
Page 38: Connecting Rod (Big-End Bearing)
DISASSEMBLY/REASSEMBLY VIII Once the head has been correctly torqued, it will not need re- torquing unless it is disassembled again. Before mounting, it is advisable to lubricate the bolt shanks and under their heads with SPARTAN SAE 460 oil. LGW 523-627 head torquing phases The bolts must be torqued in three phases, in compliance with the numeric order shown in fig. -
Page 39: Connecting Rod Complete With Bearings And Pin
DISASSEMBLY/REASSEMBLY VIII Connecting rod complete with bearings and pin Dimensions (mm) A = 106.98 to 107.02 (for LGW 523) A = 126.48 to 126.52 (for LGW 627) B = 18.015 to 18.025 C = 40.021 to 40.050 (with bearing torqued to 40 Nm) D = 17.996 to 18.000 E = 50.900 to 51.100 (B-D) = 0.015 to 0.039... -
Page 40: Cylinders
DISASSEMBLY/REASSEMBLY VIII Cylinders Reset the comparator with a calibrated ring. Check diameter D in points 1, 2 and 3; repeat the same operation by turning the comparator through 90° at the same levels. Check for possible wear in zone X where the piston rings operate and grind the cylinder to the next allowance if it exceeds the max. -
Page 41: Central Main Bearing Caps
DISASSEMBLY/REASSEMBLY VIII Central main bearing caps The central main bearing caps have reference marks that can either be numbers as shown in the figure, or punch marks. The same reference marks are also applied to the cylinder block. Match the caps with the same reference marks and on the same side. -
Page 42: Bearing Half-Rings, Oversizes
VIII DISASSEMBLY/REASSEMBLY Crank shaft float After having tightened the main bearings, measure float A between the crank shaft support on the flywheel side and the main bearing half-rings. A = 0.130 to 0.313 mm limit 0.5 mm B = 23.05 to 23.10 mm limit 23.50 mm If the play is not within the given value, check value B. -
Page 43: Crank Shaft, Lubrication Ducts
DISASSEMBLY/REASSEMBLY VIII It is important to wear protective goggles when compressed air is used during repairs Crank shaft, lubrication ducts A = Crank shaft LGW 523 B = Crank shaft LGW 627 Place the shaft in a bath of degreasing and detergent fluid. Remove the plugs and clean ducts 1 and 2 or 3 and 4 with a pointed tool. -
Page 44: Hydraulic Pump Drive (For Lgw 627)
VIII DISASSEMBLY/REASSEMBLY Hydraulic pump drive (for LGW 627) A = Third drive A hydraulic pump (2 PD, Bosch flanging or a 1 PD) type can be mounted on the third drive. The power that can be supplied by the third drive is 7 kW, corresponding to a 37 Nm torque at 3600 rpm. -
Page 45: Lubrication Circuit
LUBRICATION CIRCUIT 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. -
Page 46: Internal Oil Filter And Engine Oil Return Tube
LUBRICATION CIRCUIT It is important to wear protective goggles when compressed air is used during repairs. Wash the parts with degreasing and detergent liquid. Internal suction strainer and engine oil return tube Wash the internal suction strainer 1 and the engine oil return tube 2; blow them with compressed air. -
Page 47: Oil Filter Cartridge
LUBRICATION CIRCUIT When the oil filter is replaced, keep it separate from other waste. Dispose of the old oil correctly since it is highly polluting. Do not litter. Oil filter cartridge Components: 1 Seal 5 Filtering element 2 Plate 6 By-pass valve 3 Rubber pad 7 Spring 4 Spring... -
Page 48: Xcooling Circuit
COOLING CIRCUIT The cooling circuit contains fluid under pressure. Do not carry out any inspections until the engine has cooled and even then, open the plug of the radiator or expansion chamber with caution. Keep well away from a hot engine if an electric fan is installed since this could start up even when the engine is at a standstill. -
Page 49: Cooling Fluid Pump, Components
COOLING CIRCUIT Radiator and compensation chamber plug, Inspections and tightness Remove the plug from the compensation chamber and make sure that the coolant is at the correct level. Replace the plug with one with a connection for a manual air pump. Compress the air to a pressure of 1 bar for about two minutes. -
Page 50: Fuelling Circuit
Periodically check the condition of the fuel pipes. Fuel filter detached from tank The fuel filter for the engines in question is the Lombardini type serial N° 3730.106. You are advised to use genuine spare parts since their 350 cm³... -
Page 51: Carburetor
FUELLING CIRCUIT Carburetor Engine LGW 627 is fuelled by two "DELLORTO" carburetors type FHCD22-18. Comply with the following instructions when adjusting: - The air filter must have a clean cartridge. - Air must not be drawn through vacuum pipes, seals, etc. - Parts that use electric power must not be operating (electric fans, alternator, etc). -
Page 52: Carburetor Vacuum Adjustment
FUELLING CIRCUIT Carburetor vacuum balancing test Connect the differential vacum gauges to the two carburetors with the engine idling and make sure that the vacuum in the two intake ducts differs by no more than 0.05 bar (5 kPa). 130a Carburetor vacuum adjustment If the vacuum reading on the vacuum gauges exceeds the previously mentioned 0.05 bar (5 kPa) limit, slacken off check nuts 1 and work... -
Page 53: Adjustments And Calibration
FUELLING CIRCUIT ADJUSTMENTS AND CALIBRATION DESCRIPTION 1st CONDITION Choke Float 4.5 g. Level from float chamber surface 7 mm Fast running jet High speed air Slow running jet Idling air Progressive outlets 2nd Idling screw opening turns 2 ¼ CARBURETOR FHCD22.18E 1- Gas valve 2- Air valve 3- Diffuser... -
Page 54: Carburetor Lgw 523
FUELLING CIRCUIT Carburetor LGW 523 Engine LGW 523 is fuelled by carburetor WEBER 32TLF39. IDLING ADJUSTMENT Preliminary conditions Work with the cold starting device deactivated. Bring the engine to operating temperature by allowing it to run at approx. 2000 r/min until the thermostat opens. Do not allow the engine to idle alone as measurement of the "CO"... -
Page 55: Adjustments
FUELLING CIRCUIT CALIBRATED PARTS ADJUSTMENTS DESCRIPTION 1st CONDITION DESCRIPTION VALUE Choke MECHANICAL LEVEL Centering device WITH SEAL 27 ± 0.25 Main jet FLOAT TRAVEL 34.2 ± 0.5 Brake air jet ACCELERATION PUMP Diffuser tube F 74 Total flow rate (10..pump strokes) cc. 10 ±... -
Page 56: Cold Starting
FUELLING CIRCUIT Cold starting Enrichment is obtained by shutting off eccentric throttle 2, controlled by a cam. An intermediate cam meanwhile partially opens accelerator throttle Fast idling speed allows the engine to quickly warm up and be immediately used. Normal speed The fuel passes through the reedle valve into the float chamber where float 12, articulated in the center pivot, regulates reedle 13 opening to keep the fuel itself at a constant level. -
Page 57: Float Chamber Level
FUELLING CIRCUIT Inspections and adjustments Float chamber level The level in the float chamber must be checked with the cover of the carburetor in a vertical position and with the tongue of the float slightly touching the ball of the reedle valve. In these conditions, the distance between the float and the surface of the cover (with seal) must be 27 ±... -
Page 58: Carburetor With Variant To Keep The Engine Idling When Cold
FUELLING CIRCUIT Carburetor with variant to keep the engine idling when cold Components: 1 T union 2 Accelerated idling adjuster screw 3 Pressure hole 4 Thermovalve 5 Pneumatic actuator on the carburetor 6 Calibrated hole 7 Not in the drawing - Plant 2193-113 (see fig. 164 on page 73) Operating principle Thermovalve 4, which guarantees regulation of the on-off type in the air circuit, is installed on the water pump support to adjust to the temperature of the aluminium. -
Page 59: Ignition
IGNITION This warning is valid for engines LGW 523 and 627 Take care to fix the harness wires in the correct way to prevent twists from forming. Electromagnetic fields could create abnormal voltage values leading to faulty operation in the ignition system. LGW 523 ignition system Components 1 Sensor with the Hall effect... -
Page 60: 523 Ignition Process
IGNITION LGW 523 cut-off In engine LGW 523, the module pilots an inductive load (coil of the cut-off solenoid valve on the carburetor 2 fig. 147) by means of a contact signal (on the idling speed adjuster screw) 1 fig. 147. When the fuel throttle is released, the speed adjuster screw (which is mounted on an insulating support) is grounded. -
Page 61: Lgw 523 Coil
IGNITION The technical specifications of the modules are similar for engines LGW 523 and LGW 627. Despite this fact, different Code types can be mounted since the programming maps can vary. Make sure that the right one is installed in case of replacement. -
Page 62: Lgw 627 Ignition System
IGNITION This warning applies to engines LGW 523 and 627 Take care to fix the harness wires in the correct way to prevent coils from forming. Electromagnetic fields could create abnormal voltage values leading to faulty operation in the ignition system. LGW 627 ignition system Components 1 Sensor with Hall effect... -
Page 63: Spark Plug (Type Champion Rc 12Yc)
IGNITION The spark plug must always be demounted and remounted when the engine is cold to prevent the thread on the aluminium cylinder head from being damaged. Spark plug (type Champion RC12YC) 0.8 mm Fit the spark plugs in place by fully screwing them on to the head by hand. -
Page 64: Electrical Circuit
XIII ELECTRICAL CIRCUIT Wiring diagram of gasoline (petrol) fuelled engine LGW 627 with external alternator and module serial N° 122.2193.109 REG. CODE MODEL N° COMPILER TECO/ATI DATE OF ISSUE DATE ENDORSED REVISION 1-5302-509 50778 10.06.99 10.06.99... - Page 65 ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) fuelled engine LGW 627 with spark lead variation device serial N° 122.2193.109 COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99 10.06.99 1-5302-509...
- Page 66 XIII ELECTRICAL CIRCUIT Wiring diagram of gasoline (petrol) fuelled engine LGW 627 with external alternator and module serial N° 122.2193.114 REG. CODE MODEL N° COMPILER TECO/ATI DATE OF ISSUE DATE ENDORSED REVISION 1-5302-509 50778 10.06.99 10.06.99...
- Page 67 ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) fuelled engine LGW 627 with spark lead variation device serial N° 122.2193.114 COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99 10.06.99 1-5302-509...
- Page 68 XIII ELECTRICAL CIRCUIT Wiring diagram of LPG fuelled engine LGW 627 with external alternator and module serial N° 122.2193.114 REG. CODE MODEL N° COMPILER TECO/ATI DATE OF ISSUE DATE ENDORSED REVISION 1-5302-509 50778 10.06.99 10.06.99...
- Page 69 ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) and LPG fuelled engine LGW 627 with spark lead variation device serial N° 122.2193.114 COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99 10.06.99 1-5302-509...
- Page 70 XIII ELECTRICAL CIRCUIT Wiring diagram of gasoline (petrol) fuelled engine LGW 523 without idling back-up device, with internal alternator and module serial N° 122.2193.108 REG. CODE MODEL N° COMPILER TECO/ATI DATE OF ISSUE DATE ENDORSED REVISION 1-5302-509 50778 10.06.99 10.06.99...
- Page 71 ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) fuelled engine LGW 523 without idling back-up device serial N° 122.2193.108 COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99 10.06.99 1-5302-509...
- Page 72 XIII ELECTRICAL CIRCUIT Wiring diagram of gasoline (petrol) fuelled engine LGW 523 with idling back-up device, internal alternator and module serial N° 122.2193.113 REG. CODE MODEL N° COMPILER TECO/ATI DATE OF ISSUE DATE ENDORSED REVISION 1-5302-509 50778 10.06.99 10.06.99...
- Page 73 ELECTRICAL CIRCUIT XIII Ignition module of gasoline (petrol) fuelled engine LGW 523 with idling back-up device serial N° 122.2193.113 COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99 10.06.99 1-5302-509...
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Page 74: Alternator Iskra 14V 33A
Battery Heavy duty starting Normal starting conditions conditions(max tolerated) Starter motor class The battery is not supplied by LOMBARDINI. Type of Quick disch. Quick disch. Capacity engine (Epicyclic type) Capacity... -
Page 75: Characteristic Curve Of Alternator Marelli Aa 125 R 14V 45A
ELECTRICAL CIRCUIT XIII Marelli alternator, type AA 125 R 14V 45A Specifications: Voltage rating = 14V Rated current = 45A Maximum speed = 14000 r/min Maximum peak speed (for 15 sec.) = 15000 r/min Bearing on control side = 6203-2Z Bearing on collector side = 6201-2Z/C3 Voltage governor... -
Page 76: Alternator Housed In The Flywheel
ELECTRICAL CIRCUIT XIII Alternator housed in the flywheel 12V 20A with three output wires 12V 30A with two output wires 1 Flywheel 2 Ring gear 3 Rotor 4 Stator Battery recharging curve for 12V 20A alternator ( three output wires ) The test was conducted after a 20°C heat stabilizing process. -
Page 77: Characteristic Curve Of Starter Motor Bosch Type Dw 12V 1.1 Kw
XIII ELECTRICAL CIRCUIT STARTER MOTOR Bosch type DW 12V 1.1 KW Clockwise rotation A = 17.5 to 19.5 mm (distance from flywheel ring gear plane to starter motor flange plane) Note: Contact the Bosch after-sales service network if repairs are needed. -
Page 78: Storage
STORAGE STORAGE Engines that must be stored for more than 30 days must be prepared in the following way: Temporary protection (1/6 months). - Allow the engine to idle in a no-load condition for 15 minutes. - Fill the sump with protective oil MIL-1-644-P9 and allow the engine to run for 5 to 10 minutes at three-quarters of the top speed. -
Page 79: Lpg Fuelled Engine Lgw 627
LPG fuelled ENGINE LGW 627 Engine LGW 627 LPG fuelled COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99 10.06.99 1-5302-509... -
Page 80: Operation Of The Lpg Conversion Unit
Optimizing of the process must be ascertained beforehand in the Lombardini test rooms. Failure of Lombardini to approve this type of modification shall relieve the same from all liability for operating faults and for any damage the engine might sustain. - Page 81 LPG fuelled ENGINE LGW 627 Components : A Switch mod. 093 B Connection harness between switch and users C Fuse holder with 7.5 Amp fuse D Ignition coil E Gas solenoid valve F Gasoline (petrol) solenoid valve G Regulator Connections : 1 Brown wire (antenna: the high voltage wire of the ignition coil can be wound around this, or it can be connected to the revolution counter wire) 2 Red wire (connect to an ignition key controlled positive, making sure that 12V are supplied)
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Page 82: Operation Of The Ignition System For Gasoline (Petrol) Or Lpg Fuelled Engines
LPG fuelled ENGINE LGW 627 Operation of the ignition system for gasoline (petrol) or LPG fuelled engines Note that to operate with LPG, the engine must be equipped with module 122.2193.114 and the relative wiring serial N° 2185.942, since this ignition system has been designed to operate when the engine is fuelled with either gasoline (petrol) or LPG. -
Page 83: Components Of The Lpg Conversion Unit
LPG fuelled ENGINE LGW 627 Components of the LPG conversion unit. To fuel the engine with LPG alone, shut off the bleed tubes 1 (fig. 183a) of the carburetors. The bleed tubes must be left open if the engine is also or only to operate with gasoline (petrol). -
Page 84: Positioning The Regulator
LPG fuelled ENGINE LGW 627 Regulator installation Comply with the following recommendations when installing: · the Regulator must be installed in the engine compartment; · it must be firmly fixed to the bodywork with M10 screws; · it must be positioned parallel to the advancement direction, see fig. 185; ·... -
Page 85: Liquid Phase Lpg Shut-Off Solenoid Valve
LPG fuelled ENGINE LGW 627 Regulator heating circuit connection The regulator should be connected to the cooling circuit of the engine or the heating circuit of the passenger compartment, using the relative pipes (fluid cooling). Fit the T unions in the position indicated in fig. 186, and use the relative pipe clamps for fixing purposes. Comply with the directions indicated by the water inlet and outlet arrows stamped on the regulator/atomizer. -
Page 86: Connecting The Mixer To The Regulator
LPG fuelled ENGINE LGW 627 Gasoline (petrol) solenoid valve This solenoid valve is a device that allows the flow of gasoline to be shut off when the vehicle is fuelled with gas, and the passage of gasoline (petrol) when the vehicles uses this fuel to operate. It is equipped with a manual device to use if the electrical device breaks down, allowing the valve to be by-passed. -
Page 87: Change-Over Switch Mod. 093
LPG fuelled ENGINE LGW 627 Electrical system This is an essential component on which the correct operation of the entire system depends. Comply with the following rules: - all conductors must be equipped with insulation and protection and be installed in a perfectly workmanlike way; - the electrical circuit must be equipped with a current limiting device;... -
Page 88: Carburation Test With Exhaust Gas Analyzer
LPG fuelled ENGINE LGW 627 Incorrect adjustments may saturate the air with LPG. Make all the adjustments outdoors or in a well ventilated place, well away from naked flames that could create sparks. REGULATING PROCEDURE WITH REDUCER SE 81 SIC The first operation is to regulate the peak rate: bring the engine to about rds of its r/min speed and turn the peak... -
Page 89: How To Regulate The Sensitivity Of Reducer Se 81 Sic
LPG fuelled ENGINE LGW 627 HOW TO REGULATE THE SENSITIVITY OF REDUCER SE 81 SIC The reducers will have already been regulated by the manufacturer, but if faults such as an instable idling speed or unsteady acceleration occur, it is advisable to check the sensitivity of the reducer itself. Adjuster screw G is not used to regulate the idling speed but just to adjust the sensitivity of the reducer. - Page 90 DRIVING TORQUES MAIN DRIVING TORQUES Reference Diam. X Pitch Torque POSITION ( figure N° and page) ( mm ) ( Nm ) 14 x 1.25 30 * Spark plug N° 153 - page 63 5 x 0.8 Intake manifold fixing nut (LGW 627) N°...
- Page 91 DRIVING TORQUES DRIVING TORQUES FOR STANDARD SCREWS DENOMINATION R ³ ³ ³ ³ ³ 800 N/mm² R ³ ³ ³ ³ ³ 1000 N/mm² R ³ ³ ³ ³ ³ 1200 N/mm² Diameter x pitch (mm) 4x0.70 0.37 0.52 0.62 5x0.80 0.72 11.9...
- Page 92 SPECIFIC TOOLS XVII SPECIFIC TOOLS DENOMINATION DENOMINATION DENOMINATION DENOMINATION DENOMINATION SERIAL N° SERIAL N° SERIAL N° SERIAL N° SERIAL N° Tool to mount the intake and exhaust valve 7170-1460-047 guide seal Tool to adjust the timing belt tension 7170-1460-049 Crank shaft locking tool 7107-1460-051 Shim to insert main bearings into the engine block...
- Page 93 NOTES COMPILER TECO/ATL MODEL N° DATE OF ISSUE DATE ENDORSED REG. CODE REVISION 50778 10.06.99 10.06.99 1-5302-509...
- Page 94 Cod. fiscale e Partita IVA 01829970357 - CEE Code IT 01829970357 E-MAIL: atl@lombardinifim.it Internet: http://www.lombardinifim.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.
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