Kohler LAMBARDDINI LDW 1503 Workshop Manual
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Kohler LAMBARDDINI LDW 1503 Workshop Manual

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WORKSHOP MANUAL
LDW
1503 - 2004 - 2004/T
1603 - 2204 - 2204/T

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Summary of Contents for Kohler LAMBARDDINI LDW 1503

  • Page 1 WORKSHOP MANUAL 1503 - 2004 - 2004/T 1603 - 2204 - 2204/T...
  • Page 2 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Drafting Document Model Review Edition Revision Issue date Endorsed body code N° date DICOM/ATLO 1° ED0053031210 51439 15-03-2016 15-03-2016 Manual’s purpose...

  • Page 3: General Service Manual Notes

    - For any spare parts order please specify following details: ENGINE TYPE AND SERIAL NUMBER - Version (K) - on the engi- ne name plate - The complete and updated list of authorized Kohler service centers can be found on our web site: www.kohlerengines.com &...

  • Page 4: Table Of Contents

    CHAPTER INDEX This manual gives the main instructions on how to repair LOMBARDINI diesel engines LDW 1503 - 1603 - 2004 - 2004/T - 2204 - 2204/T, fluid cooling circuit General service manual notes ............................3 Glossary and terminology ..............................3 Preface .....................................
  • Page 5 Chapter index Crankshaft lubrication ducts ............................55 Crankshaft timing gear ..............................55 Cylinder head ................................. 40 Cylinder head gasket ..............................48 Cylinder head tightening for engines without hydraulic tappets ..................48 Cylinder head tightening steps ............................49 Cylinder roughness ................................ 46 Cylinders ..................................
  • Page 6 Index Valve spring - Check ..............................41 Valve spring - check under load ............................. 41 Valve timing check ................................. 64 Valve timing without considering timing marks ....................... 64 TURBOCHARGER ..........................68 - 69 Checking actuator setting "Waste gate" ......................... 69 Turbocharger .................................. 68 Turbocharger components .............................
  • Page 7 Index Characteristic curves for alternator type Marelli AA 125 R 14V 65A ................89 Characteristic curves for starting motor Iskra type AZE 4598 24V 3 kW ..............95 Characteristic curves for starting motor type Bosch EV 12V 2.2 kW ................91 Characteristic voltage curve for regulator type AER 1528 .....................

  • Page 8: General Remarks And Safety Information

    General remarks and safety information This manual contains safety precautions which are explained Warning below. • Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the Danger caution is ignored.

  • Page 9: General Remarks And Safety Information

    General remarks and safety information with your skin because of the health hazards involved. are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health • Fuel vapours are highly toxic, so fill up only in the open air or hazard.

  • Page 10: General Safety During Operating Phases

    General remarks and safety information GENERAL SAFETY DURING OPERATING PHASES – The procedures contained in this manual have been tested and selected by the manufacturer’s technical experts, and hence are to be recognised as authorised operating methods. – A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations.

  • Page 11: Information And Safety Signals

    General remarks and safety information Information and safety signals Accidental Starts! Explosive Fuel! DANGER DANGER Accidental Starts can cause Fuel can cause fires and severe injury or death. severe burns. Disable engine by disconnecting Do not fill the fuel tank while the negative (-) battery cable.

  • Page 12: Explanation Of The Safety Pictograms That Can Be Found On The Engine Or In The Workshop Manual

    General remarks and safety information Explanation of the safety pictograms that can be found on the engine or in the Workshop manual - Read the Operation and Workshop manual before - Use protective gloves before carrying out the performing any operation on the engine operation - Use protective glasses before carrying out the operation...
  • Page 13 General remarks and safety information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 14: Technical Information

    TECHNICAL INFORMATION Manuifacturer and Motor identification data The identification plate shown in the figure can be found directly on the engine. It contains the following information: A) Manufacturer’s identity B) Engine type C) Engine serial number D) Maximum operating speed E) Number of the customer version (form K) F) Approval data Approval data...

  • Page 15: Name Plate For Epa Rules Applied On Rocker-Arm Cap

    Technical information Name plate for EPA rules applied on rocker-arm cap Compilation example 1) Model year. 2) Engine displacement. 3) Power category, kW. 4) Particulate emission limit (g/kWh). 5) Engine family ID. 6) Kind of application i.e. 7) Injection timing (BTDC). 8) Injector opening pressure (bar).

  • Page 16: Technical Data

    Technical information TECHNICAL DATA ENGINE TYPE 1503 2004 2004/T Cylindres N° Bore Stroke Displacement 1551 2068 2068 Compression ratio 22:1 22:1 22:1 R.P.M. 3000 3000 3000 26.4 44.1 N 80/1269/CEE-ISO 1585-DIN 70020 Power KW NB ISO 3046 - 1 IFN - DIN 6270 24.6 33.0 42.0...
  • Page 17 Technical information TECHNICAL DATA ENGINE TYPE 1603 2204/T 2204 Cylindres N° Bore 90.4 90.4 90.4 Stroke 1649 2199 2199 Displacement 22:1 22:1 22:1 Compression ratio 3000 3000 3000 R.P.M. 30.0 38.0 49.2 N 80/1269/CEE-ISO 1585-DIN 70020 NB ISO 3046 - 1 IFN - DIN 6270 27.6 34,5 Power KW...

  • Page 18: Possible Causes And Trouble Shooting

    Technical information POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN: 1) - The engine rpms suddenly increase and decrease 2) - A sudden and unusual noise is heard 3) - The colour of the exhaust fumes suddenly darkens 4) - The oil pressure indicator light turns on while running.
  • Page 19 Technical information TROUBLE POSSIBLE CAUSE Damaged injector Injection pump valve damaged Injector not adjusted Faulty fuel feeding pump Hardened pump control rod Broken or loose supplementary start-up spring Worn or damaged pumping element Incorrect tuning of injection components (delivery balancing advance) Cracked or broken precombustion chamber Oil level too high Oil level low...

  • Page 20: Performance Diagrams

    Technical information PERFORMANCE DIAGRAMS CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES LDW 1503 LDW 1603 LDW 2004 LDW 2004/T N (80/1269/CEE - ISO 1585) AUTOMOTIVE RATING: intermittent operation with variable speed and variable load. NB (ISO 3046 - 1 IFN) RATING WITH NO OVERLOAD CAPABILITY: Continuous light duty operation with constand speed and variable load.
  • Page 21 Technical information CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES LDW 2204 LDW 2204/T N (80/1269/CEE - ISO 1585) AUTOMOTIVE RATING: intermittent operation with variable speed and variable load. NB (ISO 3046 - 1 IFN) RATING WITH NO OVERLOAD CAPABILITY: Continuous light duty operation with constand speed and variable load.

  • Page 22: Overall Dimensions

    Technical information OVERALL DIMENSIONS LDW 1503 - 1603 Note : Dimensions shown in mm DIMENSIONS mm 215.7 356.4 233 max 147.5 99.6 231.3 250.2 283.3 425.2 154.2 187.5 - 22 - - 22 - Workshop Manual LDW CHD _ cod. ED0053031210 - 1°...
  • Page 23 Technical information LDW 2004 - 2204 WATER DRAIN PLUG OIL DRAIN PLUG Note : Dimensions shown in mm DIMENSIONS mm 187.5 156.5 356.3 231.3 154.2 215.7 99.6 425.2 283.3 Workshop Manual LDW CHD _ cod. ED0053031210 - 1° ed_rev. 00 - 23 - - 23 -...
  • Page 24 Technical information LDW 2004/T - 2204/T Note : Dimensions shown in mm DIMENSIONS mm 166.7 186.3 224.8 233.1 156.5 153.5 386.1 168.7 373.2 452.5 133.5 190.5 468.1 - 24 - - 24 - Workshop Manual LDW CHD _ cod. ED0053031210 - 1° ed_rev. 00...
  • Page 25 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... Workshop Manual LDW CHD _ cod. ED0053031210 - 1°...
  • Page 26 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 26 - - 26 - Workshop Manual LDW CHD _ cod.
  • Page 27 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... Workshop Manual LDW CHD _ cod. ED0053031210 - 1°...

  • Page 28: Maintenance - Prescribed Lubricant - Refilling

    MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ROUTINE ENGINE MAINTENANCE Warning • Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system. ORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING Engine oilreplacement. Oil filter replacement.

  • Page 29: Acea Regulations - Sequences

    Maintenance - Recommended oil type - Refilling LUBRICANT SAE Classification In the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken into account. SAE 10W-30** The first number refers to the viscosity when the engine SAE 10W-40** is cold (symbol W = winter), while the second considers SAE 10W-60**...

  • Page 30: Prescribed Lubricant

    Maintenance - Recommended oil type - Refilling PRESCRIBED LUBRICANT API CF - SH ACEA B3-B4 AGIP SINT 2000 TURBODIESEL 5W40 specifications MIL - L-2104 C MIL-L-46152 D In the countries where AGIP products are not available, use oil API CF/SH for Diesel engines or oil corresponding to the military specification MIL-L-2104 C/46152 D.

  • Page 31: Coolant

    Maintenance - Recommended oil type - Refilling COOLANT Danger • 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. •...
  • Page 32 ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 32 - - 32 - Workshop Manual LDW CHD _ cod.
  • Page 33 ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... Workshop Manual LDW CHD _ cod. ED0053031210 - 1°...

  • Page 34: Disassembly/Reassembly

    DISASSEMBLY/REASSEMBLY RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING Important • To locate specific topics, the reader should refer to the index. – Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and operating instructions. – Always use original spare parts for proper repair operations. –...

  • Page 35: Dry Air Cleaner

    Disassembly / Reassembly Oil-bath air cleaner Danger • Never clean the filtering element 6 using solvents with a highly flash point. This could cause an explosion ! Warning • During repair operations, when using compressed air, wear eye protection. Check gaskets and replace if necessary. Check that flange welds are free of porosity or defective spots.

  • Page 36: Air Filter Clogging Indicator

    Disassembly / Reassembly Dry air components 1 Main cartridge 2 Safety cartridge 3 Axial cover 4 Vacuator valve 5 Cap complete with clamp 6 Rubber connecting hose to the air filter - manifold or compressor. 7 Air filter restriction switch 8 Mounting for clogging indicator 9 Fastener Scavenging valve 4 must be positioned as in figure 4.

  • Page 37: Cooling Fan

    Disassembly / Reassembly Intake manifold The sealing surface should be clean, smooth and free of any strains and scoring. When reassembly replace gasket A.  Tighten the fastening screws to 25 Nm. Exhaust manifold Danger • Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns.

  • Page 38: Driving Pulley (2A P.t.o.)

    Disassembly / Reassembly Driving pulley (2 P.T.O.) The maximum torque that can be drawn from the second power take-off must be at maximum 70 Nm. The driving pulley drives the alternator and the water pump and consequently the cooling fan. Bolt D can be loosened by turning clockwise.

  • Page 39: Rocker Arm Cover For Engines With Recirculating Vent

    Disassembly / Reassembly Rocker arm cover with vent into the air Components: 1 - Decanting device 2 - Oil fill cap 3 - Gasket Inside the decanting device 1 there is a small metal skein that separates the oil from the bled vapours; before reassembling it, clean it and verify its intactness.

  • Page 40: Cylinder Head

    Disassembly / Reassembly Rocker arm assemly Loosen the screws which fasten the assembly to the head. When refitting apply a drop of Loctite 270 onto the threads.  When refitting tighten to 50 Nm. Inside the rocker arm pin flows the oil that lubricates the rocker arms and feeds the hydraulic tappets.

  • Page 41: Valve Guides And Cylinder Head

    Disassembly / Reassembly Valve spring - Check Check the overall state of the valve springs. Replace if damaged or if they have lost their original elasticity. First of all, use a gauge to check that the free length matches the measurements given below.

  • Page 42: Oil Seal In The Valves Guides, (Intake And Exhaust)

    Disassembly / Reassembly Valve guide insertion, after driving Press guides considering the L distance from the head plane X. Dimensions Clearance Ref. Limit value Ref. (mm) (mm) (mm) 7,020 ÷ 7,035 0,020 ÷ 7,020 ÷ 7,035 0,100 0,050 36,8 ÷ 37,2 6,985 ÷...

  • Page 43: Valve Recess And Sealing Surfaces

    Disassembly / Reassembly Valve seats and bore Dimensions Ref. 41,500 ÷ 41,520 mm 41,575 ÷ 41,590 mm 36,500 ÷ 36,520 mm 36,575 ÷ 36,590 α 44° 53' ÷ 45° α 59° 53' ÷ 60° Valve recess and sealing surfaces Ss* = Sealing surface width on exhaust side Sa* = Sealing surface width on intake side H = Valve recess with reference to the head plane Dimensions...

  • Page 44: Hydraulic Diagram For Feeding The Tappets

    Disassembly / Reassembly Precombustion chamber The precombustion chamber can be extracted from the head banging with a punch into the hole from the injector housing. This procedure implies irreversible damages to the precombustion chamber which will have to be replaced. In the assembly stage line up the dowel 1 with the reference notch 2 located in the head.

  • Page 45: Hydraulic Tappet Operation

    Disassembly / Reassembly Hydraulic tappet operation The operating principle of the hydraulic tappet is based on the incompressibility of the liquids and on controlled leakage. Through push rod 1, the pressurised oil gets into the tappet in chamber A (low-pressure chamber), maintaining a constant flow of oil in the above chamber as well as in the high-pressure chamber B.

  • Page 46: Cylinder Roughness

    Disassembly / Reassembly Cylinders Reset dial gauge with a calibrated ring. Check diameter size D at 1, 2 and 3; repeat the same operation at the same places after turning the dial gauge by 90°. Check for wear in the X area where piston rings are located. Limit value D (mm) (mm)

  • Page 47: Piston Rings - Clearance Between Grooves

    Disassembly / Reassembly Piston weight Weigh the pistons when replacing them in order to avoid unbalance. The difference in weight should not exceed 6 g. Piston rings - End gaps Place piston rings into the cylinder and measure end gap A. 1st ring A = 0,30 ÷...

  • Page 48: Cylinder Head Gasket

    Disassembly / Reassembly Piston - Refitting Connect piston to connecting rod after lubricating piston pin and introducing it by exerting pressure with your thumb. Position the two piston pin circlips and check that they are well inside their seats. Using a ring compressor introduce the piston into the cylinder with combustion chamber facing the injection pump side.

  • Page 49: Assembling And Tightening The Cylinder Head On Engines With Hydraulic Tappets

    Disassembly / Reassembly Cylinder head tightening for engines without hydraulic tappets Use a torque wrench (fitted with tool for angular tightening). It is recommended to replace the screws whenever the head is disassembled. Important • The cylinder head must never be retightened. •...

  • Page 50: Connecting Rod

    Disassembly / Reassembly Tightening must be carried out as shown in figure 59. Once the final torque 50 Nm is reached, wait thirty minutes before manually rotating the engine to verify that the pistons do not collide LDW 1503 with the valves, if the engine turns freely start the engine normally, 1603 otherwise wait another 30 minutes before repeating the operation.

  • Page 51: Connecting Rod Alignment

    Disassembly / Reassembly 1503-2004 2004/T 1603-2204 2204/T Ref. Clearance (mm) Limit value (mm) 144.98 ÷ 145.02 147.98 ÷ 148.02 B - D 0,02 ÷ 0,03 0,06 28.02 ÷ 28.03 53.62 ÷ 53.78 27.995 ÷ 28.000 Value to measure 62.28 ÷ 62.3 65.78 ÷...

  • Page 52: Center Main Bearings

    Disassembly / Reassembly Center main bearings The main bearing caps and the crankcase have reference holes marked on them (one, two or three). Important • In the assembly stage make sure that the number of holes on the bearings matches those on the crankcase and that they are on the same side.

  • Page 53: Check Clearance Between Main Bearings And Journals

    Disassembly / Reassembly Check clearance between main bearings and journals Use "Perfect Circle Plastigage" A and position it with a few drops of oil at the center of the half bearing.  Tighten bolts to 120 Nm. Determine clearance by measuring the squeezed portion of the plastigage with the indexed scale supplied.

  • Page 54: Crankshaft End Play

    Disassembly / Reassembly Grease the shoulder half-rings so that they will remain in their seats during assembly. Halves should be fitted with grooves A as shown in the figure 77-78. Thrust bearing thickness = 2.31÷2.36 mm; oversize halves with thickness increased by 0.1 and 0.2 mm are available as spares. Thrust bearing, oversizes Grinding B according to the above table, following half-rings can be assembled:...

  • Page 55: Crankshaft Front And Rear Oil Seal

    Disassembly / Reassembly Crankshaft front and rear oil seal The front oil seal A is located in the oil pump cover while the rear oil seal ring B, is positioned in the flange on the flywheel side. Replace seals if warped, hardened or damaged. In case of replacement: •...

  • Page 56: Checking Main Journals And Crank Pins

    Disassembly / Reassembly Checking main journals and crank pins Use an outside micrometer gauge. The main bearing, the crankshaft bearing and the thrust washers have been unified as from engine serial number 7306062 for LDW1503, from serial number 7303552 for LDW 2004 and from serial number 7305782 for LDW 2004/T.

  • Page 57: Crankshaft For Engines With Dynamic Equalizer (Only Four-Cylinder Engines)

    Disassembly / Reassembly Crankshaft for engines with dynamic equalizer (only four- cylinder engines). The crankshaft comes with seat for the control gear of the counter-rotating shaft dynamic balancer. With centering hole (spring pin). Components: 1 Control gear for counter-rotating shafts 2 Seat for the control gear of counter-rotating shafts 3 Spring pin Ref.

  • Page 58: Front Cover (After The Serial Number 7366306)

    Disassembly / Reassembly Front cover (before the serial number 7366305) To remove front cover 1 bring the 1st cylinder to the top dead center. Remove throttle cover 2 and release spring 3. When refiting replace gasket 4 and 5.  Tighten front cover 1 to 25 Nm. Front cover (after the serial number 7366306) To disassemble the cover 1 rotate the crankshaft until the plug 6 of centering pulley command alternator is located in the upward...

  • Page 59: Dimensions For Injection Pump Delivery Control Yoke Adjustement

    Disassembly / Reassembly Speed governor Important • During reassembly, make sure the components are undamaged and verify they work properly. • Malfunctioning of the speed governor can cause serious damage to the engine and to people in the vicinity of it. Components: 1 Gear 2 Bell...

  • Page 60: Camshaft Gear - Speed Governor Counter Weights

    Disassembly / Reassembly Camshaft gear - Speed governor counter weights Components: 1 Camshaft gear 2 Governor weights 3 Governor weight support 4 Governor weight pin The governor weights 2 are housed inside the camshaft gear 1. The weights 2 can be of two types: light or heavy, depending on the speed rate and the type of application.

  • Page 61: Camshaft

    Disassembly / Reassembly Summary tables of the governor equipment according to the speed variation. LDW 1503_1603 LDW 2004_2204_2004/T_2204/T Weight type N.Spring Spring serial number Weight type N.Spring Spring serial number 1500 5655370 1500 5655370 Duty Duty 1500 5655154/5655156** 1500 5655154/5655156* Duty Duty 1800...

  • Page 62: Camshaft Bushing Replacement

    Disassembly / Reassembly Checking camshaft bushing internal diameter Use a bore gauge. If the diameter size does not correspond to the given value remove the bushings using the special tool (pic. 109 and 110) and replace. Camshaft journals and bushings in model LDW 1503 -1603 Clearance Worn limit Dimensions...

  • Page 63: Intake, Exhaust And Injection Cam Height For Engine With Hydraulic Tappets

    Disassembly / Reassembly Intake, exhaust and injecton cam height for model LDW 1503 Rif. A (mm) S (mm) I (mm) LDW 1503 36,058 ÷ 35,62 ÷ 33,85 ÷ LDW 2004 36,120 35,68 33,90 35,24 ÷ 33,85 ÷ LDW 2004/T 35,54 ÷ 35,60 35,30 33,90 Limit value...

  • Page 64: Camshaft Timing

    Disassembly / Reassembly Camshaft timing Fit idler gear B by making timing mark 2 coincide with timing mark 1 on the camshaft control gear A and mark 3 with 4 on the timing gear C. Valve timing without considering timing marks Locate piston 1 (on flywheel) at the top dead center.

  • Page 65: Engines With Hydraulic Tappets

    Disassembly / Reassembly Engines with mechanical tappets Timing angles for checking puposes (valve clearance = 2 mm) = 14° after S (corresponding to 35 mm on the flywheel) β = 6° after I (corresponding to 15 mm on the flywheel) γ...

  • Page 66: Camshaft End Play

    Disassembly / Reassembly Camshaft end play Check camshaft end play after removing the cylinder head, the injection and the fuel pumps from the engine. Check that plate 1 is tightened. Position the dial gauge on the camshaft front surface; push and pull the camshaft.
  • Page 67 Disassembly / Reassembly ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... Workshop Manual LDW CHD _ cod.

  • Page 68: Turbocharger

    TURBOCHARGER Turbocharger It is installed on the engine in two versions: with air intake on the flywheel side and with air intake on the fan side. To control the supercharge air pressure, screw the pressure gauge into the M8 holes A and B both for the version with air intake on flywheel side (fig.

  • Page 69: Checking Actuator Setting "Waste Gate

    turbocharger Checking actuator setting. "Waste gate" valve control rod stroke adjustment Important • This test must be done with the engine stationary. Disconnect pipe 7 from the compressor side. Using a T coupling, connect up with a pressure gauge 4 (scale from zero to 2 bar) and with the compressed air mains pipe complete with reduction unit 5.

  • Page 70: Lubrication System

    LUBRICATION SYSTEM Danger • The engine may be damaged if operated with insufficient lube oil. It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion. •...

  • Page 71: Oil Filter Cartridge

    Lubrication system Oil pump Components: 1 Suction port 5 External rotor 2 Delivery port 6 Internal rotor 3 Oil pressure adjusting Valve port 7 Key 4 Gasket The oil pump is driven by the crankshaft via key 7. Rotor 6 is locked in the circumferential but not in the axial direction.

  • Page 72: Oil Pressure Check

    Lubrication system Oil pressure check On completing assembly, fill with engine oil and fuel; connect a 10 bar pressure gauge to the pressure switch fitting. Start the engine and check pressure as a function of the oil temperature. Oil pressure curve for LDW 1503 - 1603 Fig.
  • Page 73 Lubrication system Notes : ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 74: Cooling System

    COOLING SYSTEM Danger • 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. •...

  • Page 75: Cooling System

    Cooling system Expansion tank and cap The expansion tank is separated from the radiator and is fitted with a coolant fill cap. The cap comes with vacuum valve 1 and pressure relief valve 2. The pressure relief valve opens at a pressure of 0.7 bar. Checking for cooling system leaks Remove the cap from the expansion tank and check coolant level.

  • Page 76: Fuel System

    FUEL SYSTEM Danger • To avoid explosions or fire outbreaks, do not smoke or use naked flames during the operations. • Fuel vapours are highly toxic. Only carry out the operations outdoors or in a well ventilated place. • Keep your face well away from the plug to prevent harmful vapours from being inhaled. Dispose of fuel in the correct way and do not litter as it is highly polluting.

  • Page 77: Fuel System

    Fuel system Fuel filter Components: 1 - Drain screw 2 - Cover 3 - Seal 4 - Fitting 5 - Cartridge Cartridge specifications Filtering paper:.....PF 904 Filtering area:.......5000 cm2 Filtering degree:....2/3 Max. working pressure: ..4 bar  See page 22 for maintenance details. Fuel feeding pump Components: 1 - Feeding pump...

  • Page 78: Electric Fuel Pump (24V)

    Fuel system Electric fuel pump (24V) Intake The use of the electric pump is foreseen for certain applications side (where the engine has to be started at very low temperatures). Assembly notes: When the electric fuel pump is installed in a diesel engine, it is Support necessary to: clump...

  • Page 79: How To Reassemble Injection Pump Components

    Fuel system How to reassemble injection pump components Fit the plunger with helix E directed towards the discharge union B; if it is erroneously fitted with spiral facing the fuel feed union A the injection pump will not operate (thus the possibility of the engine overspeeding is completely ruled out);...

  • Page 80: How To Reassemble Injection Pump Feeding Tubes

    Fuel system How to reassemble injection pump feeding tubes 1 Pliers for 6 mm diam. tubes (intake) - Part No. 7104-1460- 2 Pliers for 8 mm diam. tubes (discharge) - Part No. 7104- 1460-023 Feeding and discharge tubes are made of nylon; they fit into the injection pump unions by exerting pressure and using special pliers and a plastic hammer.

  • Page 81: Checking Injection Pump Delivery

    Fuel system Injection pump P. No. 6590-249 Plunger and barrel assembly Components: 1 Pump body 2 Barrel 3 Plunger 4 Plunging blade Note: Barrel 2 forms an integral part of the pump body 1. For this reason both the barrel and plunger 3 should not be replaced.

  • Page 82: Checking Low Pressure Injection Timing For Engines With Hydraulic Tappets

    Fuel system Checking low pressure injection timing for engines with hydraulic tappets To verify the delivery starting point, the first operation to carry out is to disconnect the nylon tubes at the inlet 4 and outlet 3 of every injection pump. Then, disassemble the air filter, the intake manifold and the rocker arm cap.

  • Page 83: Checking Low Pressure Injection Timing For Engines With Mechanical Tappets

    Fuel system Checking low pressure injection timing for engines with Injection timing Engine Injection timing value mechanical tappets value for type for r.p.m. ≤ 2400 r.p.m. ≥ 2400 The check of the advance on engines with mechanical tappets LDW 1503 is carried out using the same procedure as that described for the 1603 hydraulic tappets;...

  • Page 84: Injector (Pin Type)

    Fuel system Injector (pin type) Components: 1 Fuel inlet 7 Delivery union 2 Filter 8 Backflow union 3 Body 9 Setting shims 4 Delivery duct 10 Pressure spring 5 Pad 11 Pressure pin 6 Clamping ring nut 12 Nozzle 13 Fireproof bulkhead Whenever maintenance operations are carried out on the injector replace the seal ring 1.
  • Page 85 Fuel system ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Workshop Manual LDW CHD _ cod. ED0053031210 - 1°...
  • Page 86 ELECTRIC SYSTEM Wiring diagram with alternator 12V 45A / 65A / 80A Black Pink Black Green White Black Blue Grey Black Black Brown Pink/Black Black Black - 86 - - 86 - Workshop Manual LDW CHD _ cod. ED0053031210 - 1° ed_rev. 00...

  • Page 87: Electric System

    Electric system Wiring diagram with alternator 12V 45A / 65A / 80A 1 Alternator 2 Starter Motor 3 Battery (See below for sizing details) 4 Glow Plugs 5 Thermistor (Glow Plug Controller Circuit) 6 Glow Plug Controller / Timer 7 Key Switch 8 System Fuse 9 Fuse (Accessory) 10 Fuel Valve...

  • Page 88: Alternator Type Marelli Aa 125 R 14V 45A

    Electric system Alternator type Marelli AA 125 R 14V 45A Characteristics: Rated voltage ......14V Rated current ......45A Max. speed ........14000 giri/1' Peak speed (max 15 min)..15000 rpm Bearing on control side ....6203.2z Bearing on manifold side ...6201-2z/C3 Voltage regulator .......RTT 119 AC RH direction of rotation.

  • Page 89: Alternator Type Marelli Aa 125 R 14V 65A

    Electric system Alternator type Marelli AA 125 R 14V 65A Characteristics: Rated voltage ......14V Rated current ......65A Max. speed ........14.000 giri/1' Peak speed (max 15 min) ..15.000 rpm Bearing on control side ....6203.2z Bearing on manifold side ...6201-2z/C3 Voltage regulator .......RTT 119 AC RH direction of rotation.

  • Page 90: Alternator Type Iskra, Aak3139 14V 80A

    Electric system Alternator type Iskra, AAK3139 14V 80A Characteristics: Rated voltage ...........14V Rated current ............80A Speed of the load starting point ......1350 rpm Maximum permanent intermittent speed (max. 15') ......13000 -15000 rpm Front bearing ............6303 - 2RS - C3 Rear bearing .............6201 - 2RS - C3 Max.
  • Page 91 Electric system Starting Motor 12V Bosch type EV 12V 2.2 Kw RH direction of rotation. Note: Apply to a Bosch service center for any tipe of repair. Characteristic curves for starting motor type Bosch EV 12V 2.2 kW The solid lines were obtained at a temperature of +20°C; the dotted lines were obtained at a temperature of -20°C.Battery type 110 Ah 450A.
  • Page 92 Electric system Wiring diagram 24V with alternator 35A Black Pink Black Green White Black Blue Grey Black Black Brown Pink/Black Black Black - 92 - - 92 - Workshop Manual LDW CHD _ cod. ED0053031210 - 1° ed_rev. 00...
  • Page 93 Electric system Wiring diagram 24 V with alternator 35A 1 Alternator 2 Starter Motor 3 Battery (See below for sizing details) 4 Glow Plugs 5 Thermistor (Glow Plug Controller Circuit) 6 Glow Plug Controller / Timer 7 Key Switch 8 System Fuse 9 Fuse (Accessory) 10 Fuel Valve 11 Glow Plug Indicator Lamp...

  • Page 94: Alternator Type Iskra, Type Aak3570 28V 35A (For 24 V Outfits)

    Electric system Alternator type Iskra, type AAK3570 28V 35A (for 24 V outfits) Characteristics: Rated voltage ..........28V Rated current ..........35A Speed of the load starting point ...... 1140 rpm Maximum permanent intermittent speed (max. 15') ......13000 -15000 rpm Front bearing ..........
  • Page 95 Electric system Starting Motor 24V Iskra type AZE 4598 24V 3 kW RH direction of rotation. Characteristic curves for starting motor Iskra type AZE 4598 24V 3 kW The thick lines were obtained at a temperature of +20°C; the thin lines were obtained at a temperature of -20°C.
  • Page 96 Electric system Connection diagram for preheating control unit Components: 1 Cable cross-section 2.5 mm at point “50” of the key panel 2 Cable cross-section 6 mm at the fuse holder box 3 Cable cross-section 1.5 mm at the earth 4 Cable cross-section 1 mm at the spark plug warning light (max.
  • Page 97 Electric system Temperature sensor (Thermistor) The thermistor is located on the thermostat housing, adjacent to the high coolant temperature switch. The thermistor must be installed in the thermostat housing in the port located nearest to the cylinder head. (See the figure to the left).
  • Page 98 Electric system Thermistor for electric thermometer Thermistor features Temperature °C Resistance Ω 73806 ÷ 53983 52941 ÷ 39229 20825 ÷ 18006 8929 ÷ 7095 2040 ÷ 1718 589 ÷ 521 205 ÷ 189 +120 85 ÷ 87 Thermistor for preheating water temperature Thermal contact for water temperature indicator light Thermal contact T1 features Resistance Ω...
  • Page 99 Electric system ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Workshop Manual LDW CHD _ cod. ED0053031210 - 1°...
  • Page 100 SETTINGS Idling speed setting in no-load conditions (standard) After filling with oil, fuel and coolant, start the engine and warm up for 10 minutes. Adjust idling speed at 850÷950 rpm by turning screw 1 then tighten lock nut. Note: Speed decreases when loosening screw 1 and increases when tightening it.
  • Page 101 Settings Fuel limiting device (fig. 208-209) When starting up the engine the fuel limiting device has the aim of preventing excessive smoke at the exhaust. Use the delivery adjustment rod of the injection pumps 5 Fig.209 in a constant manner when ambient temperature is above 15°C. As the temperature gradually falls, this device gradually lessens its action to then exclude it at 0°C.
  • Page 102 Settings ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 102 - - 102 - Workshop Manual LDW CHD _ cod.
  • Page 103 ENGINE STORAGE ENGINE STORAGE - When the engines are not for more than 6 months, they have to be protected performing the operations described in the following pages. If the engine is not to be used for extensive periods, check the storage area conditions and the type of packaging and make sure that these are suitable for correct storage.
  • Page 104 TORQUE SPECIFICATIONS AND USE OF SEALANT MAIN TORQUE SPECIFICATIONS Reference (fig. Ø and pitch Torque Type of POSITION N° and page) sealant Alternator fixing bolt fig. 8 - pag. 37 Diesel fuel union bolts Flywheel housing Preheating glow plug fig. 197 - pag. 96 Roker arm cover fig.
  • Page 105 Torque specifications and use of sealant Table of tightening torques for standard screws (coarse thread) Resistance class (R) 10.9 12.9 Quality/ Dimensions R>400N/mm R>500N/mm R>600N/mm R>800N/mm R>1000N/mm R>1200N/mm Diameter 1000 1200 1050 1500 1800 1088 1450 2000 2400 Table of tightening torques for standard screws (fine thread) Resistance class (R) 10.9 12.9...
  • Page 106 Notes ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 106 - - 106 - Workshop Manual LDW CHD _ cod.
  • Page 107 Notes ..................................Notes : ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Workshop Manual LDW CHD _ cod.
  • Page 108 Lombardini s.r.l. is a part of Kohler Group. E U R O P E U S A & CA N A DA F R A N C E Lombardini has manufacturing facilities Lombardini Srl Kohler Co. Lombardini France S.a.s. in Italy, Slovakia and India and sales Via Cav.

This manual is also suitable for:

Lambarddini ldw 2004Lambarddini ldw 2004/tLambarddini ldw 1603Lambarddini ldw 2204Lambarddini ldw 2204/t

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