Lombardini 11 LD 625-3 Workshop Manual
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Lombardini 11 LD 625-3 Workshop Manual

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WORKSHOP MANUAL
11 LD series engines
cod. 1-5302-296_ 5° ed.
11 LD 625-3
11 LD 626-3

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Summary of Contents for Lombardini 11 LD 625-3

  • Page 1 WORKSHOP MANUAL 11 LD series engines cod. 1-5302-296_ 5° ed. 11 LD 625-3 11 LD 626-3...
  • Page 2 LOMBARDINI. Information presented within this manual assumes the following: 1 - The person or people performing service work on LOMBARDINI series engines is properly trained and equipped to safely and professionally perform the subject operation; 2 - The person or people performing service work on LOMBARDINI series engines possesses adequate hand and LOMBARDINI special tools to safely and professionally perform the subject service operation;...

  • Page 3: Table Of Contents

    INTRODUCTION This manual contains the most important information for the repair of LOMBARDINI air cooled, direct injection Diesel engines type 1LD625-3 e 11LD626-3. This information is current upto 07.30.2007. TABLE OF CONTENTS GENERAL REMARKS AND SAFETY INFORMATION ..............Pag. 7 - 9 WARRANTY CERTIFICATE ..............................
  • Page 4 INTRODUCTION Camshaft timing ................................44 Center main bearing support, locating bolts ........................39 Checking intake/exhaust cam height ..........................43 Checking main journals and crank pins ..........................40 Checks and cyiinder roughness ............................34 Clearance between main journals/crank pins and connecting rod bearings ..............41 Compression release ................................
  • Page 5 INTRODUCTION Valve / rocker arm clearance ............................28 Valve guide insertion ................................. 33 Valve guides and cylinder head housings ......................... 32 Valve material ................................... 32 Valve seat lapping ................................33 Valve seats and housings ..............................33 Valve springs ..................................32 Valve stem sealing rings - Reassembly ...........................
  • Page 6 INTRODUCTION SETTINGS __________________________________________________________________________ 68 Injection pump delivery setting ............................68 Settings ..................................... 68 Stop setting ..................................68 STORAGE ____________________________________________________________________ 100 - 101 External engine protection ............................... 100 Internal engine protection ..............................100 Injection systems protection ............................100 PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE ..............101 MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS ___________________________ 102 - 104 MAIN TORQUE SPECIFICATIONS ........................

  • Page 7: General Remarks And Safety Information

    GENERAL REMARKS AND SAFETY INFORMATION WARRANTY CERTIFICATE - The products manufactured by LOMBARDINI Srl are warranted to be free from conformity defects for a period of 24 months from the date of delivery to the first end user. - For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed within the setting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned period (24 months) is not expired.

  • Page 8: Safety Regulations

    This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the latter case, must only be carried out by persons specifically trained by LOMBARDINI and who work in compliance with the existing documentation.

  • Page 9: General Safety During Operating Phases

    • Only check belt tension when the engine is off. • Only use the eyebolts installed by LOMBARDINI to move the engine. These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should be used.

  • Page 10: Technical Information

    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 11 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) Extra fuel control level sticking Oil level too high Oil level low...

  • Page 12: Manufacturer And Motor Identification Data

    Technical information MANUFACTURER AND MOTOR IDENTIFICATION DATA r.p.m. Engine type Serial number Customer code Approval (‘K’ No.) code Name plate for EPA rules applied on rocker- arm cap - 12 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...

  • Page 13: Techinical Specifications

    Technical information TECHINICAL SPECIFICATIONS 11LD 11LD ENGINE TYPE 625-3 626-3 Number of cylinders Bore Stroke Cm³ Displacement 1870 1870 Compression ratio 17:1 17:1 - 20:1 R.P.M. 3000 3000 kW/CV N (80/1269/CEE) ISO 1585 28/38 30,8/42 kW/CV Power kW/HP NB ISO 3046 IFN 26/35,4 28,6/39 kW/CV...

  • Page 14: Performance Diagrams

    PERFORMANCE DIAGRAMS 11 LD 626-3 NR @ 3000 r.p.m. 11 LD 626-3 B2 NR @ 2800 r.p.m. 11 LD 626-3 @ 3000 r.p.m. 11 LD 625-3 @ 3000 r.p.m. - 14 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...
  • Page 15 Important Non-approval by Lombardini for any modifications releases the company from any damages incurred by the engine. Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above. - 15 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...

  • Page 16: Overall Dimensions

    Technical information OVERALL DIMENSIONS DIMENSIONI mm - MESURES mm - DIMENSION mm - EINBAUMAßE mm - DIMENSIONE mm - DIMEN0ÇÕES (mm) Note : Dimensions shown in mm - 16 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...

  • Page 17: Maintenance- Recommended Oil Type - Refilling

    MAINTENANCE - PRESCRIBED LUBRICANT - REFILLING ROUTINE ENGINE MAINTENANCE Important Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system EXTRAORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING Engine oilreplacement. Oil filter replacement. HOURS ORDINARY MAINTENANCE FREQUENCY x HOURS...

  • Page 18: Lubricant

    Maintenance - Prescribed lubricant - Refilling LUBRICANT SAE Classification In the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 into account.

  • Page 19: Api / Mil Sequences

    Maintenance - Prescribed lubricant - Refilling API / MIL Sequences PETROL DIESEL 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9...

  • Page 20: Fuel Specifications

    The only Aviation fuels that may be used in this engine are: JP5, JP4, JP8 and JET-A if 5% oil is added. For more information on Aviation fuels and Biofuels (RME, RSME) please contact the Lombardini applications department. Capacities standard fuel tank As for filters, tanks and special crankcases please refer to LOMBARDINI instructions.
  • Page 21 .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 22: Recommendations For Disassembling And Assembling

    – Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and operating instructions. – Always use original LOMBARDINI spare parts for proper repair operations. – The operator must wash, clean and dry components and assemblies before installing them.

  • Page 23: Disassembly / Reassembly

    Disassembly / Reassembly Oil-bath air cleaner Danger – Attention Do not blow the paper filter element with compressed air to clean. Caution – Warning Check gaskets and replace as necessary. Check that flange welds are free of defective spots. When reassembling, tighten the fastening nuts of the air filter to the intake manifold to 25 Nm.

  • Page 24: Belt Tension Adjustment

    Disassembly / Reassembly Intake manifold Before reassembling the manifold check the levelness of the flanges. Always replace the seals between the manifold and the intake pipes. Tighten the nuts gradually to 25 Nm. Note: In case of low temperature starting we can supply a manifold with provision for a glow plug for air preheating.

  • Page 25: Air Shroud And Baffles - Disassembly

    Disassembly / Reassembly Blower belt alternator - Reassembly The half-pulley fastening nuts must be tightened using the torque wrench to a final torque of 10 Nm. Again during this phase the nut must be in position A when tightened as in fig. 7 – page 22. Tension check A 4 Kg load located halfway between the pulleys should cause the belt to bend 5 ÷...

  • Page 26: Blower Assembly Components With 14 A Alternator

    Disassembly / Reassembly Blower assembly components with 14 A alternator 1 Housing 2 14 A alternator 3 Key 4 Ball bearing 5 Washer 6 Nut 7 Shaft 8 Bolt 9 Fan 10 14 A alternator bell 11 Spacer Blower assembly components with 21 A alternator 1 Housing 2 21 A alternator 3 Key...

  • Page 27: Blower Control Pulley Diameter

    Disassembly / Reassembly Crankshaft pulley Remove the pulley using extractor serial no. 1460.200. Components: 1 Left-handed bolt 2 Washer 3 Blower control pulley Note: It is only possible to check crankshaft axial clearance after tightening the pulley. Blower control pulley diameter There are three pulleys with different diameters A which take account of engine settings: A = 142 mm...

  • Page 28: Valve / Rocker Arm Clearance

    Disassembly / Reassembly Tank Danger – Attention Do not smoke or use naked flames during the demounting operations as these could cause explosions or fire outbreaks. Fuel fumes are highly toxic. Only carry out the operations outdoors or in a well ventilated place. Keep your face well away from the filler cap or you could inhale harmful fumes.

  • Page 29: Compression Release

    Disassembly / Reassembly Compression release (optional) Bring piston to top dead center on the compressìon stroke. Unscrew rocker arm cover side plug and measure clearance A should be 0,30 ÷ 0,40 mm. Rocker arm assembly Components: 1 Rocker arm axle lubrication hole 2 Lubrication tube Ref.
  • Page 30 Disassembly / Reassembly Unscrew the screw fastening the clamp of the high-pressure pipe using a 4 mm hexagon screwdriver. Remove the forked bracket fixing the injector to the cylinder head using a 5 mm hexagon screwdriver (see photo 29 - 30). These operations are necessary when checking injector calibration or when replacing it.

  • Page 31: Valves

    Disassembly / Reassembly The high-pressure pipe union must be tightened to the injector union to 20 ÷ 25 Nm using a torque wrench. Injector protrusion It is only possible to check injector protrusion with the cylinder head disassembled. The end of the nozzle must be 3 ÷ 3,5 mm with respect to the head surface A.

  • Page 32: Valve Guides And Cylinder Head Housings

    Disassembly / Reassembly Valve stem sealing rings - Reassembly Lubricate the inside of the sealing ring with Molikote BR2 Plus and insert them all the way onto the guides using tool 1460 – 108. To prevent deformation of the sealing ring 1 as it is inserted onto the valve guide 2 insert it onto tool 3.

  • Page 33: Valve Guide Insertion

    Disassembly / Reassembly Valve guide insertion Heat cylinder head up to 160 ÷ 180°C. Thread guides considering the A e B distances from the head plane. Ref. Dimensions (mm) ÷ ÷ Note: If the guides are supplied with the housing for the lock ring C, insert the ring, then drive the guides until the lock ring is stopped without worrying about A and B.

  • Page 34: Checks And Cyiinder Roughness

    Disassembly / Reassembly Pushrod tube spring fitting Components: 1 Spring 2 Tool Part No 1460-009 3 Rocker arm lubrication tube 4 Gasket 5 Pushrod tube 6 Gasket To mount the spring 1 on the tappet rod protection pipe 5 insert it into the tool 2 with the help of a vice.

  • Page 35: Metal Snap Rings - End Gaps

    Disassembly / Reassembly Piston weight Weigh pistons when replacing them in order to avoid unbalance. The difference in weight should not exceed 6 g. Metal snap rings - End gaps Insert the snap rings in the lower part of the cylinder, then measure the distance between the tips.

  • Page 36: Connecting Rod

    Disassembly / Reassembly Piston - Refitting Caution – Warning Lubricate the following parts with oil before mounting: the piston pin, the piston, the cylinder and the big-end bearing 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.

  • Page 37: Connecting Rod Alignment

    Disassembly / Reassembly Connecting rod small end bearing and pin Dimensions Ref. Limit value Clearance (mm) (C - D) (C - D) (mm) (mm) ÷ ÷ ÷ ÷ * with driven and machined bearing. When refitting the bearing of the connecting rod small end, as you drive in, make sure that the lubrication hole on the connecting rod coincides with the hole on the bearing.

  • Page 38: Camshaft Gear

    Disassembly / Reassembly 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 Nm. See Page 42 for timing. Oil pump gear Remove nut 1 and washer 2.

  • Page 39: Center Main Bearing Support, Locating Bolts

    Disassembly / Reassembly 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 25 Nm. See Page 40 for dimensions.

  • Page 40: Checking Main Journals And Crank Pins

    Disassembly / Reassembly Crankshaft lubrication ducts Important During repair operations, when using compressed air, wear eye protection. Remove the caps, clean ducts A, B and C using a drill bit with the same diameter and blow with compressed air. After cleaning, replace the new caps in their seats and make sure they are sealed.

  • Page 41: Clearance Between Main Journals/Crank Pins And Connecting Rod Bearings

    Disassembly / Reassembly Diameter of main bearings Use an inside micrometer to measure the inside. Main bearing and connecting rod big end bearing inside diameter Dimensions (mm) Ref. ÷ ÷ ÷ ÷ The above dimensions refer to driven in or tightened bearings. Note: Both main bearings and connecting rod big end bearings are available with inside diameter size measuring 0,25 and 0,50 less than the standard version.

  • Page 42: Camshaft

    Disassembly / Reassembly Main bearing housings Ref. Dimensions (mm) ÷ ÷ ÷ ÷ Crankshaft end play Dimensions (mm) Ref. ÷ ÷ Check crankshaft end play after refitting the crankshaft pulley and tightening its nut at 300 Nm; the crankshaft end play is equal to 0,20 ÷...

  • Page 43: Camshaft End Play

    Disassembly / Reassembly Dimensions of camshaft journals and housings Dimensions Ref. (mm) Limit Clearance Ref. value ÷ (mm) (mm) ÷ ÷ ÷ ÷ ÷ ÷ ÷ Checking intake/exhaust cam height Use an outside micrometer gauge to measure camshaft lobe height. Intake/exhaust cam height A1= 1st cylinder intake cam S1 = 1st cylinder exhaust cam...

  • Page 44: Valve Timing Check

    Disassembly / Reassembly Camshaft timing Fit camshaft gear by making timing mark 2 coincide with timing marks 1. Tighten camshaft bolt at 250 Nm. Valve timing without considering timing marks Locate piston 1 (on flywheeI side) at the top dead center. Position two small cylinders A of the same height onto the tappets.
  • Page 45 Disassembly / Reassembly Legend S = piston at top dead center I = piston at bottom dead center α = α = α = intake valve open α = α = β = β = β = β = β = intake valve closed γ...

  • Page 46: Hydraulic Pump 3Rd P.t.o., Group 2

    Disassembly / Reassembly Hydraulic pump p.t.o. group 1 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...

  • Page 47: Mechanical Speed Governor

    Disassembly / Reassembly Mechanical speed governor The governor (with centrifugal 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 9 Key 2 Stop ring...

  • Page 48: Mechanical Speed Governor Components For Special Generating Sets

    Disassembly / Reassembly 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.

  • Page 49: Lubrication System

    LUBRICATION SYSTEM Danger – Attention 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 50: Oil Filter Cartridge

    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 ÷...

  • Page 51: Oil Pressure Curve At Full Speed

    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.

  • Page 52: Fuel System

    FUEL SYSTEM Fuel feeding/injection circuit Components: 1 Tank 2 Filter 3 Fuel feeding tube 4 Fuel feeding pump 5 Injection pump 6 Injection line 7 Injector 8 Injector leak off line and self bleeding system 9 Bowl Fuel filter Components: 1 Bleeder 2 Cap 3 Seal element...

  • Page 53: Injection Pump Only For Epa Engines

    Fuel system 19 Threaded plug 20 Adjustment rod locking device 21 Area in which the pump delivery class is stamped In this engine the injection pumps are preset by the manufacturer who supplies them stamped with alphabetical classes (A, Ax, B, Bx, C, Cx or D) for standard and 97/68 EC engines, while for EPA2 engines the classes are numerical (5, 6, 7, 8, 9, 10, 11, 12, 13 and 14).

  • Page 54: How To Check Injection Pump Delivery Valve Sealing

    Fuel system Plunger Ref. Dimensions (mm) ÷ ÷ ÷ ÷ How to check plunger and barrel for internal leakage This operation is only diagnostic since pressure changes depend on the pumping speed. Connect the delivery union with a 600 bar pressure gauge with safety valve.

  • Page 55: Test Data For Injection Pump Delivery At The Test Bench For Standard And 97 / 68 Ce Engines

    Fuel system Test data for injection pump delivery at the test bench for standard and 97 / 68 CE engines 1 Rack rod lock to be removed after pump fitting to the engine 2 Injection pump axis Test data: Rod stroke from Control rod Delivery Camshaft...

  • Page 56: Injection Pump Replacement

    Fuel system Injection pump replacement 1 Rack rod lock 2 Reference mark pump class A = 82.80 mm C = Injection cam radius D = Injection pump support Important Whe replacing this type of injection pump check that the new one has a same reference mark as the old one.

  • Page 57: Size P Injector

    Fuel system Size S nozzle Features: Hole number and diameter ..4x0,28 mm Jet angles ......... 160° Needle valve elevation ..... 0,20 ÷ 0,22 mm Hole length ....... 0,7 mm Sump diameter and length ..1x1,5 mm Clean nozzle tip with a brass brush. Check that holes are not obstructed using a mandrel with steel wìre with 0,28 mm diam.

  • Page 58: Injector Setting

    Fuel system Injector setting Connect injector to high pression pump and check that setting pressure is 210 ÷ 220 bar for size S injector and 245 ÷ 255 bar for size P injector. To change injector setting replace the shim over the spring. When replacing the spring, setting should be performed at a 10 bar greater pressure to allow for bedding during operation.
  • Page 59 Fuel system Assemble tool serial no. 1460 - 266 made up of lever 2 serial no. 1460 - 275, of a dial indicator 1 serial no. 1460 - 274 inserted in a dial indicator holder serial no. 1460 - 270. The function of lever 2 is to reduce the effort required against the resistance of the spring when the valve lowers and comes into contact with the piston crown near the top dead centre.
  • Page 60 Fuel system Components: 1 Fuel supply pipe from the tank 2 High-pressure pipe 3 Capillary tester 4 Valve-lowering lever with dial indicator showing piston movement Rotate the crankshaft clockwise on the timing belt side and position the relevant cylinder piston at top dead centre. Press the lever to bring the valve into contact with the piston crown.
  • Page 61 Fuel system The capillary tube shows when the fuel is flowing out, thanks to its small transparent slot. After finding the delivery start point (when fuel stops flowing from the capillary), press the lever and use the dial indicator to check how many millimetres the piston has moved from the top dead centre.

  • Page 62: Electric System

    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;...

  • Page 63: 12 V, 21 A Alternator

    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.The rotating permanent magnet inductor is located in the fan spindle.

  • Page 64: Checking For Cable Continuity

    Electric system Magnetization checking tool (Part No. 7000-9727-001) Components: 1 Casing 2 Slider 3 Casing reference line 4 Slider reference line Rest the tool end horizontally onto the magnetic poles. Hold sfider so that its reference line coincides with the casing reference line.

  • Page 65: How To Check Voltage Regulator For Proper Operation

    Electric system How to check voltage regulator for proper operation Check that connections correspond to the layout. Disconnect the terminal from the battery positive poie. Connect a d.c. voltmeter between the two battery poles. Fit an ammeter between the positive pole and the corresponding cable 1 terminal.

  • Page 66: 33 A Bosch G1 Alternator Battery Charger Curve

    Electric system Alternator type Bosch G1 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. RH direction of rotation.

  • Page 67: Characteristic Curves For Starting Motor Type Bosch Jf (R) 12 V

    Electric system Starting motor type Bosch JF (R) 12 V, class 2.5 RH direction of rotation A = 23 ÷ 24 mm B = Ring gear plane C = Flange plane Vorsicht - Warnung The flywheel should not project from ring gear plane B. Note: Apply to Bosch Service Centers for any type of repair.

  • Page 68: Settings

    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.;...
  • Page 69 NOTES .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 70 NOTES .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 71: Engine

    APPENDIX FOR ENGINE WITH ADVANCE VARIATOR 11 LD 625-3 / 626-3 ENGINE with advance variator - 71 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...

  • Page 72: Advance Variator Operating Principle

    ADVANCE VARIATOR OPERATING PRINCIPLE INJECTION TIMING DEVICE OPERATION In order to meet EPA tier 2 limits, the engine 11LD 625-3 / 626-3 has been equipped with a variable injection timing device. The system consists of an electro–hydraulic actuated mechanical device, that allows changing the injection timing by rotating the camshaft against its driving gear.
  • Page 73 Advance variator operating principle Fig. A_2. Injection timing device: during actuation of an advance (max value 4.5°). The oil (yellow) goes into the system and moves the plunger (blue) that activates the camshaft anticlockwise. Fig. A_3. Injection timing device: moving from actuation of an advance to resting position. The oil (yellow) goes out and releases the spring to move the plunger (blue), which in turn activates the camshaft clockwise.
  • Page 74 DISASSEMBLY/REASSEMBLY Solenoid valve assembly diagram COMPONENTS TABLE Cylindrical 1/4" gas union Union bolt M 12x1.5 Connection screw M 14x1.5 Nut M 5 Copper seal 13.5x19x2 Seal Seal 14x19x1.5 Adjustable union d. 12 Screw TCEI M 5x65 Pressure switch Spacer Bolt for two adjustable unions M 12x1.5 OilSistem solenoid valve block Variator lubrication jet Pressure switch union...
  • Page 75 Disassembly / Reassembly After loosening the screws, remove the alternator belt guard. Overall view of variator speed sensor and hydraulic circuit. Components: 1 Pressure switch 2 Pressure switch union 3 Solenoid valve block oil filter pipe Components: 1 Variator oil loading pipe 2 Variator oil bypass pipe 3 Variator oil draining pipe 4 Solenoid valve block oil filter pipe...
  • Page 76 Disassembly / Reassembly Components: 1 Variator load solenoid valve 2 Variator unload solenoid valve Important Do not invert cables during reassembly. To remove connectors, press the stop tabs and draw upwards. Refer to page 78 to identify the pipes. Loosen the union screw of pipes 17 and 19. A_10 On the opposite end of the block of pipe 19 is the variator lubrication jet attached to the pipe by a click clamp.
  • Page 77 Disassembly / Reassembly Variator lubrication jet complete with banjo union. A_12 Unscrew the union of variator oil discharge pipe 20. A_13 To remove the solenoid valve block from the support bracket, unscrew the two screws M 5. A_14 View of the unassembled solenoid valve block with two spacers between the block and the bracket.
  • Page 78 Disassembly / Reassembly Speed sensor and variator assembly diagram COMPONENTS TABLE Oil seal ring 20x30x7 Washer 6x12xSp1 Screw TCEI M 5x10 Screw TCEI UNI 5931 M 6x10 Screw TCEI UNI 5931 M 6x14 Lid seal (rev. counter) Oil seal support ring Variator oil bush Special tab for variator Advance variator device...
  • Page 79 Disassembly / Reassembly To remove the speed sensor cable connector press the spring as shown in figures A_16 and A_17 and draw upwards. A_16 A_17 Loosen the two screws M8 to disassemble the solenoid valve support bracket. A_18 Loosen screw M6 to remove the speed sensor from its support. A_19 - 79 - 11 LD Workshop Manual_cod.
  • Page 80 Disassembly / Reassembly Draw he speed sensor outwards, being careful not to damage the rubber seal ring. A_20 View of speed sensor housing. A_21 Blower belt alternator - Disassembly See page 22 - 23. A_22 A_23 - 80 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...
  • Page 81 Disassembly / Reassembly Blower control pulley - Disassembly See page 24 - 25. A_24 A_25 After loosening the screws, remove the timing cover. A_26 Pay attention to the oil seal support ring when disassembling the timing cover. A_27 - 81 - 11 LD Workshop Manual_cod.
  • Page 82 Disassembly / Reassembly Remove the timing cover seal. A_28 Unscrew screws M10 on the variator to the camshaft. A_29 Remove screw M10. A_30 Remove the variator. The figure shows the camshaft pin for correct variator timing. A Cylindrical pin Ø 5x16 B Pin housing A_31 - 82 -...
  • Page 83 Disassembly / Reassembly View of the camshaft ends with pin inserted. A_32 Remove the shoulder housing of the idle gear that drives the speed governor. A_33 - 83 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...
  • Page 84 Disassembly / Reassembly After refitting the housing tighten the screws to 20 Nm using a torque wrench. A_34 Remove the distribution control gear from the crankshaft. A_35 Assemble the variator onto the end of the camshaft taking care to properly insert the timing pin into place and ensuring that the variator comes into contact with the surface of the speed governor idle gear.
  • Page 85 Disassembly / Reassembly Replace the timing cover, placing a new seal and lining up with the two centring pins. A_38 Tighten the screws to a 25 Nm torque. A_39 Refit the oil feed bushing to the variator, placing the oil seal support ring in between.
  • Page 86 Disassembly / Reassembly Attach the sensor using screw M6 to a torque of 8 Nm. A_42 Reassemble the blower control pulley onto the crankshaft. Tighten the left-handed fastening bolts to torque of 300 Nm. A_43 Replace and check the belt tension (see page 22-23). A_44 Replace the variator circuit oil pipes.
  • Page 87 Disassembly / Reassembly Insert the solenoid valve connectors following the references (IN and OUT) shown on the cables and on the solenoid valve block. A_46 Replace the built guard and tighten to 15 Nm. A_47 - 87 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...
  • Page 88 Disassembly / Reassembly Angular position sensor and AC pump assembly diagram - 88 - 11 LD Workshop Manual_cod. 1.5302.296_5° ed_ rev. 04...

  • Page 89: Disassembly / Reassembly

    Disassembly / Reassembly COMPONENTS TABLE Screw TCEI M 8x18 Stud bolt M8x20 Fuel supply pump seal Silicone O-ring Sensor pump connection rod Snap pin 2x10 AC pump and angular position sensor cover Conical screw STEI M 10x1.5 Sensor control lever Self-locking flanged hex nut Connecting pin between rod and sensor Copper washer...
  • Page 90 Disassembly / Reassembly Phase sensor assembly diagram Adjust with 0.2 mm shims COMPONENTS TABLE 1 Silicone O-ring 2 Washer 6x12xSp1 3 Screw TCEI UNI 5931 M 6x10 4 Screw TCEI UNI 5931 M 6x25 5 Speed and phase sensors 6 Phase sensor air gap adjustment shim 7 Phase sensor support - 90 - 11 LD Workshop Manual_cod.
  • Page 91 Disassembly / Reassembly To assemble the phase sensor connector press the locking spring. A_48 Remove the connector from the sensor. A_49 Loosen screw M6. When refitting, tighten to 8 Nm. A_50 Remove the sensor from the support taking care not to damage the O-ring.
  • Page 92 Disassembly / Reassembly Components: 1 Dial indicator 2 Support for dial indicator 3 Sensor control gauge measurement: 30,24 ÷ 30,26 mm 4 Control master measurement: 30,24 ÷ 30,26 mm for sensor gauge If replacing the phase sensor, check the length of the sensor pin using the tool in figure A_52.
  • Page 93 Disassembly / Reassembly Resetting the dial indicator Components: 1 Dial indicator 2 Support for dial indicator 30.24 ÷ 30.26 mm 3 Camshaft sensor support surface control gauge measurement: 30,24 ÷ 30,26 mm 4 Resetting master measure: 30,24 ÷ 30,26 mm for gauge 5 Resetting reference base If replacing the sensor, camshaft or engine block via the tool see figure 56.
  • Page 94 Disassembly / Reassembly Remove the connector from the position sensor on the injection pump control rod. A_60 A_61 Unscrew the two screws to disassemble the fuel pump; when refitting, tighten the flathead screws, the nuts and hexagonal-head screws to 25 Nm. A_62 When reassembling, replace the sealing gasket.
  • Page 95 Disassembly / Reassembly Remove the conical inspection plug. A_64 Unscrew the two screws to disassemble the injection pump rod position sensor. A_65 Remove the three flanged nuts and the flathead screw. A_66 Unscrew the last screw (flathead) after rotating the sensor anticlockwise.
  • Page 96 Disassembly / Reassembly Remove the cover supporting the sensor and the fuel pump. A_68 Rotate the position sensor shaft to direct the fork on the side opposite the connector. A_69 Insert the fork into the slot in the support. Rotate the sensor body 180°, keeping the fork in the position shown in figure A _70.
  • Page 97 Disassembly / Reassembly Set the cover against the crankcase so that the injection pump rod drive pin 1 is inserted between the two prongs of the fork 2. A_72 Look through the upper inspection hole on the cover to make sure that the pin 1 is correctly inserted into the fork 2.
  • Page 98 Disassembly / Reassembly Refit the fuel pump after replacing the seal; tighten the screws to 25 A_76 Correct assembly position of the control unit that runs the engine variator. A_77 Example of adhesive plate on the control panel 1 Engine type 2 Control panel serial number 3 Version number (form K) 4 SN plus engine serial number plus date...
  • Page 99 NOTES .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 100: Storage

    STORAGE When the engines are not used for more than 3 months, they must be protected by the measures described below: STORAGE External engine protection: - Start the engine and heat it. - Remove the drain plug and let the oil flow completely. - Replace the oil filter with a new one (screw manually the new filter).

  • Page 101: Procedures To Be Carried Out Before Start The Engine

    Storage PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE - Remove all protections and coverings. - Remove the rust preventer from the external part of the engine by means of adequate products (solvent or degreaser). - Tension the blower timing belt. - Disassemble the injectors and introduce, by means of a bowl, motor oil on the piston crown ( no more than 2 cc for every cylinder).

  • Page 102: Main Torque Specifications And Use Of Sealants

    MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS MAIN TORQUE SPECIFICATIONS Diameter and pitch Torque Sealants COMPONENT ( mm ) Tank bracket vibration dampers Loctite 270 8x1,25 Connecting rod Injection pump delivery valve union 18x1,5 Bell flywheel side 10x1,5 Central support collar 8x1,25 Intake manifold 8x1,25...

  • Page 103: Use Of Sealants

    MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS MAIN TORQUE SPECIFICATIONS Diameter and pitch Torque COMPONENT Sealants ( mm ) Oil sump Loctite 270 8x1,25 Belt guard 16x1,5 Blower crankshaft pulley 12x1,5 Fan pulley 14x1,5 Fuel filter union 10x1 Fuel pump union 14x1,5 Radiator union 20-25...

  • Page 104: Table Of Tightening Torques For Standard Screws (Coarse Thread)

    MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS 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 105: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS DESCRIPTION Part No. Overall: 1460 - 266 1 Valve control lowering tool static injection advance 1460 - 275 2 Dial indicator support 1460 - 270 3 Dial indicator 1460 - 274 High-pressure pump static advance control. 1460 - 273 Injection pump static injection advance tester 1460 - 024...
  • Page 106 42100 Reggio Emilia – Italia - ITALY Via Cav. del Lavoro Adelmo Lombardini, 2 - Cas. Post. 1074 Tel. (+39) 0522 3891 - Telex 530003 Motlom I – Telegr.: Lombarmotor R.E.A. 227083 - Reg. Impr. RE 10875 Cod. fiscale e Partita IVA 01829970357 - CEE Code IT 01829970357 E-MAIL: atl@lombardini.it...

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