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Summary of Contents for Lombardini LGA 280 OHC
- Page 1 WORK SHOP MANUAL LGA 280-340 OHC Series engines,code 1-5302- 528 LGA 280 OHC LGA 340 OHC 1st Edition SERVICE COMPILER TECO/ATI MODEL N° DATE OF ISSUE REG. CODE DATE ENDORSED REVISION 1-5302-528 50805 31.07.2001 31.07.2001...
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Page 2: General Service Manual Notes
However, development on the Lombardini series is continuos. Therefore, the information within this manual is subject to change without notice and without obligation. The information contained within this service manual is the sole property of Lombardini. As such, no reproduction or replication in whole or part is allowed without the express written permission of Lombardini. -
Page 3: Warranty Certificate
The above warranty certificate will be in effect starting July 1, 1993 and cancels/replaces any and all explicit or implicit warranty policies on the part of Lombardini. The above warranty conditions can from this date forward be modified only in writing. - Page 4 INDEX This manual gives the main instructions on how to repair LOMBARDINI LGA 280-340 OHC gasoline-fuelled engines, updated as of 31.07.2001. INDEX TROUBLE SHOOTING Page WARNING SIGNS - SAFETY INSTRUCTIONS " ENGINE IDENTIFICATION " TECHNICAL FEATURES " CHARACTERISTICS " OVERALL DIMENSION "...
- Page 5 INDEX Timing pulley assembling ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
- Page 6 NOTE REG. CODE MODEL N° COMPILER TECO/ATL DATE OF ISSUE DATE ENDORSED REVISION 1-5302-528 50805 31.07.2001 31.07.2001...
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Page 7: Troubleshooting
TROUBLE SHOOTING TROUBLE SHOOTING Listed below are some of the possible causes of engine operating defects. Carry out simple tests before proceeding with disassembly operations or making substitutions. TROUBLE POSSIBLE CAUSES • Tank plug breather clogged • • • Tap clogged •... -
Page 8: Warning Signs - Safety Instructions
SAFETY INSTRUCTIONS • Lombardini engines are built to provide safe and longlasting performances, but in order to obtain these results it is essential that the maintenance requirements described in the manual are observed along with the following safety recommendations. - Page 9 Check the belt tension only when the engine is turned off. • In order to move the engine use exclusively the eyebolts fitted for this purpose by Lombardini. These lifting points are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer.
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Page 10: Engine Identification Number
ENGINE IDENTIFICATION LOMBARDINI ENGINE TYPE SWEPT VOLUME CUSTOMER CODE ENGINE IDENTIFICATION NUMBER REG. CODE MODEL N° COMPILER TECO/ATL DATE OF ISSUE DATE ENDORSED REVISION 1-5302-528 50805 31.07.2001 31.07.2001... -
Page 11: Technical Features
TECHNICAL FEATURES TECHNICAL FEATURES LGA 280-340 OHC ENGINE TYPE LGA 280 LGA 340 Cylinder Bore Stroke Swept volume 8.5 - 1 Compression ratio 8.5 - 1 3000 - 3800 Standard R.P.M. 3000 - 3800 7.4/10 - 8.1/11 N DIN 70020 kW/HP 6.0/8.1 - 6.6-9.0 6.9/9.4 - 7.7/10.4... -
Page 12: Characteristics Power, Torque And Specific Fuel Consumption Curves
Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 20°C. Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above. COMPILER TECO/ATL REG. -
Page 13: Overall Dimensions
OVERALL DIMENSIONS - OPTIONAL P.T.O. AND FLANGES OVERALL DIMENSIONS POWER TAKEOFFS AND SPECIAL FLANGING Note: The values are given in mm COMPILER TECO/ATL MODEL N° DATE OF ISSUE REG. CODE DATE ENDORSED REVISION 1-5302-528 50805 31.07.2001 31.07.2001... -
Page 14: Maintenance
MAINTENANCE - RECOMMENDED OIL - FUELS AND LUBRICANTS Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system MAINTENANCE INTERVAL (HOURS) OPERATION COMPONENT 10 20 25 50 100 300 500 1000 2500 •... -
Page 15: Recommended Oil
MAINTENANCE - RECOMMENDED OIL - 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. The lubrication oil influences the performances and life of the engine in an incredible way. - Page 16 NOTE REG. CODE MODEL N° COMPILER TECO/ATL DATE OF ISSUE DATE ENDORSED REVISION 1-5302-528 50805 31.07.2001 31.07.2001...
- Page 17 Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and During repair operations, when using operating instructions. Always use original LOMBARDINI spare parts compressed air, wear eye protection. for repair operations. GENERAL INFORMATION FOR CORRECT REPAIRS - In order to work quickly and safely, strictly observe the instructions in the manual and the following general rules: - Lock the machine in position before disassembling the engine.
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Page 18: Cylinder Head
VIII DISASSEMBLY/REASSEMBLY DISASSEMBLY OF CAMSHAFT - TAPPETS VALVES Remove the tappet cover, rotate the camshaft so that the cams face upward, remove the side support, extract the camshaft (fig.2). Remove the tappets and, with tool CODE 1460.113 on page 42 , remove the valve cotters;... - Page 19 If the general condition is good, reset the face track P in the seat with a grinding of: 90' exhaust - 90' intake for engine LGA 280 OHC 90' exhaust - 121' intake for engine LGA 340 OHC Check the guides, valves, seats after assembly.
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Page 20: Valve Guides
DISASSEMBLY/REASSEMBLY VIII Valves and valve-guides gap NOMINAL LIMIT C - A 0.028 - 0.070 0.14 D - B 0.045 - 0.080 0.14 VALVE GUIDES Check that the valve guides are not scored, show signs of seizing or carbon deposits. Cheeking of the valve guides wear (fig. 10) can be carried out using a plug go-no-go gauge with pitch code 1460.103 on page 42. -
Page 21: Valve Seats
88° exhaust- 120° intake for engine LGA 340 OHC N.B.: Valve seats with angles of 90° (exhaust) and 120° (intake) will be used in the LGA 280 OHC too. Please check technical informative sheet for introdution date. Following prolonged engine operation, the hammering of the valves on the seats, at high temperatures, hardens the track P (fig.8) making manual grinding impossible. -
Page 22: Valve Springs
DISASSEMBLY/REASSEMBLY VIII VALVE SPRINGS Check the general conditions of the valve springs, replacing them if they are damaged or their original characteristics are compromised. Check that the lengths under load corresponds to the values indicated in fig. lf these values are not achieved, change the spring. TAPPETS Check the general conditions, if the side surfaces of the cylinders are scored, replace the tappets... -
Page 23: Connecting Rod
(fig.21). The skirt wear should not exceed 0.05 mm. Engine type Nominal diameter of piston LGA 280 OHC 73.945 - 73.955 LGA 340 OHC 81.945 - 81.955 lf the clearance between the cylinder/piston exceeds 0.23 mm, rebore the cylinder and fit new piston and rings (see tab. - Page 24 (fig. 22). This distance should be: Engine type Nominal end Initial Max limit LGA 280 OHC gap mm end gap mm end gap mm limit compress. ring 0.20 0.40...
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Page 25: Drive Shaft
DISASSEMBLY/REASSEMBLY VIII DRIVE SHAFT Check that the main journal and crank pin are not scored and show no signs of seizing. Slight scores or notches can be taken up using a fine file and finished with the same type of emery cloth. Check that the cones, keys and end threads are not deformed and free of notches. -
Page 26: Speed Governor
DISASSEMBLY/REASSEMBLY VIII BALANCING SHAFT (optional) (fig. 27b) This shaft is monted on two ball bearings, one in the crankcase, the other in the timing cover. For assembling the balancing shaft, position the crankshaft as in fig 27a in order that he reference marks of the balancing shaft gear are in corrispondence with the ones of the crankshaft gear. -
Page 27: Recoil Starter
DISASSEMBLY/REASSEMBLY VIII RECOIL STARTER This is a manual starting device that, with the use of a spring, rewinds the rope on a disk after starting. The starter components are listed below: 1) Dogs guide housing 5) Rope return spring 2) Spring 6) Rope 3) Starter dogs 7) Handle... -
Page 28: Piston And Connecting Rods
DISASSEMBLY/REASSEMBLY VIII OIL WATCH DEVICE (optional) This is a protection system that activates by switching off the engine when the oil drops below the required level during operation. The OIL WATCH device activates in the following cases: 1) insufficient oil; 2) low oil level. -
Page 29: Timing Cover
VIII DISASSEMBLY/REASSEMBLY SPEED GOVERNOR Fit the governor gear on the pin attached to the timing cover and lock it in position with the circlip, then fit the cap and the counter weight. The two counter weights are fixed to the governor gear by means of two holed rivets;... - Page 30 DISASSEMBLY/REASSEMBLY VIII CAMSHAFT ASSEMBLY AND VALVE CLEARANCE ADJUSTMENT Oil the tappet seats and insert the tappets into the housing. Fit the camshaft and fix the side support in position. Fit the belt tensioner support casing and the camshaft pulley, tighten the pulley retaining screw to a 11.8 Nm - 1.2 Kgm torque value.
- Page 31 DISASSEMBLY/REASSEMBLY VIII TIMING ADJUSTEMENT AND ASSEMBLING OF THE TOOTHED BELT In order to fit the toothed belt and adjust the timing, proceed as follows: 1) turn the timing pulley until the mark on the pulley coincides with the mark on the crankcase (fig.41-b) (otherwise use tool code 1460.115 on page 42 which should be inserted into the plug hole in order to find the TDC);...
- Page 32 DISASSEMBLY/REASSEMBLY VIII Carburetor Details 1) throttle rod 2) air adjustment screw 3) spring 4) throttle 5) spring 6) screw 7) main jet 8) loat 9) drain valve 10) float chamber 11) gasket 12) floating pin 13) needle valve 14) idle jet 15) choke plate 16) choke plate command rod CARBURETOR CHARACTERISTICS...
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Page 33: Electronic Ignition
ELECTRONIC IGNITION ELECTRONIC IGNITION Inductive discharge electronic ignition with variable spark advance (fig. 45); The spark advance prevents any type of kik-back during starting, making this operation simple and safe both for the operator and the mechanical parts. SPARK PLUG Clean the electrodes with a metal brush and compressed air, cheek that the gap between electrodes (fig. -
Page 34: System Checks
ELECTRIC STARTING Electric starting 1) Battery 5) Remote control switch 2) Rectifier 6) Switch with key 3) Alternator 7) Ignition coil 4) Starting motor 8) Indicator light Electrical start system standard Alternator 12 v - 70w Rectifier IR type 26 MB 20A Starting motor SYCE PN1 12V - 0,15 KW Remote control switch EFEL 12V - 75A Battery 30 Ah... -
Page 35: Starter Motor
The starter motor is of the SYCE PN1 12 v - 0.15 KW type. BATTERY The battery (not supplied by LOMBARDINI) must provide a voltage of 12 V and a capacity of not less than 30 Ah. N.B.: The battery capacity functions according to ambient temperature, therefore batteries with greater capacities are required for particularly low temperatures. -
Page 36: Engine Assembly
ADJUSTMENTS ENGINE ASSEMBLY BREATHER VALVE: clean the breather valve with petrol and check the condition; before assembly check that the rubber gasket is not damaged. FAN COWL AND COOLING AIR DUCTS: check that are not dam- aged and tighten the screws at a torque of: 9.8 Nm - 1 Kgm. INTAKE MANIFOLD AND CARBURETOR: fit the intake manifold on the engine and, after having positioned the gaskets, fit the carburetor. -
Page 37: Electric Starting
ADJUSTMENTS STARTING WITH THE RECOIL STARTER After having carried out the operations noted above, pull the rope sharply (fig. 57) and allow the engine to turn over for a few seconds before opening the starter. ELECTRIC STARTING Before turning the starter key, make sure that all connections are in order, especially the rectifier and the battery ground connections. -
Page 38: Preparation For Starting
STORAGE STORAGE TEMPORARY INACTIVITY lf the engine has to remain temporarily unused, it is advised to carry out the following operations: - allow the engine to turn over for ten minutes, drain off the oil from the crankcase when the engine is hot (fig 60); - replace the oil drain plug and fill up with new oil (fig.61) of the type described on page 15;... -
Page 39: Installation - Inclination Limits Of Operation
INSTALLATION - INCLINATION LIMITS OF OPERATION XIII INSTALLATION INCLINATION LIMITS OF OPERATION (fig. 63-64) AXIAL LOAD - RADIAL LOAD AND MAXIMUM OVERHANG The axial thrust in both directions Fa (fig. 65) must not exceed 250 The maximum radial load Fr (fig. 65) for belt transmission is 80 Kg with a maximum overhang (S) of the cylinder axis of 140 mm. -
Page 40: Torque Settings
TORQUE SETTINGS MAIN TORQUE SETTINGS Ref. Bolt size POSITION (fig. N° ) ( mm ) ( Nm ) Cylinder head 38 b - page 29 M 10 39.2 15.7 Connecting rod cap 34 a - page 28 Flywheel 42 - page 31 M 18 x 1.5 137.2 11.8... -
Page 41: Standard Bolt Torque Specifications
TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS DESCRIPTION R ≥ ≥ ≥ ≥ ≥ 800 N/mm² R ≥ ≥ ≥ ≥ ≥ 1000 N/mm² R ≥ ≥ ≥ ≥ ≥ 1200 N/mm2 Diameter per pitch (mm) 4x0.70 0.37 0.52 0.62 5x0.80 0.72 1.01 11.9... -
Page 42: Special Tools
SPECIAL TOOLS SPECIAL TOOLS DESCRIPTION CODE Valve guide check tool 1460.103 Tool for insertion and removal valve guides 1460.104 Flywheel and timing cover puller 1460.119 Oil seal installation cone flywhell side 1460.105 Oil seal installation cone P.T.O. side 1460.106 Belt stretcher tool 1460.107 Valve stem oil seal assembly tool 1460.108... - Page 43 PISTON-CYLINDER OVERSIZE TABLE - CRANKSHAFT JOURNAL AND CONNECTING ROD GRINDING TOLERANCES - CLEARANCES AND ADJUSTMENTS TABLE PISTON- CYLINDER OVERSIZE TABLE Engine Nominal First re-boring Second re-boring Liner diam. Liner diam. Liner diam. +0.02 +0.02 +0.02 LGA 280 74.5 0 74.5 0 LGA 340 82 +0.02 82.5 +0.02...
- Page 44 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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