Lombardini LDW 502 Workshop Manual
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Lombardini LDW 502 Workshop Manual

Focs engine series
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WORKSHOP MANUAL
FOCS Engine Series
cod. 1-5302-351

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  • Page 1 WORKSHOP MANUAL FOCS Engine Series cod. 1-5302-351...
  • Page 3 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 4 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 CUSE/ATLO 1-5302-351 50563 7° 04-90 15.03.2008 - 4 -...

  • Page 5: Table Of Contents

    CHAPTER INDEX This manual contains pertinent information regarding the repair of LOMBARDINI water-cooled, indirect injection Diesel engines type LDW 502-602-903-1204-1204/T e LDW 702-1003-1404: updated March 15 , 2006. CHAPTER INDEX GENERAL REMARKS AND SAFETY INFORMATION ..............Pag. 9 - 11 GENERAL SAFETY DURING OPERATING PHASES ....................
  • Page 6 Crankshaft, check journals and crank ..........................63 Crankshaft, lubrication lines ............................. 63 Cylinder head assembly ..............................57 Cylinder head tightening procedure LDW 1204-1204/T-1404 ..................57 Cylinder head tightening procedure LDW 502-602-702-903-1003 ................. 57 CYLINDER HEAD, removal .............................. 48 Cylinder roughness ................................59 Cylinder, class ................................... 59 CYLINDERS ..................................
  • Page 7 Chapter index Timing belt removal ................................36 Vacuum pump and vacuum pump flange ........................33 Valve / Rocker arm clearance ............................44 Valve guide insertion ................................ 49 Valve guides and valve guide housings ........................... 49 Valve recess and seat sealing width ..........................50 Valve seats and housings - Dimensions ..........................
  • Page 8 Chapter index Setting of injector according to current pump/injector unit ..................... 79 Static injection advance regulation ..........................82 Static injection advance tuning ............................81 TDC (Top Dead Center) references ..........................81 Test head B assembly ..............................82 Tester and special coupling for injection advance control (Old-type injection pump) ........... 81 ELECTRIC SYSTEM ..........................

  • Page 9: 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 10: Safety And Warning Decals

    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 11: 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 12: Trouble Shooting

    TECHNICAL INFORMATION 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. TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation.

  • Page 13: Technical Information

    Technical information TROUBLE POSSIBLE CAUSE High oil level Low oil level Dirty or blocked pressure regulation valve Worn oil pump Air to the oil suction hose Faulty manometer or pressure switch Oil in sump suction hose blocked Oil in sump drainage pipe blocked Faulty spray nozzles (Turbo engines only) Damaged injector Damaged injection pump valve...

  • Page 14: Manufacturer And Engine Identification

    Technical information MANUFACTURER AND ENGINE IDENTIFICATION Engine type Maximum operating speed Engine serial number Number of the customer version (form K) - 14 - FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06...
  • Page 15 Technical information EC-directives certification references punched on the engine plate. Name plate for EPA rules applied on rocker-arm cap. - 15 - FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06...

  • Page 16: Techinical Specifications

    **** **** **** **** **** Combustion sequence 1-3-2 1-3-4-2 1-3-4-2 At NB power LDW 502/602 Referred to NB power Measured at NA power **** Depends on application • At 3600 Rpm •• Measured at NB power LDW 903 LDW 1204/T...
  • Page 17 Technical information ENGINE TYPE 1003 1404 Cylinders N° Bore Stroke 77.6 77.6 77.6 Displacements Cm³ 1028 1372 Compression rate 22,8:1 22,8:1 22,8:1 3600 3600 3600 N 80/1269/CEE-ISO 1585-DIN 70020 12.5(17.0) 19.5(26.5) 26.0(35.2) Maximum power NB ISO 3046 - 1 IFN - DIN 6270 11.7(16) 18(24.5) 24.5(33.3)

  • Page 18: Performance Diagrams

    Mt : Torque at N. a : Range of application for continuous operation. In case of application outside this range please contact LOMBARDINI. The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of 20°C and 1 bar.
  • Page 19 Mt : Torque at N. a : Range of application for continuous operation. In case of application outside this range please contact LOMBARDINI. The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of 20°C and 1 bar.
  • Page 20 Mt : Torque at N. a : Range of application for continuous operation. In case of application outside this range please contact LOMBARDINI. The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of 20°C and 1 bar.

  • Page 21: Overall Dimension

    Technical information OVERALL DIMENSION LDW 502 LDW 602 LDW 903 - 21 - FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06...
  • Page 22 Technical information 1204 1204/T - 22 - FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06...
  • Page 23 Technical information 1003 LDW 1003 with EGR circuit, Gear-box and CVT (Continuous Variable Transmission) 701.7 685.7 350.2 328.7 58.8 215.9 152.9 300.5 176.5 30° 361.8 330.5 236.4 641.8 703.5 1404 - 23 - FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06...

  • Page 24: Maintenance - Recommended Oil Type - Refilling

    MAINTENANCE - RECOMMENDED OIL TYPE - 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. ORDINARY MAINTENANCE AFTER THE FIRST Engine oil replacement. Oil filter replacement. 50 WORKING HOURS ORDINARY MAINTENANCE FREQUENCY x HOURS...

  • Page 25: Acea Regualtions - Acea Sequences

    Maintenance - Recommended oil type - Refilling LUBRICANT SAE Classification n the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken into account. SAE 10W* The first number refers to the viscosity when the engine is SAE 20W* cold (symbol W = winter), while the second considers SAE 30*...

  • Page 26: Prescribed Lubricant

    Maintenance - Recommended oil type - Refilling PRESCRIBED LUBRICANT API SJ/CF AGIP SINT 2000 specifications ACEA A3-96 B3-96 5W40 MIL - L-46152 D/E 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 27: Coolant

    The only Aviatin 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. - 27 -...
  • Page 28 – 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 29: Disassembly / Reassembly

    2 .25" Tab connection Note: The indicator is calibrated at 600÷650 mm of water column for LDW 502, 602, 702, 903, 1003, 1204, 1404; and 370÷420 mm of water column for LDW 1204/T. Oil bath air cleaner ( on request ) Important Check the sealing rings regularly.

  • Page 30: Air Filter Support

    Disassembly / Reassembly Air filter support The support for air filter 1 incorporates the intake manifold and the accelerator control box. Remove all bolts that secure the air filter support 1 to the cylinder head. Carefully pull the air filter support from the cylinder head. Using suitable pliers, release the governor spring 2 from the air filter support assembly.

  • Page 31: E.g.r. Circuit

    Disassembly / Reassembly E.G.R. Circuit Operation The main function of the E.G.R. (Exhaust Gas Recirculation) system is the reduction in emission of NOx (nitrogen oxides), gases harmful to people and the environment, via lowering the combustion temperature. The system takes a certain quantity of exhaust gas from the exhaust manifold 1 (fig.

  • Page 32: Exhaust Maniflod

    Disassembly / Reassembly Vacuum pump and vacuum pump flange Unscrew the three fastening screws 1 that fix the vacuum pump to the flange and remove the vacuum pump. Unscrew the fastening screws that fix the flange to the engine crankcase and remove it. Components: 1.

  • Page 33: Alternator/Cooling Fan Belt Drive

    Disassembly / Reassembly Cooling fan Danger - Attention Carry out the cooling fan disassembly, only after isolating the positive battery cable to prevent accidental short-circuiting and, consequently, the activation of the starter motor. Carefully clean and check all blades. Replace the fan even if there is only a single damaged blade.

  • Page 34: Driving Pulley

    Disassembly / Reassembly Flywheel Danger - Attention During dismounting be particularly careful not to let the flywheel fall, as this can be very dangerous for the operator. Use protective goggles while removing the starter ring gear. Unscrew the screws that fasten it to the crankshaft. In order to replace the ring gear, it is necessary to disassemble the flywheel.

  • Page 35: Ringfeder-Type Rings On Ldw 1204-1204/T-1404

    Disassembly / Reassembly Ringfeder-type rings on LDW 1204-1204/T-1404 It is possible to draw ¾ of the power from the second drive of LDW 1204-1204/T-1404 engines. If you want to draw the entire power it is necessary to mount the Ringfeder rings on the crankshaft handle. Components: 1 Puleggia appropriata 6 Ringfeder external ring...

  • Page 36: Timing Belt Removal

    Disassembly / Reassembly Timing belt / Timing pulley arrangement Components: 1 Camshaft pulley 2 Timing belt 3 Crankshaft pulley 4 Coolant pump pulley 5 Belt tensioner pulley Timing belt removal Important When you remove the distributor belt replace it even if its prescribed operation time has not expired yet.

  • Page 37: Camshaft Timing - Belt Reassembly

    Camshaft timing pulley - Reference marks 1 Timing reference mark on cylinder head. 2 Camshaft pulley timing mark, for LDW 502 engines only 3 Camshaft pulley timing mark, for LDW 602, 702, 903, 1003, 1204, 1204/T and 1404 engines.

  • Page 38: Camshaft Timing - Belt Tightening And Fastening

    Disassembly / Reassembly Camshaft timing - Belt tightening tool Position belt preload tool 7107-1460-049 1 over the timing belt idler adjustment ear 2. See "Camshaft timing - Belt Tightening and Fastening". Camshaft timing - Belt Tightening and Fastening Insert the torque wrench in the suitable tool so that the A axis of the key fig.

  • Page 39: Valve Timing - Angles

    Disassembly / Reassembly Valve timing - Angles The angle values are determined by turning the driving shaft clockwise. S = Piston at top dead centre I = Piston at bottom dead centre α α α α α = Intake valve open β...

  • Page 40: Governor Springs

    Disassembly / Reassembly SPEED GOVERNOR The weight-type mechanical governor, is driven directly by the camshaft and is housed with the cylinder head. Components: 1 Thrust washer 2 Spool 3 Flyweight assembly Note: In engines with the minimum/maximum (see fig. 49) the weights are lightened by 25%.

  • Page 41: Speed Governor - Limiting Speed Governor

    Disassembly / Reassembly Speed governor - Limiting speed governor With applications for the automotive sector the regulator spring C fig. 45 is replaced by a device (plunger barrel) that only enables a constant speed at the minimum and maximum rpm rating. Components: 1 Nut 2 Idle speed spring...

  • Page 42: Oil Pump - Disassembly

    Disassembly / Reassembly Oil pump - disassembly The FOCS oil pump is supplied as an assembly. Lombardini therefore recommends that the oil pump be handled as an assembly from a service standpoint Lombardini does not recommend that the oil pump be disassembled, then reassembled for purposes of installation on the engine except during emergency situations.

  • Page 43: Crankcase Vacuum Regulator Valve

    Disassembly / Reassembly Rocker arm cover gasket The rocker arm cover gasket A ensures the seal of the lubrication circuit for the camshaft and rocker arm shaft. Always replace it and mount it with especial care above all in zones 1 and 2 where, for greater safety, it is advisable to apply a few drops of silicon sealant.

  • Page 44: Crankcase Breather Ldw 502

    For LDW 602-702-903-1003-1204-1204/T-1404 engines, the exhaust gases exit from the cylinder head cover, see Fig. 53, 54. In the LDW 502 engine the exhaust gases exit directly from the crankcase via cover 1. Remove the cover, check the integrity of the air valve and oil decanting wire gauze.

  • Page 45: Pump/Injector Unit - Disassembly

    Disassembly / Reassembly Pump/injector unit - non-return valve Non-return valve A immediately stops the engine whenever the stop is activated. Dimensions (mm): ÷ ÷ ÷ ÷ ÷ ÷ Note: If the value of B is not achieved, the two rings C are not subject to enough compression to ensure the seal;...

  • Page 46: Camshaft, Disassembly

    Disassembly / Reassembly Rocker arm pivot, dismounting and remounting To remove pivot 1 from the support 2 it's necessary to drill out pin 3 using a 4mm drill bit. On remounting insert a new pin and reinsert it in bearing surface A (0 to 1 mm).

  • Page 47: Camshaft Journals And Housings - Dimensions

    ÷ ÷ Note: The camshaft journal and cylinder head camshaft bore dimensions are identical for all LDW-FOCS series engines (LDW 502-602-702-903-1003-1204-1204/T-1404). Camshaft lobe measurement Use an outside micrometer gauge. Intake / Exhaust / Injection camshaft lobe height - LDW 903...

  • Page 48: Valve Springs

    Disassembly / Reassembly CYLINDER HEAD, removal Important Do not remove the cylinder head when hot to avoid deformation. lf cylinder head is deformed by more than 0.10 mm, level it off by removing a maximum of 0.20 mm. For the cylinder head tightening procedure see page 57. Valves To remove the valves it is necessary to remove the collets;...

  • Page 49: Valve Guide Insertion

    Disassembly / Reassembly Valve, specifications Exhaust valve A Shaft and head are made of 2 different materials. 2 Welded joint 3 Chromium-plated joint 4 Portion made of: ..X 45 Cr Si 8 UNI 3992 5 Portion made of: ..X 70 Cr Mn NI N 216 UNI 3992 α...

  • Page 50: Valve Recess And Seat Sealing Width

    Disassembly / Reassembly Valve seats and housings - Dimensions α α α α α α α α α α ÷ ÷ ° 4 ÷ ° 5 ° 9 ÷ ° 0 ÷ ÷ α α α α α α α α α α ÷...

  • Page 51: Pre-Combustion Chamber

    The hammer effect of the special tool will extract the pre-combustion chamber 3. Note: There are many types of precombustion chambers for the various engines described as follows. - LDW 502 - LDW 602-903-1204-1204/T. - LDW 702-1003-1404. Pre-combustion chamber, installation The pre-combustion chamber has a hole on the side where the pre- heating glow plug 2 must be inserted.

  • Page 52: Oil Pan, Removal

    Remove the connecting rod big end cap. Remove the piston-connecting rod assembly. Note: The LDW 502’s piston is different from the LDW 602 in terms of its combustion chamber. The LDW 1204/T piston is different from that of the LDW 1204 in term of its cooling nozzle’s slot bleed and an insert...

  • Page 53: Piston, Class

    Pistons oversized by 0.50 and 1.00 mm are supplied with reference to the increased level on the piston crown: Ø 72.5 - Ø 73 for LDW 502-602-906-1204-1204/T engines and Ø 75.5 – 76.0 for LDW 702-1003-1404 engines. - 53 -...

  • Page 54: Piston Ring, Clearance Between Grooves

    Disassembly / Reassembly Piston, weight Weigh pistons when replacing them in order to avoid unbalance. Important The difference in weight should not exceed 4 g. Piston rings - End gaps (mm) Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap A.

  • Page 55: Piston Clearance

    Disassembly / Reassembly Piston ring, mounting order A = 1° ring (internal tapered and torsional) B = 2° ring (internal tapered and torsional) C = 3° Oil control ring D = Chrome-plated area E = Chrome-plated area Note: When there is writing on the surface of a piston ring, mount that surface with face upward.

  • Page 56: Head Gasket

    Disassembly / Reassembly Head gasket Important Remove the cylinder head gasket seal from its protective covering only when you are going to mount it. The gasket thickness is identified by the number of notches located in point B. Choose the appropriate gasket considering that each A value on the table corresponds to a gasket with: no hole, one hole, two holes, or for the 1404 one notch, two notches, three notches.

  • Page 57: Cylinder Head Assembly

    = 50 Nm phase = Rotate the wrench 90° in a clockwise direction. phase = Rotate the wrench again 90° in a clockwise direction. For LDW 502 with pressure cast (aluminium) crankcase: With head H tightening bolts: phase = 60 Nm With head 8.8 tightening bolts: 1...

  • Page 58: Big End Bearing

    Note: The big end bearing is supplied both at the nominal value and undersized by 0.25 and 0.50 mm. In the LDW 502 engine with light alloy crankcase the connecting rod is aluminium type and not provided with connecting rod big end bearing and small end bush.

  • Page 59: Connecting Rod Alignment

    Note: For LDW 502 with an aluminium crankcase, the cast iron cylinders can be adjusted normally to increase values by 0.5 and 1.0 mm.

  • Page 60: Central Main Bearing Caps

    Disassembly / Reassembly Central main bearing caps The central support caps are marked with locations that can be numbers as in the diagram or dots. The same locations are given on the crankcase. Couple the caps with the same references and on the same side. In any case locate the bearing’s two centring notches that are to be found on the same side.

  • Page 61: Crankshaft Axial Clearance

    Disassembly / Reassembly Piston coolant nozzles Caution – Warning The piston has a recess so that during up-down movements and vice versa it cannot come into contact with the nozzle. When remounting the nozzle be careful that it is placed so that when the piston goes past it is in the centre of the recess.

  • Page 62: Crankshaft Front And Back Oil Seal Rings

    Disassembly / Reassembly Shoulder half rings, oversized elements Dimensions (mm): ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ * A of Fig. 134. ** B of Fig. 135. Grinding B as per relevant table, you can mount the following half rings: Oversized element Half rings 1 and 2 + 0.10 mm on both sides of the bearing...

  • Page 63: Crankshaft, Check Journals And Crank

    Remove the caps and clean lines 1 and 2 or 3 and 4 with a bit; blow with compressed air. Reposition the new caps in their seating and check the seal. Note: The LDW 502 crankshaft with aluminium crankcase is not interchangeable with the cast iron crankcase, having different counterweights.

  • Page 64: Clearances Between The Bearings And Corresponding Pins

    Disassembly / Reassembly Main bearings and connecting rod big ends diameters Dimensions (mm): Ref. Tolerance ÷ ÷ Ref. Tolerance ÷ ÷ The dimensions given refer to tightened bearings. For tightening torque see figures 116 e 126. Clearances between the bearings and corresponding pins See figures.
  • Page 65 Disassembly / Reassembly Hydraulic pump drive A = Third drive You can mount a 2P hydraulic pump on the third drive with Bosch flanging, or a 1 PD type one. You can draw 7 KW of power from the third drive corresponding to a 37 Nm torque at 3600 rpm (engine revolutions).

  • Page 66: Turbocharger

    TURBOCHARGER TURBO CHARGER Only the LDW 1204/T is supplied with the turbocharger. The LDW 1204/T is available in two versions: TD 025 03C 2.8 for 3600 r/min TD 025 03C 2.0 for 3000 r/min. Turbocharger components 1 Waste gate tube 2 Attuatore 3 Collare 4 Corpo turbina...

  • Page 67: Turbocharger West Gate Adjustment - Regolazione Corsa Asta Comando Valvola " Waste Gate

    Turbocharger Turbocharger west gate adjustment - Regolazione corsa asta comando valvola " Waste gate " Disconnect westgate tube 7 from the turbocharger compressor side. Using a T-joint connect a pressure gauge 4 (scale 0 to 2 bar) and with the compressed air network pipe complete with reducer 5. The network air supply pressure must be from 1.5 to 2 bar.

  • Page 68: Lubrification Circuit

    LUBRIFICATION CIRCUIT 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.

  • Page 69: Lubrification Circuit

    Tighten oil drain plug at a torque of 40 Nm. Oil pump The oil pump mounted on LDW 502-602-903 engines has a lower delivery rate than that mounted on LDW 1204-1204/T engines. Oil pump delivery test at 1000 revs per minute with an oil temperature of 120°C.

  • Page 70: Oil Filter Cartridge

    Lubrification circuit Oil pressure regulating valve Components: 1 Valve 2 Spring 3 Gasket 4 Screw cap Spring length = 27.50÷27.75 mm Blow the valve’s seating with compressed air and carefully clean all the components before remounting them. Nota: The valve begins to open at a pressure of 4.5÷5.5 bar. Oil filter cartridge Components: 1 Gasket...
  • Page 71 Lubrification circuit ...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 72: Coolant Circuit

    COOLANT CIRCUIT Danger – Attention - The coolant circuit is pressurised. Do not check it before the engine has cooled down and, also in that case, open the radiator cap or expansion tank plug with caution. - When there is an electric fan do not approach a hot engine because it could also come on with the engine off. - The liquid coolant is a pollutant and therefore must be disposed of with care according to environmental provisions.

  • Page 73: Coolant Circuit

    Coolant circuit Radiator and compensation, check and seal tank cap. Remove the cap from compensation tank cap and check that the liquid is at the correct level. Replace the cap with a new one provided with hand air pump socket. Compress air at a pressure of 1 bar for about two minutes.

  • Page 74: Fuel System

    FUEL SYSTEM Fuel feeding / injection circuit Components: 1 Fuel Tank 2 Fuel filter 3 Fuel feeding tube 4 Fuel lift pump 5 lnjection pump 6 Injector 7 Fuel rail passage rubber joint 8 Injector exhaust pipe 9 Fuel tank cap 10 Solenoid valve Note: The tank complete with filter is supplied on request.

  • Page 75: Pump/Injector Unit

    Fuel system Pump/injector unit Designed by LOMBARDINI, the pump/injector is exclusive to FOCS series engines. The injection system includes two, three, four identical pumps/ injector units, each one of which feeds a cylinder. Note: On pumps/injector units of recent construction (for serial numbers and references see the table on page 78) the pump has been modified (see fig.

  • Page 76: Injection Pump Assembly/Disassembly

    Fuel system Plunger barrel ring nut assembly/disassembly To disassemble ring nut 9 fig. 169, use the suitable wrench A se.no. 7107-1460-029 When refitting tighten it a torque of 34 Nm. Injection pump assembly/disassembly Disassemble the unit following the progressive order of fig. 169. Reassemble following the same steps in reverse order.

  • Page 77: Pump/Injector Unit Se.no. 6590.285 Control Data

    Fuel system Pumping element (old-type injection pump) 1 Plunger 2 Upper plunger section 3 Plunger barrel 4 Delay notch 5 Control slot Dimensions (mm): nominal value ÷ inlet hole diameter ÷ outlet hole diameter Pumping element 1 Plunger 2 Upper plunger section 3 Plunger barrel 4 Delay notch 5 Control slot...
  • Page 78 CURRENT PUMP INJECTOR OLD TYPE INJECTOR PUMP Lombardini injection system is being steadily implemented, seeking the best performance of its engines. For this reason the pump injector body has been modified three times in the course of its evolution. Three different pump injectors are shown in the top figure.

  • Page 79: Injector, Nozzle Projection

    Fuel system Injector, setting (old type) Connect the injector to a hand pump after removing cap screw 20 fig. 169. By means of the tool - se.no. 7107-1460-028 - check that the setting pressure is 130÷145 bar. Adjust, if necessary, by changing the spacer located under the spring.

  • Page 80: Injection Advance Control And Regulation

    Fuel system Injection advance control and regulation - Dismount the rocker arm cover, see page 40. - Position the device on the head, in contact with cylinder no. 1. - Mount the dial gauge on the valve controlled by tool ref. 1460.048. - Via lever 1 of the tool, open the valve until it comes into contact with the piston.

  • Page 81: Injection Advance References On Timing Belt Protector

    D coincides with A = TDC of 1 cylinder of all series engines, of 4 cylinder LDW 1204-1204/T-1404, and of 2 cylinder LDW 502. E coincides with A = TDC of the 2 cylinder LDW 903-1003. F coincides with A = TDC of 2nd cylinder LDW 602-702., of 3 and 2 cylinder LDW 1204-1204/T-1404.

  • Page 82: Closing The Oilhole

    By actuating lever 2 check piston lowering with respect to the TDC that shall be between 0.89 and 1.24 mm for LDW 602-903-1204, and between 0.73 and 1.02 for LDW 502 engine model. The table on page 80 shows both piston lowering expressed in mm, with respect to the TDC, and the corresponding rotation of the crankshaft, expressed in degrees.

  • Page 83: Injection Pumps Delivery Balancing

    Fuel system Instrument connection Place the instrument 1, se.no. 7104-1460-127 at least 20 cm above the pump/injector level. Connect pipe A (outlet from every instrument test piece) with pipe A (inlet of every pump/injector) and pipe B (return to the instrument) with pipe B (outlet from the pump/injector).

  • Page 84: Electric Control Panel With Automatic Engine Stop

    ELECTRIC SYSTEM ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP (UPON REQUEST) BLACK BLUE FUEL SOLENOID GLOW-PLUGS ORANGE BATTERY CONNECTION BLACK BLUE POST PURPLE EXCITATION TERMINAL GRAY WHITE GREEN STARTING LIGHT BLUE MOTOR PINK BROWN PUSH-ON CONNECTION ALTERNATOR CONNECTOR COOLANT COOLANT TEMP. TEMP.THERMISTOR SENDING UNIT (FOR GLOW TIMER/...

  • Page 85: Electric System

    Electric System Alternator, Iskra 14V 33A Nominal voltage ....14V Nominal current output ..33A Maximum Rpm ....12.000 giri/1' Maximum peak Rpm ..13.000 giri/1' Voltage regulator AER 1503 Rotation (viewed at puley end): Clockwise Tighten nut 1 at a torque of 35÷45 Nm. Alternator, Iskra 14V 33A - Performance Curve The curve was obtained at room temperature of +25°C with 13 V battery voltage.

  • Page 86: Electric Starting Layout (12V) With Iskra Alternator 14V 33A

    4 Glow Plugs 5 Coolant temperature thermistor 6 Glow Plug Controller / Timer 7 Key Switch 8 System Fuse, 30A for LDW 502-602-702; 50 A for LDW 903- 1003; 80 A for LDW 1204-1204/T-1404. 9 Fuse (Accessory)- 5A 10 Fuel Solenoid Valve...

  • Page 87: Alternator, Marelli Type Aa 125 R 14V 45A

    Electric System Alternator, Marelli type AA 125 R 14V 45A Characteristics: Nominal voltage ........= 14V Nominal current output ......= 45A Maximum Rpm ......... = 14000 giri/1' Maximum peak Rpm (for 15') ....= 15000 giri/1' Bearing, Pulley End ........= 6203-2Z Bearing, Voltage Regulator End ....

  • Page 88: Electric Starting Layout (12V) With Marelli Type Aa 125 R 14V 45A Alternator

    4 Glow Plugs 5 Coolant temperature thermistor 6 Glow Plug Controller / Timer 7 Key Switch 8 System Fuse, 30A for LDW 502-602-702; 50 A for LDW 903- 1003; 80 A for LDW 1204-1204/T-1404. 9 Fuse (Accessory)- 5A 10 Fuel Solenoid Valve...

  • Page 89: Alternator Battery Charger Curve 12V 20A

    Electric System Alternator battery charger curve 12V 20A (three cables at output) This curve is obtained at 20°C. The statistical charging output of the flywheel alternator is +10% to - 5% of the values shown. Alternator battery charger curve 12V 30A (two cables at output) This curve is obtained at 20°C.

  • Page 90: Electric Starting Layout (12V) With Flywheel Alternator

    19 Air Filter Restriction Switch 20 Low Fuel Level Lamp 21 Low Fuel Level Switch A Accessory Position B Off Position C On Position D Starting Position Note: Battery 3 not supplied by LOMBARDINI. Voltage regulator connections Conncetion dimensions Cable colour Width Thickness...

  • Page 91: Starter Motor - Bosch Dw 12V 1,1 Kw

    Electric System STARTER MOTOR - Bosch DW 12V 1,1 KW Rotation: Clockwise A = 17,5÷19,5 mm (distance from starter mounting flange to ring gear face) Note: Please refer to your local BOSCH distributor for service parts, repair criterion and warranty service. Starter motor, Bosch DW 12V 1,1 KW - Performance Curve The curve was obtained at room temperature of -20°C with a fully charged 66Ah battery.

  • Page 92: Pre-Heating Glow Plug

    Electric System Starter motor, Bosch DW 12V 1,6 KW - Performance Curve The curve was obtained at room temperature of -20°C with a fully charged 88 Ah battery. U = Starter Motor Voltag n = Armature r/min I = Absorbed Amperage P = Starter Output Power (KW) M = Starter Output Torque (Nm) Pre-heating glow plug...

  • Page 93: Coolant High Temperature Lamp Sensor

    Electric System Temperature sensor for control unit In engines fitted with the above-mentioned type of control unit, the introduction of the glow plugs depends on a temperature sensor that varies preheating temperature in relation to the coolant temperature. Characteristics: Temperature range ....-30 ÷ +50°C Voltage range ......

  • Page 94: Settings

    SETTINGS SPEED SETTINGS Setting the idle minimum (standard) After filling the engine with oil, fuel and coolant, start it and let it warm up for 10 minutes. Turn the screw 1 to adjust the idle speed at 850 to 900 rpm. Tighten then the locknut.

  • Page 95: Injection Pump Flow Limiter And Standard Engine Torque Gearing Device

    Settings Injection pump flow limiter and engine torque gearing device Flow limiter C has the function of limiting the injection pump’s maximum delivery. The same mechanism acts also as a torque gearing device. Indeed, under torque, spring N operating lever L overcomes the resistance of spring M located in the plunger barrel.

  • Page 96: Pump/Injector Unit Delivery Setting With Braked Engine

    Settings Pump/injector unit delivery setting with braked engine 1) Run the engine to the maximum speed. 2) Screw flow limiter C (see fig. 219). 3) Load the engine up to the power and number of revs required by the application’s manufacturer. 4) Check that consumption is within the values allowed for in the settings table (see below).

  • Page 97: Calibration

    Settings E.G.R. calibration Mount a T-branch on vacuum valve - E.G.R. valve connection pipe (1), and connect it to a vacuum pressure gauge with 1 bar bottom scale so as to be able to read the degree of vacuum within the pipe. Note: It is also possible to use a mercury column, 1 metre long, since the maximum suction pressure exerted by the vacuum pump is 720 mmHg.

  • Page 98: Storage

    STORAGE ENGINE STORAGE (NOT INSTALLED) - If the engine is not to be used for long periods, check the storage environment, the type of packaging and make sure these conditions will allow proper maintenance. If necessary, cover the engine with protective sheeting. - Do not store the engine directly on the ground, in damp environments, in areas exposed to the elements, near sources of danger, including less visible hazards such as high-voltage power lines, etc.

  • Page 99: Preparing The Engine For Operation After Protective Treatment

    Storage PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT After a period of inactivity and before installing and running the engine, it is necessary to carry out a few measures in order to ensure that it runs at maximum efficiency. 1 - Remove the protective sheeting.

  • Page 100: Torque Specifications And Use Of Sealant

    TORQUE SPECIFICATIONS AND USE OF SEALANT Table of tightening torques for the main components Torque Riference Diam. & pitch Sealant POSITION (figure and page n°) ( Nm ) ( mm ) Injection pump control rod 62÷63 - p. 44 M 3 spec. Connecting rod **** 116 - p.

  • Page 101: Table Of Tightening Torques For Standard Screws (Coarse Thread)

    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 102: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS DESCIPTION Part N°. Injection pumps delivery balancing instrument 7107-1460-127 Precombustion chamber extractor 7107-1460-030 Injection pump static injection advance tester(old type) 7271-1460-024 Sheet metal for insertion of main bearings in the crankcase 7107-1460-053 Ring nut wrench for fastening pump/injector pumping element 7107-1460-029 Precombustion chamber wrench...
  • Page 103 Notes .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 104 .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 106 FOCS Engine Series cod. 1-5302-351 La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione. Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication. Data reported in this issue can be modified at any time by Lombardini.

This manual is also suitable for:

Ldw 903Ldw 602Ldw 1204Ldw 1204/t

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