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Summary of Contents for Lombardini 12LD 435-2
- Page 1 WORK SHOP MANUAL 12LD Series engines, cod. 1-5302-460_3 12LD 435-2 12LD 435-2/B1 12LD 475-2 12LD 475-2 EPA...
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Page 2: Workshop Manual 12 Ld _ Cod. 1.5302.460 - 3° Ed_ Rev. 02
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
CHAPTER INDEX This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled, direct injection Diesel engines type 12 LD 435-2 - 435-2/B1 - 475-2 - 475-2 EPA, updated 05-03-2007. TABLE OF CONTENTS GENERAL REMARKS AND SAFETY INFORMATION ___________________________________ P. 7 - 9 GENERAL SERVICE MANUAL NOTES ........................... - Page 4 Chapter index Flywheel .................................. page 21 Governor springs with rocker arm ........................... 31 How to measure intake/exhaust cam height ........................30 Hydraulic pump p.t.o. (1P) .............................. 31 Injector projection ................................22 Main bearing and connecting rod big end bearing internal diameter ................29 Main bearing housing ..............................
- Page 5 Chapter index Characteristic curves for starting motor type Bosch DWL 12 V, 1.7 kW ............Page 42 Electrical starting layout with battery charging light ....................... 40 How to check voltage regulator for proper operation ..................... 42 OPTIONAL ELECTRIC EQUIPMENT ..........................41 Starting motor type Bosch DWL 12 V, 1.7 kW .......................
- Page 6 Chapter index Notes : .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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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: Glossary And Terminology
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 · Only check belt tension when the engine is off. · Only use the eyebolts installed by Lombardini to move the engine. These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should be used.
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Page 10: Technical Information
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 11: Manufacturer And Motor Identification Data
Technical information MANUFACTURER 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 12: Techinical Specifications
Technical information TECHINICAL SPECIFICATIONS Engine type, 12LD: 475-2 435-2 435-2/B1 475-2 GENERAL DETAILS Four-stroke diesel Operating cycle Cylinders 2 in line n° Bore x stroke 86x75 86x75 90x75 90x75 Displacements Compression rate 18.0:1 18.0:1 18.0:1 20.0:1 Intake Oil bath air cleaner or dry air cleaner Cooling Air (fan integral to the flywheel) Crankshaft rotation... - Page 13 Technical information Engine type, 12LD: 475-2 435-2 435-2/B1 475-2 FUEL SUPPLY CIRCUIT Automotive diesel fuel (minimum cetane: 51) Fuel type Mechanical fuel lift pump, diaphragm type Fuel supply Fuel filter, internal Filtering surface 2400 µ Filter capacity 2÷3 Maximum operating pressure Fuel filter, external Filtering surface µ...
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Page 14: Performance Diagrams
Max. power tolerance is 5%. Power decreases by approximately 1 % every 100 m 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. - 14 -... -
Page 15: Overall Dimensions
Technical information OVERALL DIMENSIONS 12LD 435-2 – 435-2/B1 – 475-2 – EPA - 15 - Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02... -
Page 16: Maintenance - Recommended Oil Type - Refilling
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ROUTINE ENGINE MAINTENANCE 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 Engine oil replacement. Oil filter replacement. 50 WORKING HOURS ORDINARY MAINTENANCE FREQUENCY x HOURS... -
Page 17: Acea Regulations - Acea 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* The first number refers to the viscosity when the engine is SAE 20W* cold (symbol W = winter), while the second considers SAE 30*... -
Page 18: Prescribed Lubricant
Maintenance - Recommended oil type - Refilling PRESCRIBED LUBRICANT AGIP API CF4 / SG SUPERDIESEL ACEA B2 - E2 specifications MULTIGRADE MIL - L-4165 D/E 10W40 In the countries where AGIP products are not available, use oil API SJ/CF for Diesel engines or oil corresponding to the military specification MIL-L-4165 D/E. -
Page 19: 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 20: Disassembly/ Reassembly
– Always use original LOMBARDINI spare parts for proper – In order to fix assemblies and/or components securely, the repair operations. -
Page 21: Alternator
Disassembly / Reassembly Dry air cleaner 1 Hand wheel 2 Cover 3 Cartridge 4 Seal ring 5 Bracket 6 Clogging indicator Important Replace cartridge immediately when indicator shows that it's clogged. Flywheel Remove flywheel with puller (part N°. 7271-3595-048). Check starter ring gear and tapered crankshatt mating surfaces. Unscrew bolt 1 clockwise;... -
Page 22: Compression Release (Optional)
Disassembly / Reassembly Compression release (optional) Bring piston to top dead center on the compression stroke. Unscrew rocker arm cover side plug and measure clearance A, which must be 0.30÷0.40 mm. For setting purposes remove rocker arm cover, unscrew lock nut C and set clearance A by adjusting the screw B. -
Page 23: Valve Guide Insertion
Disassembly / Reassembly Valves Components: 1 Intake valve 2 Spring seat 3 Valve stem seal 4 Spring 5 Retainer 6 Half collets To remove half collets firmly press down as shown in the figure. Important Valve stem seal 3 must be fitted to the intake valve only. Valve guides and valve guide housings Components: Dimensions (mm) -
Page 24: Cylinder
Disassembly / Reassembly Valve seat grinding After cutting grind valve seats with fine emery paste in oil suspension. The sealing surface S should not exceed 2 mm. Valve recess after grinding D = 0.75÷1.25 mm; maximum worn limit 1.65 mm. Cylinder Measure diameter size between two diametrically opposed points at three different heights. -
Page 25: Piston 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. Piston rings - End gaps Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap. -
Page 26: Connecting Rod Big End Bearing
Disassembly / Reassembly Piston - Refitting Connect piston to connecting rod in a way that the combustion chamber center b is at right angle under nozzle tip a. Lubricate piston pin and introduce it into the piston by exerting pressure with your thumb. Check that both circlips are well inside their seats. -
Page 27: Connecting Rod Weight
Disassembly / Reassembly Connecting rod weight Weigh connecting rods when replacing them in order to avoid unbalance. The difference in weight should not exceed 10 g. Crankshaft timing gear Use tool 1 (Part N°. 7560-4000-052) and puller 2 (Part N°. 7271-3595- 048) to remove the gear. -
Page 28: Center Main Bearing Support, Locating Bolt
Disassembly / Reassembly CRANKSHAFT Center main bearing support, locating bolt Straighten plate 1 and unscrew bolt 2 before removing crankshaft. When refitting, tighten bolt 2 to 30 Nm. Crankshaft end play When refitting crankshaft check end play be means of a feeler gauge; this value should be 0.08 ÷... -
Page 29: Clearance Between Main Journals/Crank Pins And Connecting Rod Bearings
Disassembly / Reassembly Main bearing and connecting rod big end bearing internal diameter Dimensions (mm) Dimensions (mm) Ref. Ref. ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ The above dimensions refer to driven in or tightened bearings. Both main bearings and connecting rod big end bearings are available with inside diameter size measuring 0.25 and 0.50 mm less than the standard version. -
Page 30: Camshaft End Play
Disassembly / Reassembly Dimensions of camshaft journals and housings Limit value Dimensions Clearance Ref. (mm) (mm) (mm) ÷ ÷ ÷ ÷ ÷ ÷ How to measure intake/exhaust cam height A = 1 cylinder intake cam A2 = 2 cylinder intake cam S = 1 cylinder exhaust cam S2 = 2... -
Page 31: Governor Springs With Rocker Arm
Disassembly / Reassembly Hydraulic pump p.t.o. (1P) 1 Seal ring 2 Centering ring 3 Coupling 4 Half coupling 5 Flange 6 Gear 7 Bracket 8 Thrust washer 9 Stop ring 10 Cover The maximum torque is 27 Nm corresponding to 7,64 kW at 3000 r.p.m. -
Page 32: Lubrication System
LUBRICATION SYSTEM LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM Danger - Attention - The oil viscosity must suit the ambient temperature in which the engine operates. - 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 Danger - Attention rotation speed. -
Page 33: Oil Filter Cartridge (External)
Lubrication system Oil Pump Check that gear teeth are intact and that clearance between gear edge and pump body does not exceed 0.15 mm. Further more check that control shaft is free to rotate with end float not exceeding 0.15 mm. Oil pump delivery at 3000 r.p.m. -
Page 34: 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 centigrade. Oil pressure curve at full speed The curve is obtained at the oil filter level with engine working at 3000 r.p.m., at a room temperature of +25°C and at 25,84 HP. -
Page 35: 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 Fuel filter, inside fuel tank Components: 1 Spring 2 Disc... -
Page 36: How To Reassemble Injection Pump Components
Fuel system Injection pump Components: 1 Pump body 10 Plunger 2 Fitting 11 Barrel 3 Seal ring 12 Rack rod 4 Filler 13 Sector gear 5 Shim 14 Spring 6 Spring 15 Upper retainer 7 Delivery valve 16 Lower retainer 8 Seat 17 Tappet 9 Gasket... -
Page 37: Injection Pump/Mechanical Speed Governor Timing
Fuel system Injection pump/mechanical speed governor timing Loosen screw 1. Move injection pump lever 2 to maximum delivery (to the right). Check that drive rod 3 closes the speed governor; keeping lever 2 pressed to the right the drive rod should have no clearance. Tighten screw 1. -
Page 38: Injector, For Standard Engines
Fuel system Fasten capillary tube 4 on the delivery union of the cylinder on which the valve lowering tool is installed. Turn the flywheel and alternatively fill the capillary tube until the fuel flows out. Turn the flywheel clockwise (pic. 77) and, during the compression phase, turn it slowly. -
Page 39: Injector Setting
Fuel system Injector, for EPA engines Components: 1 Injector housing 7 Nozzle 2 Intake fitting 8 Cup 3 Shim 9 Needle valve 4 Spring 10 Sump 5 Pressure rod 11 System duct 6 Taper pin 12 Overflow pipe When refitting tighten ring 8 nut at 50 Nm. Injector setting Connect injector to a hand pump and check that setting pressure is 210÷220 bar (258÷270 bar for EPA engines);... -
Page 40: Electric System
6 Oil pressure warning light 7 Key switch 8 Battery charging light Note: Battery, which is not supplied by Lombardini, should feature 12 V voltage and capacity not below 70 Ah. 12.5 V, 14 A Alternator Features a fixed armature winding mounted on the air shroud bracket. -
Page 41: Alternator Battery Charger Curve (12 V, 18 A)
Alternator battery charger curve (12 V, 18 A) This curve is obtained at + 25°C with 12.5 V battery voltage. Voltage regulator Type LOMBARDINI, supplied by SAPRISA and DUCA TI: Voltage 12 V, max. current 26A. References for SAPRISA connections with the cor-responding DUCATI connections. -
Page 42: Characteristic Curves For Starting Motor Type Bosch Dwl 12 V, 1.7 Kw
Electric system How to check voltage regulator for proper operation Caution - Warning When the engine is running do not disconnect battery cables or remove the key from the control panel. Keep regulator away from heat sources since temperatures above 75°C might damage it. No electric welding on engine or application. -
Page 43: Settings
SETTINGS Settings 1) Idling speed setting in no-load conditions After filling with oil and fuel, start the engine and let it warm up for 10 minutes. Adjust idling speed at 1200÷1300 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 44: Injection Pump Delivery Setting With Engine At The Torque Dynamometer
Settings Injection pump delivery setting with engine at the torque dynamometer 1) Bring engine to idling speed 2) Unscrew delivery limiting device C (see pic. 94) 3) Bring engine to the power and r.p.m. required by the manufacturer of the device. 4) Check that consumption falls within the table specifications (see below). -
Page 45: Storage
STORAGE When the engines are not used for more than 3 months, they have to be protected by performing the operations described: STORAGE Internal engine protection: - Start the engine and heat it. - Stop the engine. - Remove the drain plug and let the oil flow completely. - Replace the oil filter with a new one (screw manually the new filter). -
Page 46: Torque Specifications And Use Of Sealant
TORQUE SPECIFICATIONS AND USE OF SEALANT Table of tightening torques for the main components Picture Diam. and pitch Torque POSITION N° ( mm ) ( Nm ) Connecting rod 8X1,25 Injection pump union 71÷73 18X1,5 8X1,25 Rocker arm cover 8X1,25 Central support collar Intake manifold 8X1,25... -
Page 47: 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>1200N/mm R>400N/mm R>500N/mm R>600N/mm R>800N/mm R>1000N/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 48: Special Tools
SPECIAL TOOLS Special tools and equipment for maintenance SPECIAL TOOLS DESCIPTION Part N°. Valve lowering tool for static injection timing check 1 Spacers, h=40mm 1460 - 285 2 Dial gauge indicator 3 Dial gauge extension High-preassure pump static injection timing check 1460 - 273 1460 - 024 Static timing tool... - Page 49 Notes : ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 50 E-MAIL: atl@lombardini.it Internet: http://www.lombardini.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. Data reported in this issue can be modified at any time by Lombardini.
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