FOREWORD We have done all in our power to give up to date and accurate technical information in this manual. Lombardini engines are, however, constantly developing thus the data in this publication may be liable to modification without prior notice.
WARRANTY CERTIFICATE 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.
TROUBLE SHOOTING POSSIBLE CAUSES AND TROUBLE SHOOTING The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before removing or replacing any part. TROUBLE POSSIBLE CAUSE Clogged pipes Clogged fuel filter Air inside fuel circuit Clogged tank breather hole Faulty fuel pump...
SAFETY INSTRUCTIONS • Lombardini Engines are built to supply their performances in a safe and long-lasting way. To obtain these results, it is essential for users to comply with the servicing instructions given in the relative manual along with the safety recommendations listed below.
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• 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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NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-467 50707 06-95 22.12.2003...
MODEL NUMBER AND IDENTIFICATION MODEL NUMBER ENGINE IDENTIFICATION Displacement (cc) R.P.M. Diesel Customer's code LOMBARDINI Approval code Engine group number Engine Serial Number COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-467 50707 06-95 22.12.2003...
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TECHNICAL DATA CHARACTERISTICS 15 LD 225, 15 LD 315, 15 LD 350 TIPO MOTORE 15LD 225 15LD 315 15LD 350 Number of cylinders Bore Stroke Swept volume Compression ratio 21:1 20,3:1 20,3:1 R.P.M. 3600 3600 3600 N 80/1269/EEC-ISO 1585 3,5(4,8)
TECHNICAL DATA CHARACTERISTICS 15 LD 400, 15 LD 440 TIPO MOTORE 15LD 400 15LD 440 Number of cylinders Bore Stroke Swept volume Compression ratio 20,3:1 20,3:1 R.P.M. 3600 3600 N 80/1269/EEC-ISO 1585 7,0(9,5) 7,7(10,5) Power kW (HP) NB ISO 3046 - 1 IFN 6,4(8,7) 7,0(9,6) NA ISO 3046 - 1 ICXN...
Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C. Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above. COMPILER TECO/ATI REG.
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Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C. Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above. COMPILER TECO/ATI REG.
The cetane rating of the fuel must be higher than 45 to prevent difficult starting. Do not use dirty diesel fuel or mixtures of diesel fuel and water since this would cause serious engine faults. The capacity of the standard tank is: 15 LD 225 l. 3.0 15 LD 315 l.
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46152 D/E. In the countries where AGIP and ESSO products are not available, use oil API SJ/CF for Diesel engines or oil corresponding to the military specification MIL-L-46152 D/E. SAE 10W OIL SUPPLY ( liters ) 15 LD 225 SAE 20W Standard oil sump SAE 30...
Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair using compressed air, wear eye and operating instructions. Always use original LOMBARDINI spare protection. parts for repair operations. Clean the filtering element with air blast. Air must be blown from inside to outside the cartridge at a distance of at least 15 cm from the paper.
DISASSEMBLY/REASSEMBLY VIII Clean the filtering element with air blast. Air must be blown from inside to outside the cartridge at a distance of at least 15 cm from the paper. Lightly and repeatedly tap the element on a hard surface to eliminate all excess dirt.
VIII DISASSEMBLY/REASSEMBLY Never clean the filtering element 6 using solvents with a low flash point. This could cause an explosion ! Make sure that the retention rings 4 - 5 are in a good condition and replace them if they are damaged. Oil-bath air cleaner (optional) Components: 1 Upper shell...
Make sure that oil plug 5 is correctly closed. Refit cover 1 and tighten rocker arm cover to 10 Nm. Valve/rocker arm clearance ( 15 LD 225-315-350 ) Set valve/rocker arm clearance when the engine is cold: bring piston to top dead center on the compression stroke and set clearance at 0.10-0.15 mm using a thickness gauge.
VIII DISASSEMBLY/REASSEMBLY Hydraulic tappets 15 LD 400-440 Distribution uses hydraulic tappets for automatic adjustment of valve clearance. The figure shows the tappet used in 15 LD 400 engines. Caption 1- Lock ring 2- Upper collar 3- Oil inlet holes 4- Low-pressure chamber 5- Piston 6- Play-recovery spring 7- Case...
See page 18 for the frequency with which the fuel filter must be replaced. See fig. 99 for the dimensions. Fuel filter for 15 LD 225 - 315 - 350 - 400 - 440 (version with external filter) Loosen the clamps and disconnect the hoses.
VIII DISASSEMBLY/REASSEMBLY Re-coil starting Operation: When pulling handle 10, thanks to the action of friction spring 12, teeth 4 protrude from cap 3. After starting these teeth go back to the initial position because the cap rotates. Rope 9 is re-wound around pulley 6 by means of spring 7.
Injector projection The end of nozzle A should project 2,5 mm for 15 LD 225-315-350 and 3,0÷3,5 mm for 15 LD 400-440 from the cylinder head plane. Adjust with copper gaskets B with thickness of 0.5, 1 and 1.5 mm COMPILER TECO/ATI REG.
1 serial N° 7107-1460-047 after having thoroughly lubricated it, then proceed as indicated in the figure. Valve, springs Measure the free length with a caliper. Engine 15 LD 225-315-350 Free length A = 33.72 Engine 15 LD 400-440 Free length A = 34,88 Note: Replace the spring if the free length A is 1 mm less than specified.
Dimensions (mm) for 15 LD 315-350-400-440 A = 40 B = 31 C = 11.000-11.018 D = 11.040-11.055 Dimensions (mm) for 15 LD 225 A = 35 B = 30 C = 10.000-10.020 D = 10.040-10.055 Note: Valve guides with outer diameters increased by 0.5 mm are also available as spares.
After cutting valve seats, lap valve seats with fine lapping compound. The sealing surface S should not exceed 2 mm. Lowering valve for 15 LD 225-315-350 (D = 0.55÷0.85 mm). Lowering valve for 15 LD 400-440 (D = 0.35÷0.65 mm).
DISASSEMBLY/REASSEMBLY VIII Cylinder Set a bore gauge to zero with a calibrated ring. Check diameter at 1, 2 and 3; repeat the operation at the same points after turning the bore gauge 90°. If wear exceeds the max. given value by 0.05, bore the cylinder and fit oversize piston and rings.
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VIII DISASSEMBLY/REASSEMBLY COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-467 50707 06-95 22.12.2003...
÷ ÷ l i o ÷ Wear limit 1 mm - for the 2nd piston ring of 15 LD 225 and 15 LD 350 engines, the wear limit is 2.0 mm. COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE...
120° to each other. In 15 LD 350 and 15 LD 225 engines, the second piston ring is not torsional, while the first and third piston rings do not have chromium plated zones but are nitrided.
DISASSEMBLY/REASSEMBLY VIII Piston protrusion check To calculate the right thickness for the gasket, the protrusion between the piston and the cylinder head surface must be measured. Use a dial indicator with base plate. Reset to zero while resting on a surface plate, then position against the cylinder head base plane as shown in the diagram, so that the dial indicator rod rests against the piston.
When remounting, mount the cap from the same side as in C of the figure. Tighten the 15 LD 225 bolts to a 23 Nm torque value. Tighten the bolts to a 30 Nm torque value for 15 LD 315-350-400-440.
A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems. Use genuine oil retainers with the LOMBARDINI logo (see B). Drive shaft oil seals Oil retainer 1 is located in the gear cover on the timing side while retainer 2 is located in the crankcase on the flywheel side.
VIII DISASSEMBLY/REASSEMBLY Crankshaft - journal diameter (mm) ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ The undersizes for the crankpin and main journal are 0.25, 0.50 and 1 mm. The gears must be mounted with the right tools so that they can be correctly timed.
DISASSEMBLY/REASSEMBLY VIII Camshaft Components: 1 Journal, gear cover on timing side 2 Gear 3 Exhaust lobe 4 Injection lobe 5 Fuel pump eccentric 6 Intake lobe 7 Journal, crankcase side Camshaft journals and bore Use a comparator for interiors Dimensions of camshaft journals and bore (mm) ÷...
VIII DISASSEMBLY/REASSEMBLY Camshaft timing Fit camshaft by aligning marks' A with mark D on the crankshaft. Camshaft – Antireverse system 15 LD 400-440 it consists of a device on the camshaft which lifts the intake valve in case of a startup in reverse direction with respect to normal rotation.
DISASSEMBLY/REASSEMBLY VIII Automatic decompression With the engine at a standstill and up to a rate of about 300 RPM, spring 1, acting on weights 2 and 3 via lever 4 and pin 5, keeps the exhaust valve open during the compression phase also. Once the engine exceeds the 300 RPM rate, weights 1 and 2 keep pin 5 in the hold position owing to the action of the centrifugal force.
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NOTE VIII COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-467 50707 06-95 22.12.2003...
VIII DISASSEMBLY/REASSEMBLY Dinamic balancer timing Position crankshaft as shown in the figure. Introduce the dynamic balancer so that timing mark 1 engages between teeth 2 of the crankshaft gear. Valve timing check Remove the tank and conveyor to access the flywheel. Carry out the inspections on the drive shaft.
DISASSEMBLY/REASSEMBLY VIII Timing angles for operation (0.15 valve play). For 15 LD 225 α α α α α = 6° before A corresponding to 12 mm β β β β β = 22° after B corresponding to 44 mm γ γ γ γ γ...
If contact with the oil is unavoidable, you are advised to wash your hands with soap and water as soon as possible. Dispose of old oil in the correct way as it is highly polluting. 15 LD 225 - 315 - 350 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM...
LUBRICATION SYSTEM 15 LD 400-440 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM Components: 1) Oil fill cap 6) Oil drain plug 11) Oil intake filter 2) Safety valve 7) Metal filter element 12) Pushrods 3) Rod journal 8) Main journal 13) Hydraulic tappets 4) Pressure control valve 9) Oil filter 14) Calibrated union...
Components for 15 LD 315 and 15 LD 350: 1 Spring 2 Valve 3 Plug Free length A of the spring is 27.50-27.75 mm. Components for 15 LD 225: 4 Ball 5 Spring 6 Plug Free length A of the spring is 23.50-24.50 mm.
E = 8.5 Characteristics: Useful filtering area = 75 cm Degree of filtration = 50 µm. The by-pass valve is set at 0.6-0.8 bar. Filter components: 15 LD 225 7 Rubber pad 8 Upper cover 9 Filter element 10 Lower cover Dimension mm: A = 19.0-19.3 B = 12.5...
LUBRICATION SYSTEM Oil pressure curve at idle speed The curve is obtained at the oil filter port with engine running at a constant speed of 1200 r.p.m. in no-load conditions; pressure is given in bar and temperature in centigrades. The curve represents the minimum pressure value while the maximum value is 5 bar.
FUEL SYSTEM Fuelling/injection circuit for 15 LD 315-350-400-440 Components: 1 Tank 2 Return tube 3 Fuel filter 4 Injection pump 5 Injector leak-off line 6 Injector 7 High pressure line 8 Return tube Fuelling/injection circuit for 15LD 225 1 Tank 2 Injector leak-off line 3 Injector 4 High pressure line...
FUEL SYSTEM Fuel filter 15 LD 225-315-350-400-440 A = 7.3 B = 3.8 C = 1.5 D = 42 H = 75 Characteristics: Filtering area ≥ 390 cm² Filtration level ≤ 7 µm See page 18 for fuel filter replacement...
Check while eccentric 4 is at rest (lowest point of travel). Protrusion A of drive rod 3 is 1.5-1.9 mm; it is not adjustable. Drive rod length = 58-58.2 mm for 15 LD 225 Drive rod length = 65.8-66.0 mm for 15 LD 315/350 Drive rod length = 61,4÷61,6 mm for 15 LD 400/440...
The volume shifted by delivery valve 5 is 15 mm in the pump of 15 LD 315-350 and 25 mm³ in the pump of 15 LD 225 is 21 mm in the pump of 15 LD 400/440...
FUEL SYSTEM Injection pump non-return valve The exhaust union has a non-return valve A. The purpose of this 15 LD valve is to improve the injection phase by expelling the air in the fuel 225-315-350 and preventing it from being sucked in by the pump during the intake phase.
FUEL SYSTEM Injection pump delivery check on test bench 1 Delivery control rack rod 2 Rack rod 1 in stop position 3 Rack rod 1 in max. delivery position A = 18-19 mm (max.rack rod stroke) α α α α α = 66° Static injection timing Disconnect pipe 1 from injection pump and close it, to avoid fuel leakages.
FUEL SYSTEM Static injection lead test on flywheel Fill the tank and make sure that the fuel is not more than 10-15 cm above the tester. Set the flow governor lever of the injection pump in the stop position and lock it there. Turn the flywheel in the engine rotation direction.
FUEL SYSTEM Injection advance adjustment Injection advance beyond the thickness of gasket A is determined by the thickness of the pad inside the injection tappet. To alter the value of injection advance the pad must be replaced with another of a suitable thickness (see fig. 117-118). To extract pad B, use a rod with a suction cap or magnet at one end.
FUEL SYSTEM Nozzles The set-up between the needle and the guide must leave the needle free to fall and merely as a result of its own weight, when lifted 7mm from its seat and rotated in different directions, with the nozzle kept at a 45°...
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NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-467 50707 06-95 22.12.2003...
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6 Oil pressure light 7 Key switch 8 Battery charging light Note: The battery, which is not supplied by LOMBARDINI, should have 12V nominal voltage rating and a capacity of not less than 44 Ah / 210 Amp. of fast discharge intensity.
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ELECTRICAL SYSTEM 24V, 9A alternator battery recharging curve 12V, 30A alternator battery recharging curve The test was conducted after heat stabilizing at 20°C. The value of the current delivered in relation to the curve may be subjected to a variation of between +10 % and -5%. Voltage regulator 12V, 12A: for standard alternators with 3 output wires 12V, 30A: for 12V, 20A alternators with 2 output wires...
5 Pressure switch 6 Solenoid valve 7 Ignition switch Note: The battery, which is not supplied by LOMBARDINI, should have 12V nominal voltage rating and a capacity of not less than 44 Ah / 210 Amp. of fast discharge intensity.
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ELECTRICAL SYSTEM Diagram of electric starter motor protection with sole self- winding starter - without battery - (optional) Components: 1 Alternator 2 Solenoid valve 3 Pressure switch 4 Thermostat 5 A.c. motor stop device COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED...
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Starting motor Bosch type DW (L) 12V, 1.1 KW for 15 LD 315-350-400-440 Bosch type DW (L) 12V, 0.9 KW for 15 LD 225 Anti-clockwise rotation direction (viewed from pinion side) A = 17.5-19.5 mm (distance from flywheel rim surface to starter motor flange surface) Note: Contact Bosch service centers for repair operations.
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ELECTRICAL SYSTEM Characteristic curves of Bosch starter motor type DW (L) 12V, 0.9 kW The curves were measured at a temperature of -20°C with a 55 Ah battery. U = Voltage on motor terminals in Volts. n = Motor speed in rpm M = Torque in Nm I (A) = Power draw in Amperes.
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SETTINGS / ADJUSTMENTS ADJUSTMENTS - 15 LD 315-350 Idling 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 to 1000-1250 rpm by turning set screw 1; then tighten lock nut.
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SETTINGS / ADJUSTMENTS ADJUSTMENTS - 15 LD 225-400-440 No-load idling adjustment (standard) After having filled the engine with oil and fuel, start it and allow it to warm up for 10 minutes. Using adjuster screw 1, regulate the idling rate at 1000-1250 rpm.
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SETTINGS / ADJUSTMENT Injection pump delivery setting 1) Bring engine to idling speed 2) Unscrew delivery limiting device C ( see fig. 145) 3) Bring the engine to the power and rpm required by the manufacturer of the device. 4) Check that fuel consumption falls within the table specifications (see below).
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STORAGE XIII Storage Prepare engines as follows for storage over 30 days Temporary protection (1/6 months) • • • • • Let engine run at idling speed in no-load conditions for 15 minutes. • • • • • Fill crankcase with protection oil MIL-1-644-P9 and let engine run at 3/4 full speed for 5/10 minutes.
TORQUE SPECIFICATIONS MAIN TORQUE SPECIFICATIONS Reference ( fig. Diam. and pitch Torque Torque ( Nm ) Torque ( Nm ) POSITION N° and page) ( mm ) ( Nm ) 225 315-350 400-440 Re-coil starting fig. 18 - p. 25 Connecting rod 8x1 (315-350) fig.
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TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS DESCRIPTION R ≥ ≥ ≥ ≥ ≥ 1000 N/mm R ≥ ≥ ≥ ≥ ≥ 1200 N/mm R ≥ ≥ ≥ ≥ ≥ 800 N/mm Diameter per pitch (mm) 4x0,70 0,37 0,52 0,62...
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COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-467 50707 06-95 22.12.2003...
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Cod. fiscale e Partita IVA 01829970357 - CEE Code IT 01829970357 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.
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