Lombardini 12LD 435-2 Instruction manual

12LD 435-2
12LD 435-2/B1
12LD 475-2
12LD 475-2 EPA
WORK SHOP MANUAL
12LD Series engines,
cod. 1-5302-460_3rd ed.

- 2 - Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
CUSE/ATLO
-
PREFACE
- Every attempt has been made to present within this service manual, accurate and up to date technical
information.
However, development on the LOMBARDINI series is continuous.
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.
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;
3 - The person or people performing service work on LOMBARDINI series engines has read the pertinent
information regarding the subject service operations and fully understands the operation at hand.
-This manual was written by the manufacturer to provide technical and operating information to authorised
LOMBARDINI after-sales service centres to carry out assembly, disassembly, overhauling, replacement and
tuning operations.
-Aswellasemployinggoodoperatingtechniques andobservingtherighttimingforoperations,operatorsmustread
the information very carefully and comply with it scrupulously.
-Time spent reading this information will help to prevent health and safety risks and financial damage.
Written information is accompanied by illustrations in order to facilitate your understanding of every step of the
operating phases.
Drafting
body Document code Edition Issue date Review date
Model
N° Revision Endorsed
9-93 14.06.20071-5302-460 50705 3° 2
REGISTRATIONOFMODIFICATIONSTO THEDOCUMENT
Anymodificationstothisdocumentmustberegisteredbythedraftingbody,bycompletingthefollowingtable.

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
-
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
1 GENERAL REMARKS AND SAFETY INFORMATION ___________________________________ P. 7 - 9
GENERAL SERVICE MANUAL NOTES ........................................................................................................................... 7
GLOSSARY AND TERMINOLOGY................................................................................................................................... 8
SAFETY REGULATIONS ...............................................................................................................................................8-9
WARRANTY CERTIFICATE.............................................................................................................................................. 7
2 TECHNICAL INFORMATION _______________________________________________________ 10 - 15
MANUFACTURER AND MOTOR IDENTIFICATION DATA........................................................................................... 11
OVERALL DIMENSIONS................................................................................................................................................. 15
PERFORMANCE DIAGRAMS......................................................................................................................................... 14
TECHINICAL SPECIFICATIONS ...............................................................................................................................12-13
TROUBLE SHOOTING.................................................................................................................................................... 10
3 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING _____________________________ 16 - 19
ACEA Regulations - ACEA Sequences........................................................................................................................... 17
API / MIL Sequences ....................................................................................................................................................... 17
FUEL SPECIFICATIONS................................................................................................................................................. 19
International specifications.............................................................................................................................................. 17
LUBRICANT ..................................................................................................................................................................... 17
PRESCRIBED LUBRICANT ............................................................................................................................................ 18
ROUTINE ENGINE MAINTENANCE............................................................................................................................... 16
SAE Classification .......................................................................................................................................................... 17
4 DISASSEMBLY/ REASSEMBLY_____________________________________________________ 20 - 31
Alternator.......................................................................................................................................................................... 21
Camshaft end play........................................................................................................................................................... 30
Camshaft timing............................................................................................................................................................... 30
Center main bearing support, locating bolt .................................................................................................................... 28
Clearance between main journals/crank pins and connecting rod bearings ................................................................. 29
Compression release (optional) ...................................................................................................................................... 22
Connecting rod big end bearing ...................................................................................................................................... 26
Connecting rod small end bushing.................................................................................................................................. 26
Connecting rod weight ..................................................................................................................................................... 27
CRANKSHAFT ............................................................................................................................................................28-29
Crankshaft center main bearing support ........................................................................................................................ 28
Crankshaft end play......................................................................................................................................................... 28
Crankshaft journal radius ................................................................................................................................................ 28
Crankshaft lubrication ducts............................................................................................................................................ 28
Crankshaft timing gear .................................................................................................................................................... 27
Cylinder ............................................................................................................................................................................ 24
Cylinder Head .................................................................................................................................................................. 22
Cylinder roughness .......................................................................................................................................................... 24
Dimensions of camshaft journals and housings............................................................................................................. 30
Dry air cleaner.................................................................................................................................................................. 21
CHAPTER INDEX

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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 ...................................................................................................................................................... 29
Main bearing support, PTO-Side..................................................................................................................................... 27
Main bearing support, timing gear side .......................................................................................................................... 27
Main bearing supports ..................................................................................................................................................... 29
Mechanical speed governor............................................................................................................................................. 31
Oil-bath air cleaner .......................................................................................................................................................... 20
Piston ............................................................................................................................................................................... 24
Piston - Refitting .............................................................................................................................................................. 26
Piston clearance .............................................................................................................................................................. 26
Piston rings - End gaps ................................................................................................................................................... 25
Piston rings - Fitting sequence........................................................................................................................................ 25
Piston weight.................................................................................................................................................................... 25
Pistons ringis - Clearance between grooves................................................................................................................... 25
RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING .......................................................................... 20
RECOMMENDATIONS FOR OVERHAULS AND TUNING............................................................................................ 20
Rocker arm assembly...................................................................................................................................................... 22
Spring for extra fuel supply at starting............................................................................................................................ 31
Valve guide insertion ....................................................................................................................................................... 23
Valve guides and valve guide housings.......................................................................................................................... 23
Valve I Rocker arm clearance ......................................................................................................................................... 21
Valve seat grinding .......................................................................................................................................................... 24
Valve seats and housings................................................................................................................................................ 23
Valve timing without considering timing marks .............................................................................................................. 30
Valves............................................................................................................................................................................... 23
5 LUBRICATION SYSTEM ____________________________________________________________ 32- 34
LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM .................................................................... 32
Oil filter cartridge (external)............................................................................................................................................. 33
Oil filter cartridge (internal) ............................................................................................................................................. 33
Oil preassure relief valve ................................................................................................................................................. 33
Oil pressure curve at full speed....................................................................................................................................... 34
Oil pressure curve at idling speed................................................................................................................................... 34
Oil Pump .......................................................................................................................................................................... 33
6 FUEL SYSTEM __________________________________________________________________ 35 - 39
Fuel feeding pump ........................................................................................................................................................... 35
Fuel feeding/injection circuit............................................................................................................................................ 35
Fuel filter, inside fuel tank ............................................................................................................................................... 35
Fuel filter, removed from the tank (upon request).......................................................................................................... 35
How to reassemble injection pump components............................................................................................................ 36
Injection pump ................................................................................................................................................................. 36
Injection pump/mechanical speed governor timing........................................................................................................ 37
Injection static advance adjustment...........................................................................................................................37-38
Injector setting ................................................................................................................................................................. 39
Injector, for EPA engines................................................................................................................................................. 39
Injector, for standard engines.......................................................................................................................................... 38
Test data for injection pump delivery.............................................................................................................................. 36
7 ELECTRIC SYSTEM ______________________________________________________________ 40 - 42
Alternator battery charger curve (12 V, 18 A)................................................................................................................. 41
Alternator battery charger curve (12.5 V, 14A)............................................................................................................... 40
Alternator, 12 V - 18A ...................................................................................................................................................... 41
Alternator, 12.5 V - 14 A.................................................................................................................................................. 40
Chapter index

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
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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............................................................................................................... 42
Voltage regulator.............................................................................................................................................................. 41
8 SETTINGS ______________________________________________________________________ 43 - 44
Full speed setting in no-load conditions (standard) ....................................................................................................... 43
Idling speed setting in no-load conditions ...................................................................................................................... 43
Injection pump delivery limiting and extra fuel device.................................................................................................... 43
Injection pump delivery setting........................................................................................................................................ 43
Injection pump delivery setting with engine at the torque dynamometer ...................................................................... 44
Stop setting ...................................................................................................................................................................... 44
9 STORAGE __________________________________________________________________________ 45
External engine protection............................................................................................................................................... 45
Injection systems protection............................................................................................................................................ 45
Internal engine protection ................................................................................................................................................ 45
PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE ..................................................................... 45
STORAGE........................................................................................................................................................................ 45
10 TORQUE SPECIFICATIONS AND USE OF SEALANT __________________________________ 46 - 47
Table of tightening torques for standard screws (coarse thread) .................................................................................. 47
Table of tightening torques for standard screws (fine thread) ....................................................................................... 47
Table of tightening torques for the main components.................................................................................................... 46
Use of sealant .................................................................................................................................................................. 46
11 SPECIAL TOOLS ____________________________________________________________________ 48
Chapter index

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Chapter index
Notes :

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
1
- 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.
- If no hour-meter is fitted , 12 working hours per calendar day will be considered.
- For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling system,
sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above mentioned period
(24 months) is not expired.
- For correctmaintenanceandreplacementoftheseparts,itisnecessarytofollowtheinstructionsreportedinthedocumentation
supplied with each engine.
- To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be carried out
by qualified personnel only.
- The list of the Lombardini authorized dealers is reported in the “Service” booklet, supplied with each engine.
- Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump), filtering
system, turbo-charged models, will require special written warranty agreements.
- Within the above stated periods Lombardini Srl directly or through its authorized network will repair and/or replace free of
charge any own part or component that, upon examination by Lombardini or by an authorized Lombardini agent, is found to
be defective in conformity, workmanship or materials.
- Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine use or
from both the total or partial impossibility of use, is excluded.
- The repair or replacement of any component will not extend or renew the warranty period.
Lombardini warranty obligations here above described will be cancelled if:
- Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected
and altered.
- Lombardini engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied with
each engine.
- Any seal affixed to the engine by Lombardini has been tampered with or removed.
- Spare parts used are not original Lombardini.
- Feeding and injection systems are damaged by unauthorized or poor quality fuel types.
- Electrical system failure is due to components, connected to this system, which are not supplied or installed by Lombardini.
- Engines have been disassembled, repaired or altered by any part other than an authorized Lombardini agent.
- Following expiration of the above stated warranty periods and working hours, Lombardini will have no further responsibility
for warranty and will consider its here above mentioned obligations for warranty complete.
- Any warranty request related to a non-conformity of the product must be addressed to the Lombardini Srl service agents.
GENERAL SERVICE MANUAL NOTES
1 - Use only genuine Lombardini repair parts.
Failure to use genuine Lombardini parts could result in
sub-standard performance and low longevity.
2 - All data presented are in metric format.
That is, dimensions are presented in millimeters (mm),
torque is presented in Newton-meters (Nm), weight is
presented in kilograms (kg), volume is presented in liters
or cubic centimeters (cc) and pressure is presented in
barometric units (bar).
WARRANTY CERTIFICATE
GENERAL REMARKS AND SAFETY INFORMATION

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1
· LombardiniEnginesare builttosupply their performancesina safe andlong-lastingway.
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.
· The engine has been made according to a machine manufacturer's specifications and all actions required to meet the essential
safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit.
All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined
by Lombardini which thus declines all liability for any accidents deriving from such operations.
· The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine
operation in particular, along with the relative routine maintenance work.
· The user must read these instructions carefully and become familiar with the operations described.
Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the
vicinity of the machine.
· The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and
the deriving dangers.
This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the
lattercase, must only be carried out bypersons specificallytrained byLombardini andwho workin compliancewith the existing
documentation.
· Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal of seals,
demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall
relieve Lombardini from all and every liability for deriving accidents or for failure to comply with the laws in merit.
· On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the case of
manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous objects, also
considering the movements made by the operator.
Pull-starting with a free cord (thus excluding self-winding starting only), is not permitted even in an emergency.
· Make sure that the machine is stable to prevent the risk of overturning.
· Become familiar with how to adjust the rotation speed and stop the engine.
· Never start the engine in a closed place or where there is insufficient ventilation.
Combustioncreatescarbon monoxide, anodourlessandhighly poisonousgas.
Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death.
General remarks and safety information
GLOSSARY AND TERMINOLOGY
For clarity, here are the definitions of a number of terms used
recurrently in the manual. - Cylinder number one: is the first piston viewed from the
«1st P.T.O. side of the engine».
- Rotation direction: anticlockwise viewed from the «1st
P.T.O. side of the engine».
-Important remarks and features of the text are highlighted
using symbols, which are explained below:
Danger – Attention
Thisindicates situations of grave danger which,if ignored,
mayseriously threatenthehealthand safetyofindividuals.
SAFETY AND WARNING DECALS
Caution – Warning
Thisindicatesthatitisnecessarytotakeproperprecautions
to prevent any risk to the health and safety of individuals
and avoid financial damage.
Important
This indicates particularly important technical information
that should not be ignored.
SAFETY REGULATIONS

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
1
· Theenginemustnotoperateinplacescontaininginflammablematerials,inexplosiveatmospheres,wherethereisdustthatcan
easilycatchfireunlesspecific,adequateandclearlyindicatedprecautionshavebeentakenandhavebeencertifiedforthemachine.
· To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.
· Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from
their operation.
· Fuel is inflammable.
The tank must only be filled when the engine is off.
Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil.
Make sure that no soundproofing panels made of porous material are soaked in fuel or oil.
Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil.
· Fully tighten the tank plug each time after refuelling.
Do not fill the tank right to the top but leave an adequate space for the fuel to expand.
· Fuel vapour is highly toxic.
Only refuel outdoors or in a well ventilated place.
· Do not smoke or use naked flames when refuelling.
· The engine must be started in compliance with the specific instructions in the operation manual of the engine and/or
machine itself.
Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).
· Before starting, remove any tools that were used to service the engine and/or machine.
Make sure that all guards have been refitted.
· During operation, the surface of the engine can become dangerously hot.
Avoid touching the exhaust system in particular.
· Before proceeding with any operation on the engine, stop it and allow it to cool.
Never carry out any operation whilst the engine is running.
· The coolant fluid circuit is under pressure.
Never carry out any inspections until the engine has cooled and even in this case, only open the radiator plug or
expansion chamber with the utmost caution, wearing protective garments and goggles. If there is an electric fan, do not
approach the engine whilst it is still hot as the fan could also start operating when the engine is at a standstill.
Only clean the coolant system when the engine is at a standstill.
· When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to safeguard
the environment.
The spongy filtering material in oil-cooled air filters must not be soaked in oil.
The reservoir of the separator pre-filter must not be filled with oil.
· The oil must be drained whilst the engine is hot (oil T ~ 80°C).
Particular care is required to prevent burns.
Do not allow the oil to come into contact with the skin.
· Make sure that the drained oil, the oil filter and the oil it contains are disposed of in the correct way in order to safeguard
the environment.
· Pay attention to the temperature of the oil filter when the filter itself is replaced.
· Only check, top up and change the coolant fluid when the engine is off and cold.
Take care to prevent fluids containing nitrites from being mixed with others that do not contain these substances since
"Nitrosamine", dangerous for the health, can form.
The coolant fluid is polluting and must therefore be disposed of in the correct way to safeguard the environment.
· During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect and
insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter motor from being
energized.
· 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.
General remarks and safety information

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2
ELECTRIC
SYSTEM
SETTINGS / REPAIR LUBRIFICATION FUEL CIRCUIT
MAINTE-
NANCE
POSSIBLE CAUSE
Engine starts but stops
Engine does not start No acceleration Non uniform speed
Dripping oil and fuel from the exhaust
Oil pressure too low
White smoke
Black smoke
TROUBLE
Excessive oil consumption
Obstructed fuel line
Clogged fuel filter
Air inside fuel circuit
Collged tank breather
Faulty feed pump
Injector stuck
Injection pump valve damaged
Injector not adjusted
Plunger excessive leakage
Hardened pump control rod
Wrong injection pump delivery setting
Too high oil level
Oil pressure valve blocked or dirty
Worn oil pump
Air inside oil suction pipe
Faulty pressure gauge or switch
Clogged oil suction pipe
Battery discharged
Wrong or inefficient cable connection
Defective starter switch
Defective starting motor
Clogged air filter
Excessive idle operation
Incomplete running-in
Engine overloaded
Advanced injection timing
Retarded injection timing
Incorrect governor linkage adjustment
Governor spring broken or unhooked
Too low idle-speed setting
Worn-out or stuck piston rings
Worn cylinders
Worn valve guides
Valves sticking or damaged
Worn-out bearings
Non-sliding speed governor leverage
Crankshaft not turning freely
Damaged cylinder head gasket
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.
Always perform these simple checks before removing or replacing any part.
TECHNICAL INFORMATION
Oil level increase

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
A
F
D
E
B
C
2
1
23
4
7
65
Theidentification plateshown inthe figurecan be found directly onthe
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
The approval reference directives EC are on the engine plate.
Thedata plate forEPAStandards isappliedon theairshroud.
Itcontainsthefollowinginformation:
1) Currentyear
2) Engine displacement
3) Rated power, measured in kW
4) EPA family ID
5) Injection timing
6) Injection opening preassure
7) Valve clearance
Technical information
MANUFACTURER AND MOTOR IDENTIFICATION DATA

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180°
n°
mm
cm3
kg
kW/CV
Nm/kgm
Nm/kgm
Kg
n°
g/kWh - g/CVh
kg/h
435-2 435-2/B1 475-2
EPA
260-191
0,020
80
35°
25°
1150
15500
80
35°
25°
1250**
16200**
3600
14.7/20.0
13.2/18.0
12.0/16.3
49.0/5.0
25.0/2.5
300
3000
14.0/19.0
12.7/17.2
11.4/15.5
49.0/5.0
25.0/2.5
300
3000
15.8/21.5
14.8/20.1
13.5/18.3
57.0/5.8
25.0/2.5
300
245-180
0,025
280-206
0,020
90x75
954
18.0:1
86x75
871
18.0:1
2
475-2
86x75
871
18.0:1
80
35°
25°
1050
13300
90x75
954
20.0:1
3000
-
14.8/20.1
13.5/18.3
48.0/4.9
25.0/2.5
300
80
35°
25°
1150
15500
257-189
0,025
Momentary
Up to 1 hour
l/min
l/min
2 per cylinder
Camshaft inside the crankcase
Mechanic
Direct, on piston
side camshaft, rods and rocker-arms
Driving shaft degrees
Oil bath air cleaner or dry air cleaner
Air (fan integral to the flywheel)
Counter-clockwise (1st P.T.O. side)
2 in line
Four-stroke diesel
POWER AND TORQUE
CONSUMPTION AT MAXIMUM POWER
GENERAL DETAILS
Operating cycle
Cylinders
Bore x stroke
Displacements
Compression rate
Intake
Cooling
Crankshaft rotation
Combustion sequenc
Timing system
Valves
Shaft
Tappets
Fuel injection
Dry weight of engine
Maximum tilt while operating
Maximum tilt while operating
Combustion air volume at 3000 r.p.m.
Cooling air volume at 3000 r.p.m.
Maximum operating speed N 80/1269/CEE ISO 1585
Max power NB ISO 3046 IFN
NA ISO 3046 ICXN
Maximum torque (NB power)*
Maximum torque 3rd P.T.O.
Axial load allowed on crankshaft
Specific fuel onsumption***
Oil consumption
r.p.m.
TECHINICAL SPECIFICATIONS
Technical information
Engine type, 12LD:
* 2000 rpm for 435-2 e 435-2/B1 engines, 2100 rpm for 475-2 engines, 2200rpm for 475-2 EPA engines.
** At 3600 rpm.
*** At NB power.

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
bar
bar
µ
bar
cm2
bar
µm
bar
V
V
A
A
kW
2.7
2.5
0,6
2.7
2.5
0,6
7
20
15
1.5÷1.7
730
4.5
70
0.60÷0.75
12,5
12
14
18
1.7
2
2.7
2.5
0,6
2.7
2.5
0,6
cm2
µ
bar
cm2
µ
2400
2÷3
4
460
7
435-2 435-2/B1 475-2
EPA
475-2
FUEL SUPPLY CIRCUIT
Fuel type
Fuel supply
Fuel filter, internal
Filtering surface
Filter capacity
Maximum operating pressure
Fuel filter, external
Filtering surface
Filter capacity
Alternator, Internal Standard (nominal voltage)
Alternator, Internal Optional (nominal voltage)
Alternator, Internal Standard (nominal current) *
Alternator, Internal Optional (nominal current) *
Starter motor power (Bosh GF)
Type of lubrication
Circuit supply
Maximum oil quantity
Maximum oil quantity
Oil pressure at min. speed (oil temperature: 120°C)
Oil filter cartridge, external
Maximum operating pressure
Maximum combustion pressure
Filter capacity
By-pass valve setting
Filtering surface
Oil filter cartridge, internal
Maximum operating pressure
Filter capacity
By-pass valve setting
Including filter (l)
Excluding filter (l)
bar
Completely forced
Gear pump
LUBRICATION CIRCUIT
ELECTRICAL SYSTEM
Automotive diesel fuel (minimum cetane: 51)
Mechanical fuel lift pump, diaphragm type
* (see “Alternator battery charger curve” pages 40÷41)
Technical information
Engine type, 12LD:

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2
12 LD 475-2 EPA12 LD 475-2
12 LD 435-2 B112 LD 435-2
N (80/1269/CEE - ISO 1585) AUTOMOTIVE RATING: Intermittent operation with variable speed and variable load.
NB (ISO 3046 - 1 IFN) RATING WITH NO OVERLOAD CAPABILITY: Continuos light duty operation with constant speed
and variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOUS RATING WITH NO OVERLOAD CAPABILITY: Continuos heavy duty with constant
speed and constant load.
MN Torque curve (N curve) - MB (NB curve) - MA (NA curve).
C Specific fuel consumption curve.
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.
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.
PERFORMANCE DIAGRAMS
Technical information

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
2
12LD 435-2 – 435-2/B1 – 475-2 – EPA
OVERALL DIMENSIONS
Technical information

- 16 - Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
10 125 250 500 1000 2500 5000
(***)
(***)
(***)
(*)
(*)
(*)
(**)
(**)
(***)
(°)
(***)
(°)
3
ENGINEOIL LEVEL
OIL BATH AIR CLEANER
DRYAIR CLEANER
FUEL PIPES
COOLING SYSTEM CLEANING
VALVE-ROCKER ARMS CLEARANCE
ADJUSTMENT
SETTING AND INJECTORS CLEANING
RUBBER INTAKE HOSE (DRY AIR
CLEANER - INTAKE MANIFOLD)
ENGINE OIL RADIATOR CLEANING
ALTERNATOR AND STARTING MOTOR
FUEL TANK CLEANING
ENGINE OIL
EXTERNALOIL FILTER
FUELFILTER
RUBBER INTAKE HOSE (DRY AIR
CLEANER - INTAKE MANIFOLD)
FUEL PIPES
DRY AIR CLEANER EXTERNAL
CARTRIDGE
DRY AIR INTERNAL EXTERNAL
CARTRIDGE
PARTIAL
TOTAL
Engine oil replacement. Oil filter replacement.
EXTRAORDINARY MAINTENANCE
AFTER THE FIRST
50WORKINGHOURS
ORDINARY MAINTENANCE
OPERATION DESCRIPTION FREQUENCY x HOURS
CHECK
REPLACEMENT
OVERHAUL
AFTER 6 CHECKS WITH CLEANING
(*) - In case of low use: every year.
(**) - In case of low use: every 2 years.
(***) - The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates.
The air filter must be cleaned and replaced more frequently In very dusty conditions.
(°) - Alternately when the clogging indicator, if present, indicates it’s necessary to replace the filter.
Failure to carry out the operations described in the table may lead to technical damage to the machine
and/or system
ROUTINE ENGINE MAINTENANCE
AFTER 3 CHECKS WITH CLEANING
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
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1
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8
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CF CE CD CC CB CA SA SB SC SD SE SF SG
L - 2104 D / E L - 46152 B / C / D / E
SH
API SJ SLCH-4 CG-4 CF-4 CF-2
MIL
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DIESEL
3
SAE 20W*SAE 30*
SAE 40*
SAE 10W-30**
SAE 10W-40**
SAE 10W-60**
SAE 15W-40 **
SAE 15W-40 **
SAE 20W-60 **
SAE 5W-30 ***
SAE 0W-30 ***
-
30 - 25 - 20 -
15 -
10 - 50+
5+ 10 + 15 + 20 +
25 +
30 + 35 +
40 + 45
SAE 10W*
+
50
-
35
-
40
SAE 5W-40 ***
International specifications
They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing
and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.
A.P.I : ( American Petroleum Institute )
MIL : Engine oil U.S. military specifications released for logistic reasons
ACEA : European Automobile Manufacturers Association
Tables shown on page 53 are of useful reference when buying a kind of oil.
Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different brands
and choosing the kind with the right characteristics.
Usually a specification showing a following letter or number is preferable to one with a preceding letter or number.
An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.
API / MIL SEQUENCES
PETROL
A1 =Low-viscosity, for frictions reduction
A2 =Standard
A3 =High performances
LIGHT DUTY DIESEL ENGINES
B1 =Low-viscosity, for frictions reduction
B2 =Standard
B3 =High performances (indirect injection)
B4 =High quality (direct injection)
HEAVY DUTY DIESEL ENGINES
E1 =OBSOLETE
E2 = Standard
E3 = Heavy conditions (Euro 1 - Euro 2 engines )
E4 = Heavy conditions
(Euro 1 - Euro 2 - Euro 3 engines )
E5 = High performances in heavy conditions (Euro 1 - Euro 2 -
Euro 3 engines )
ACEA REGULATIONS - ACEA SEQUENCES
LUBRICANT
SAE Classification
In the SAE classification, oils differ on the basis of their
viscosity, and no other qualitative characteristic is taken
into account.
The first number refers to the viscosity when the engine is
cold (symbol W = winter), while the second considers
viscosity with the engine at régime.
The criteria for choosing must consider, during winter, the
lowest outside temperature to which the engine will be
subject and the highest functioning temperature during
summer.
Single-degree oils are normally used when the running
temperature varies scarcely.
Multi-degree oil is less sensitive to temperature
changes.
*Mineralbase
**Semi-syntheticbase
***Synthetic base
SAE- Grade
OBSOLETE
PETROL
CURRENT
Maintenance - Recommended oil type - Refilling

- 18 - Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
2.7
2.5
3
AGIP
SUPERDIESEL
MULTIGRADE
10W40
API CF4 / SG
ACEA B2 - E2
MIL - L-4165 D/E
2.5
2.4
475
435-2
435-2/B1
12 LD ENGINES OIL CAPACITY
Litres
Litres
OIL VOLUME AT MAX LEVEL (OIL FILTER INCLUDED)
OIL VOLUME AT MAX LEVEL (WITHOUT OIL FILTER)
Danger - Attention
- The engine may be damaged if operated with insufficient lube oil.
- It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by
its combustion.
- Use proper lube oil preserve your engine.
Good quality or poor quality of the lubricating oil has an affect on engine performance and life.
- If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking, and
accelerated wear of the cylinder liner, bearing and other moving components increases significantly.
- Always use oil with the right viscosity for the ambient temperature in which your engine is being operated.
Use the chart when chosing your engine oil.
Danger - Attention
- The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.
- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.
- Do not disperse the oil in the ambient, as it has a high pollution power.
PRESCRIBED LUBRICANT
specifications
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.
For a temperature of -10°C an oil with a 5W40 viscosity is recommended.
For a temperature of -15°C an oil with a 0W30 viscosity is recommended.
Maintenance - Recommended oil type - Refilling

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Workshop Manual 12 LD _ cod. 1.5302.460 - 3° ed_ rev. 02
API CF4 - CG4
API CF - CD - CE
15
3
As for filters, tanks and special crankcases please refer to LOMBARDINI instructions.
Fuel with low sulphur content
Fuel with high sulphur content
PRESCRIBED LUBRICANT
FUELS FOR LOW TEMPERATURES
It is possible to run the engine at temperatures below 0°C using special winter fuels.
These fuels reduce the formation of paraffin in diesel at low temperatures. If paraffin forms in the diesel, the fuel filter becomes
blocked interrupting the flow of fuel.
Fuel can be: - Summer up to 0°C
- Winter up to -10°C
- Alpine up to -20°C
- Arctic up to -30°C
For all fuel types, the cetane number cannot be lower than 51.
AVIATION KEROSENE AND RME FUELS (BIOFUELS)
The use of these fuels is allowed. However they may condition the performance of the engine.
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
Litres
The countries in which diesel normally has a low sulphur content are: Europe, North America and Australia.
Danger - Attention
- To avoid explosions or fire outbreaks, do not smoke or use naked flames during the operations.
- Fuel vapours are highly toxic. Only carry out the operations outdoors or in a well ventilated place.
- Keep your face well away from the plug to prevent harmful vapours from being inhaled.
- Dispose of fuel in the correct way and do not litter as it is highly polluting.
To achieve optimum performance of the engine, use good quality fuel with certain characteristics:
Cetane number (minimum 51): indicates the ignition quality.
A fuel with a low cetane number may cause problems when starting from cold and have a
negative effect on combustion.
Viscosity (2.0/4.5 centistokes at 40°C): this is the resistance to flow and performance may decline if not within the limits.
Density (0.835/0.855 Kg/litre): alowdensityreducesthepower of theengine, anddensity thatis toohigh increases performance
and opacity of the exhaust
Distillation (85% at 350°): this is an indication of the mixture of different hydrocarbons in the fuel.
A high ratio of light hydrocarbons may have a negative effect on combustion.
Sulphur (maximum 0.05% of the weight): high sulphur content may cause engine wear.
In those countries where diesel has a high sulphur content, it is advisable to lubricate
the engine with a high alkaline oil or alternatively to replace the lubricating oil
recommended by the manufacturer more frequently.
FUEL SPECIFICATIONS
Maintenance - Recommended oil type - Refilling

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1
4
Oil-bath air cleaner
Check gaskets and replace if necessary.
Check that flange weld is free of porosity or defective spots.
Carefully clean bowl and filtering element with Diesel oil and blow
through with compressed air.
Top up with engine oil to the mark.
When refitting tighten nuts at 25 Nm.
See page 16 for periodic maintenance details.
Components:
1Bowl 5Internal seal ring
2Oil level mark 6Cover
3Filtering element 7Clamp
4Seal ring 8Prefilter
Important
To locate specific topics, the reader should refer to the
index.
–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.
–The operator must make sure that the contact surfaces
are intact, lubricate the coupling parts and protect those
that are prone to oxidation.
–Before any intervention, the operator should lay out all
equipment and tools in such a way as to enable him to
carry out operations correctly and safely.
–For safety and convenience, you are advised to place the
engine on a special rotating stand for engine overhauls.
–Before proceeding with operations, make sure that
appropriate safety conditions are in place, in order to
safeguard the operator and any persons involved.
–In order to fix assemblies and/or components securely, the
operator must tighten the fastening parts in a criss-cross
or alternating pattern.
–Assemblies and/or components with a specific tightening
torque must initially be fastened at a level lower than the
assignedvalue, and then subsequently tightened to thefinal
torque.
RECOMMENDATIONS FOR OVERHAULS AND TUNING
Important
To locate specific topics, the reader should refer to the
index.
–Before any intervention, the operator should lay out all
equipment and tools in such a way as to enable him to
carry out operations correctly and safely.
–The operator must comply with the specific measures
described in order to avoid errors that might cause damage
to the engine.
–Before carrying out any operation, clean the assemblies
and/or components thoroughly and eliminate any deposits
or residual material.
–Wash the components with special detergent and do not
use steam or hot water.
–Do not use flammable products (petrol, diesel, etc.) to
degrease or wash components. Use special products.
–Dry all washed surfaces and components thoroughly with
a jet of air or special cloths before reassembling them.
–Apply a layer of lubricant over all surfaces to protect them
against oxidation.
–Checkall componentsfor intactness, wearand tear, seizure,
cracks and/or faults to be sure that the engine is in good
working condition.
–Some mechanical parts must be replaced en bloc, together
with their coupled parts (e.g. valve guide/valve etc.) as
specified in the spare parts catalogue.
Danger - Attention
During repair operations, when using compressed air,
wear eye protection.
RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING
DISASSEMBLY / REASSEMBLY