Lombardini 3LD 450 Instruction manual

WORKSHOP
MANUAL
3/4 LD, CODE1-5302-556 ENGINE SERIES
SERVICE
3LD 450
3LD 510
3LD 450/S
3LD 510/S
4LD 640
4LD 705
4LD 820
3rd edition
DATE
30.11.2001
TECO/ATL AUTHOR BOOK CODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 APPROVAL 1

BOOK CODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 DATE
30-11-2001
APPROVAL
TECO/ATL AUTHOR
2
INDEX OF CHAPTERS
IMODEL AND IDENTIFICATION
II CHARACTERISTIC CURVES
III MAINTENANCE
RECOMMENDED OIL, CAPACITIES
VI TROUBLE SHOOTING
VDISASSEMBLING AND REASSEMBLING
VI LUBRICATION CIRCUIT
VII FUEL/INJECTION CIRCUIT
VIII ELECTRIC CIRCUIT
IX ELECTRIC EQUIPMENT
XADJUSTMENTS
XI UPKEEPING
XII TECHNICAL DATA
XIII MAIN DRIVING TORQUES
XIV USE OF SEALANT
XV CLAMPING TORQUES
This handbook provides the main information concerning the repair of the following LOMBARDINI Diesel
engines 3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S, 4LD 640, 4LD 705, 4LD 820, which are air-cooled,
provided with direct injection and revised on the 30-11-2001.
Page 3
" 4
" 5
" 6
" 7
" 18
" 20
" 22
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" 27
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" 29
" 30
" 31
INTRODUCTION

DATE
30-11-2001
TECO/ATL AUTHOR BOOKCODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 APPROVAL 3
REGISTRATION CODE AND IDENTIFICATION
Approval code
Engine serial number
Customer's code
Approval code
DIESEL
LOMBARDINI
Engine grup number
Displacement CC
Displacement CC
DIESEL
Customer's code
Engine serial number
LOMBARDINI
Engine group number
I

BOOK CODE
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MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 DATE
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4
N (80/1269/EU - ISO 1585) AUTOMOTIVES POWER : Discontinuous services at variable rpm and load.
NB (ISO 3046 - 1 IFN) NON-OVERLOADABLE POWER:Continuous light services at constant rpm and variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOUS OVERLOADABLE POWER: Continuous heavy-duty services at constant rpm and load.
The above mentioned power levels refer to the engine equipped with air filter, standard silencer, suction fan - which previously underwent a
breaking-in period - at 20°C ambient conditions, at 1 bar.
The maximum power is guaranteed with a 5% tolerance.
These powers are reduced of abt. 1% every 100 m height and of 2% for every 5°C exceeding 25°C.
C (NB): Specific fuel consumption at NB power
MT : Torque at N power
a: Continuous service field of use. For any purpose out of this field of use, please contact company LOMBARDINI.
CHARACTERISTIC CURVES CONCERNING POWER, TORQUES AND SPECIFIC
CONSUMPTION
Il CHARACTERISTIC CURVES

DATE
30-11-2001
TECO/ATL AUTHOR BOOKCODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 APPROVAL 5
SAE 5W/30
SAE 10W/40
SAE 15W/40
SAE 15W/30
-20 -10 +10 +20 +30
0
-13 -4 514 23 32 41 86
50 59 68 77
SAE 40
°C
°F
SAE 30
SAE 20W/20
RATING
SAE 10W
CAPACITIES IN LITERS
Standard fuel tank
3LD450, 3LD510, 3LD451/S, 3LD510/S = 5.3
4LD 640, 4LD705, 4 LD 820 = 7.2
Standard oil sump:
3LD450, 3LD510, 3LD451/S, 3LD510/S =1.75
4LD640, 4LD705, 4LD 820 = 2.60
Air filter oil bowl = 0.3
For special filters, tanks and oil sumps, please
follow LOMBARDINI instructions.
INTERVALS (HOURS)
OPERATION DETAIL 10 50 125 250 500 1000 2500 5000
AIR FILTER (OIL-BATH) (*)
CLEANING HEAD AND CYLINDER FINS (*)
FUEL TANK
INJECTORS AIR FILTER OIL
CHECK LEVEL SUMP OIL
BATTERY LIQUID
FUEL HOSE COUPLING FASTENING
VALVE AND ROCKER ARM CLEARANCE
INJECTOR SETTING
AIR FILTER(**) (***)
CHANGE SUMP (***)
OIL FILTER CARTRIDGE
FUEL FILTER CARTRIDGE
OVERHAUL PARTIAL (****)
GENERAL
First replacement.
(*) In particular running conditions even every day.
(**) In particularly dusty environments every 4-5 hours.
(***) See prescribed oil.
(****) It includes the check of cylinders, segments, guides, valve seat springs and grindings, head and cylinder
descaling, injection pump and injector checks.
RECOMMENDED OIL
AGIP DIESEL SIGMA S SAE 30-40 MIL-L-2104 C
ESSOLUBE D3 specification, MIL-L-2104 D and
UNIFARM specification MIL-L-2104 C. For
Countries in which AGIP and ESSO products
are not available, the prescribed oil is API
SERVICE CD for diesel engines or oil which
should be in conformity with the MIL -L-2104 C
and MIL -L-2104D military specifications.
MAINTENANCE -PRESCRIBED OIL - REFUELLINGS III

BOOK CODE
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MODEL No.
50839
DATEOFISSUE
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6
PROBABLE CAUSES
ELECTRICAL EQUIPMENT
SETTINGS AND REPAIRINGS LUBRICATION FUEL CIRCUIT
Excessive oil consumption
Low oil pressure
Oil level increase
Inconsistent rpm
It does not ac- celerate
It starts but does not stop
It does not start
This table shows some possible causes concerning malfunctions that could arise during the machine running. Always,
systematically carry out simpler checks before any disassembly or replacement.
Oil and fuel leakage from the exhaust
TROUBLE
Black smoke
White smoke
Cylinder head gasket
MAINTENANCE
Clogged pipings
Clogged fuel filter
Presence of air in the fuel circuit
Clogged tank breather
Faulty fuel pump
Blocked injector
Blocked injection pump valve
Wrong injector setting
Plunger excessive leakage
Stuck injection pump delivery control
Wrong injection pump delivery setting
High oil level
Blocked pressure relief valve
Worn oil pump
Presence of air inside the oil intake pipe
Faulty pressure gauge or switch
Clogged oil intake duct
Discharged battery
Inefficient or wrong cable connection
Faulty starting switch
Faulty starting motor
Clogged air filter
Excessive idle operation
Incomplete running-in
Overloaded engine
Advanced injection
Delayed injection
Incorrect governor tinkage adjustment
Broken or loose govener spring
Low idling setting
Worn or stuck piston rings
Worn or scored cylinders
Worn valve guides
Sticking valves
Worn crankshaft-connecting rod bearings
Non-sliding speed governor leverage
Crank shaft not turning freely
TROUBLE SHOOTING
IV

DATE
30-11-2001
TECO/ATL AUTHOR BOOKCODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 APPROVAL 7
3
DISASSEMBLY AND REASSEMBLY
Apart from disassembly and reassembly operations, this chapter
also includes checks, setting up, dimensions, repairs and running
instructions.
It is necessary to use LOMBARDINI original spare parts for a correct
repair.
Oil-bath air filter (standard)
Oil-bath type with double filtering mass.
The lower mass is made of metal, while the upper is made of
polyurethan.
Check the gasket conditions and replace them in case they are
damaged.
Make sure that the weldings are not damaged.
Carefully clean the lower body and the filtering masses using
some gas oil, blow the lower mass with compressed air and dry
the upper mass by means of a cloth. Fill with engine oil filter to the
indicated level.
While reassembling, tighten the nuts at 25 Nm (3LD450, 3LD510,
3LD451/S, 3LD 510/S), at 30 Nm (4LD 640, 4LD 705, 4LD 820)
Details:
1Upper body 4External sealing ring
2Filtering mass made of polyurethan 5 Filterning mass
3 Internal sealing ring 6Bowl
Silencer (standard)
Make sure that it is free from any carbon and oily residues, if
contaminated, replace it. While reassembling it, replace the gaskets
and tighten the brass nuts at 25 Nm.
Flywheel
Clockwise unscrew nut 1and remove the flywheel using the puller
2Part. no. 7271-3595-050 for 3LD 450, 3LD 451/S, 3LD510, 3LD510/S,
while for 4LD 640, 4 LD 705, 4LD 820 use puller with Part. no. 7271-
3595-048.
Check that the starter ring gear, when it is present, and the conic
surface of the driving shaft coupling hole are intact.
While reassembling, tighten the screws 1 at 170 Nm for 3LD 450,
3LD 451/S, 3LD510, 3LD 510/s and at 350 Nm for 4LD 640, 4LD
705, 4LD 820.
Note: The flywheels of the left-hand engines (3LD 451/S, 3LD 510/
S) have a blading turned in the opposite direction and the nut
1shall be anticlockwise unscrewed.
2
1
DISASSEMBLY/REASSEMBLY V

BOOK CODE
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MODEL No.
50839
DATEOFISSUE
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8
9
Starting pulley
In order to carry out any easier staring, it is necessary to place the
driving shaft at the TDC (Top dead center) and to assemble the pulley
with notch 1 moved back at ( 45°) according to the rotation direction of
the engine, as per picture 4 and 5 .
Tighten the screws at 35 Nm for 3LD 450, 3LD 451/S, 3LD510, 3LD
510/S, at 40 Nm for 4LD 640, 4LD 705, 4LD 820.
Vent plug
Components
1Vent plug and oil refiling
2O-ring
3Diaphragm
Valve/rocker arm clearance
Place the piston at the compression top dead centre.
Place thickness gauge 1between the valve stem and the rocker
arm; cold-adjust the clearance at 0.15 ÷0.20 mm for both valves.
Tighten the rocker arm box cap at 20 Nm.
Decompression (by request)
Components:
1Cover 6 Pin
2Gasket 7Ring
3 Lock ring 8Lever
4Spring 9 Pin
5 Shaft
The engine rocker arm cover can be equipped with a
decompression device which compresses the exhaust valve at the
TDC (top dead centre), lowering it of abt. 1mm. during the starting
phase. The lowering is adjusted by the gaskest thickness 2. Make sure
that the lever turns for abt. half a stroke before it actuates the valve.
Warning!
The use of decompression to stop the engine may cause serious
damages.
4
6
8
5
7
VDISASSEMBLY/REASSEMBLY

DATE
30-11-2001
TECO/ATL AUTHOR BOOKCODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 APPROVAL 9
15
12
14
Rocker arm pin, extraction
Before extracting the rocker arm pin in 3LD 450, 3LD 451/S, 3LD
510, 3LD510S engines, unscrew screw 1, as per picture 10.
Extract the pin using tool 2 Part. no. 7276-3595-040, picture 11 also for
4LD 640, 4LD 705, 4LD 820 engines.
Rocker arm pin and hole
Dimensions (mm)
A= 15.032 ÷ 15.050
B = 14.989 ÷ 15.000
Clearances
(A-B) = 0.032 ÷ 0.061
(A-B) = worn limit = 0.120
Head
Do not disassemble while it is hot as to avoid any possible
distortion.
If the head surface is distorted, smooth it by removing up to 0.3 mm
thickness.
Always replace the copper gasket, see picture 34 for the choice of
thickness.
Gradually tighten the nuts according to the following order 1, 3, 2, 4,
at 50 Nm for 3LD 450, 3LD 451/S, 3LD 510, 3LD510/S, and at 80
Nm for 4LD 640, 4LD 705, 4LD 820.
Injector, projection
The projection of the nozzle ends Awith respect to the head surface
shall be:
2.5÷3 mm for 3LD 450, 3LD 451/S
3÷3.5 mm for 3LD 510, 3LD 510/S
3.5÷4 mm for 4LD 640, 4LD 705, 4LD 820
Adjust by means of a copper gasket B having a thickness of 0.5
mm, 1 mm, 1.5mm .
10 11
13
VDISASSEMBLY/REASSEMBLY

BOOK CODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 DATE
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APPROVAL
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10
19
20
16
Valves
1Valve stem
2 Spring holding disk
3Spring
4Cap
5Cotters
Note: In order to remove the cotters, put a shim under the valve
head and strongly press, as shown in picture 16.
Valves guides and housings
1 Exhaust valve guide
2Intake valve guide
Dimensions (mm):
3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S
A= 43.80 ÷ 44.20 B = 55.80 ÷ 56.20
C = 11.00 ÷ 11.018 D= 11.05 ÷ 11.06
4LD 640, 4LD 705, 4LD 820
A = 47.80 ÷ 48.20 B = 65.80 ÷ 66.20
C = 12.000 ÷ 12.018 D= 12.05 ÷ 12.06
Note: Valve guides with an external dia. increased of 0.5 mm can be
used as spare parts; in this case it is necessary to increase
the housing Cof 0.5 mm for the assembly.
Valve guides insertion
Heat the head at 160° ÷ 180°. Force the guides according to A and
Bdistance with respect to the head surface.
3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S
A= 30.80 ÷ 31.2 B= 18.8 ÷ 19.2
4LD 640, 4LD 705, 4LD 820
A= 35.8 ÷ 36.2 B = 17.8 ÷ 18.2
Note: if the guides are supplied with the housing for the lock ring C,
insert the ring, then drive the guides without worrying about A
and B.
Valve guide dimensions and clearances
3LD 450, 3LD 451/s, 3LD 510, 3LD 510/S (mm):
D= 7.030 ÷ 7.050 E = 6.985 ÷ 7.000
(D-E) = 0.030 ÷ 0.065 (D-E) limit= 0.13
4LD640, 4LD 705, 4LD 820
D = 8.030 ÷ 8.050 E = 7.985 ÷ 8.000
(D-E) = 0.030 ÷ 0.065 (D-E) limit =0.13
Valve housings and seats
3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S (mm);
A = 34.99 ÷ 35.01 C= 30.99 ÷ 31.01
B = 35.10 ÷ 35.12 D= 31.10 ÷ 31.12
4LD 640, 4LD 705, 4LD 820 (mm):
A = 42.99 ÷ 43.01 C= 36.99 ÷ 37.01
B = 43.12 ÷ 43.14 D= 37.10 ÷ 37.12
Drive the seats in the housings and mill at 45°.
18
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DISASSEMBLY/REASSEMBLYV