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
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MODEL No.
50839
DATEOFISSUE
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APPROVAL
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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
" 23
" 25
" 27
" 28
" 29
" 30
" 31
INTRODUCTION

DATE
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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

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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
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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

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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
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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
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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
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DATE
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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
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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°.
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DATE
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25
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V
DISASSEMBLY/REASSEMBLY
Valve seat grinding
After milling, grind with fine emery paste in engine oil bath.
The Ssealing surface shall not exceed 2 mm.
Embed valves D after grinding for 3LD 450, 3LD 451/S, 3LD 510,
3LD 510/S = 0.55 ÷ 1.05 mm; for 4LD 640, 4LD 705, 4LD 820 =
0.45 ÷ 0.95 mm.
Cylinder and piston
Set a bore gauge to zero with a calibrated ring. Check the dia. Ø at
points A and B at three different heights, see pictures 23 and 24.
In case of wear exceeding 0.06 mm to the maximum value prescribed,
grind the cylinder at the subsequent increased value.
The increases suggested are 0.50 and 1.00 mm.
Measure the piston Qdia. (picture 26) at Aheight from the skirt
base:
A = 17 mm (3LD 450, 3LD 451/S, 4LD 820)
A= 12 mm (3LD 510, 3LD 510/S)
A = 22 mm (4LD 640, 4LD 705)
Remove the stop rings and extract the piston pin, picture 25.
Remove the piston rings and clean the slots.
Replace the piston as well as the segments in case the dia. wear
exceeds 0.05 mm as regards to the minimum value prescribed.
Dimensions (mm)
ENGINES Ø Q (Ø-Q)
3LD 450, 3LD 451/S
3LD 510, 3LD 510/S
4LD 640 95.00 ÷ 95.02 94.88 ÷ 94.90 0.10 ÷ 0.14
4LD 705 100.00 ÷ 100.02 99.83 ÷ 99.85 0.15 ÷ 0.19
4LD 820 102.00 ÷ 102.02 101.85 ÷ 101.89 0.11 ÷ 0.17
Note: Even if 3LD 450, 3LD 451/S and 3LD510, 3LD510/S pistons
have the same bore, they differ in other dimensions, thus
they are not interchangeable.
Distance among segment ends (mm)
Insert the piston ring in the lower part of the cylinder, then measure the
distance among the points.
3LD 450, 3LD 451/S, 3LD510, 3LD 510/S
1st piston ring (chromium plated) A= 0.30 ÷ 0.50
2nd piston ring (torsional) A= 0.30 ÷ 0.50
3rd piston ring (scraper ring) A= 0.25 ÷ 0.50
4LD 640, 4LD 705, 4LD 820
1st piston ring (chromium plated) A = 0.40 ÷ 0.65
2nd piston ring (torsional) A= 0.40 ÷ 0.65
3rd piston ring (torsional) A= 0.40 ÷ 0.65
4th piston ring (oil scraper ring) A = 0.30 ÷ 0.60
0.05 ÷ 0.09
84.925 ÷ 84.945
85.00 ÷ 85.02

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Piston ring - Clearances among slots (mm)
3LD 450, 3LD 451/S, 3LD 510, 3LD 510S, picture28
A= 0.08 ÷ 0.09
B = 0.06 ÷ 0.07
C= 0.05 ÷ 0.06
4LD 640, 4LD 705, 4LD 820, picture 29
A = 0.12 ÷ 0.14
B = 0.07 ÷ 0.09
C = 0.07 ÷ 0.09
D= 0.06 ÷ 0.08
Piston ring assembly order
3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S, picture 30
A= slot for first piston ring (chromium plated)
B= slot for piston ring segment (torsional)
C= slot for third piston ring (oil scraper ring)
4LD 640, 4LD 705, 4LD 820, picture 31
A= slot for first piston ring (chromium plated)
B = slot for second piston ring (torsional)
C= slot for third piston ring(torsional)
D = slot for fourth piston ring(oil scrarper ring)
Note: before inserting the piston in the cylinder, oil the piston ringwith
engine oil and turn them, thus the cuts are misaligned.
Piston reassembly
Couple the piston with the connecting rod, thus the combustion
chamber centre Bis perpendicularly under end A of the nozzle
housed inside the head.
Lubricate the piston pin and insert it in the piston, lightly pressing
with your thumb.
Make sure that the two stop rings are well housed inside their
seats.
28
30
32 33
31
29
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Clearance volume
A= Clearance volume
B= Head gasket
The thickness B head gasket determines the clearance volume A
which shall be 0.75 ÷ 0.90 mm for 3LD 450, 3LD 451/S, 3LD 510,
3LD 510/S and 0.80 ÷ 1.00 mm for 4LD 640, 4LD 705, 4LD 820.
Measure the piston crown position as to the cylinder surface and
chose a gasket having a suitable thickness.
Always consider that the piston at the top dead centre could be at the
same level, either under or over the cylinder.
Connecting rod equipped with bearings and piston pin
For 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S
Dimensions (mm)
A= 144.05 ÷ 145.05
B= 23.02 ÷ 23.03 (with driven and machined bearing)
C= 42.028 ÷ 42.052 (with bearing tightening at 3 Nm)
D = 27.995 ÷ 23.000
For 4LD 640, 4LD 705, 4LD 820
Dimensions (mm)
A= 162.95 ÷ 163.05
B= 28.02 ÷ 28.03
C= 55.40 ÷ 55.43
D= 27.995 ÷ 28.000
The connecting rod big end bearings are supplied either at nominal
value and diminished to 0.25 and 0.50 mm.
Connecting rod, big end bearings
While reassembling, the A and B centering marks should not be on the
same side.
Tighten the screws at 30 Nm for 3LD 450, 3LD 451/S, 3LD 510,
3LD 510/S and at 45 Nm for 4LD 640, 4LD 705, 4LD 820.
Main bearing on flywheel side
Extract the bearing using three screws, as per picture 38.
While reassembling, replace gasket 1. Check that the oil seal ring
is intact. Tighten the screws at 25 Nm.
Drive shaft axial clearance
After having screwed the main bearing on the flywheel, check drive
shaft axial clearance. Its value is 0.10 ÷ 0.40 mm for 3LD 450, 3LD
451/S, 3LD 510, 3LD 510/S and 0.10 ÷ 0.30 mm for 4LD 640, 4LD
705, 4Ld 820.
The adjustment is carried out by changing the gasket 1 thickness.
38
34
35
39
37
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Side distributor port
It can be found in engines equipped with industrial type drive shaft.
The gaskets 3and 5, thanks to their thickness, assure the oil seal
and affect the camshaft axial clearance, as well. For the check, see
information hereunder.
Components
For 3LD 450, 3LD 510 picture 40
1 Port 2 Bush 3Gasket
Fix the door at its base at 25 Nm.
For 4LD 640, 4LD 705, 4LD 820 picture 41
4Port 5 Gasket 6 Ball bearing
Fix the port at its base at 40 Nm.
Camshaft axial clearance
Carry out this check before assembling the head. Fix the side
distributor port or bell 1at 25 Nm. Remove the intake and exhaust
tappets and with an implement operate on the camshaft forward
and backward in an axial direction.
The axial clearance A shall be:
A= 0.20 ÷ 0.60 mm 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S.
A = 0.15 ÷ 0.65 mm for 4LD 640, 4LD 705, 4LD 820.
Adjust the clearance by changing the gasket thickness between the
distributor port (if it is assembled) or bell 1 and the base; it is
forbidden to assemble more than one gasket.
Drive shaft
There are two types of standard drive shafts:
AAutomotive type (agricultural machines)
Bindustrial type (motor pumps generating set, etc.)
Note:For left-handed engines, i.e 3LD 510/S, the drive shaft turns
anticlockwise (seen from the flywheel position) and their
thread is clockwise on the power takeoff side as well as on
the flywheel side.
Drive shaft lubrication ducts
Remove the caps, clean the ducts A and B with a point and blow
them with compressed air.
Replace the caps by caulking them on their seat, then check their
seal.
Drive shaft connecting radius
R = 3 mm
R1= 3.5 mm
Note: When the main journal and the crank are ground, it is
essential to reset R and R1values in order to avoid any possible
breaking of the drive shaft.
44
40
42
43
41
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Drive shaft main journal and crank diametres (mm)
3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S
A= 39.990 ÷ 40.000
B = 41.987 ÷ 42.000
C= 41.990 ÷ 42.000
D= 29.990 ÷ 30.000
4LD 640, 4LD 705, 4LD 820
A = 44.900 ÷ 45.000
B= 55.340 ÷ 55.353
C= 44.900 ÷ 45.000
D = 29.990 ÷ 30.000
Drive shaft internal diam. crankshaft bearing / connecting rod
head and clearances regarding their respective pins (mm)
3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S
E = 40.040 ÷ 40.050 F = 42.028 ÷ 42.052
G= 42.04 ÷ 42.05 H = 30.07 ÷ 30.09
A, B, C, D, see picture 45
E - A = 0.040 ÷ 0.060 worn limit 0.12
F - B = 0.028 ÷ 0.065 worn limit 0.13
G - C = 0.040 ÷ 0.060 worn limit 0.12
H - D = 0.070 ÷ 0.10 worn limit 0.18
4LD 640, 4LD 705, 4LD 820
E= 45.045 ÷ 45.070 F = 55.40 ÷ 55.43 G = 45.045 ÷ 45.070
A, B, C, D, see picture 45
E - A = 0.065 ÷ 0.080 worn limit 0.16
F - B = 0.051 ÷ 0.10 worn limit 0.18
G - C = 0.45 ÷ 0.080 worn limit 0.16
CAMSHAFT
Components:
1Base side pin
2 Intake cam
3 Injection cam
4Exhaust cam
5Gear
6 Side distributor port pin
Note: The two engine series 3LD 450, 3LD 510 and 4LD 640, 4LD
820 have the same camshaft; it differs in 3LD 451/S and 3LD
510/S left-handed engines.
Camshaft intake and exhaust cam timing
For 3LD 450, 3LD 510, 4LD 640, 4LD 705, 4LD 820, see picture 48.
Clockwise rotation.
TDC = Top dead centre of the piston
A= Intake cam axis
S = Exhaust cam axis
at = 50° 30' ÷ 51° 30'
For 3ld 451/S, 3LD 510/S, see picture 49
Clockwise rotation
TDC= Top dead centre of the piston
A= Intake cam axis
S= Exhaust cam axis
at = 50° 30' ÷ 51° 30'
48
45
46
47
49
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Camshaft pin and housing dimensions (mm)
A= 18.000 ÷ 18.018 (housing on the base)
B= 17.945 ÷ 17.975
C= 18.000 ÷ 18.018 (housing on the port)
D= 17.945 ÷ 17.975
A-B and C-D = 0.025 ÷ 0.073 Worn limit = 0.13
Camshaft intake and exhaust cam height.
The two cam heights are different.
Dimensions (mm) :
H= 33.92 ÷ 34.02 (intake cam)
H1 = 33.42 ÷ 33.52 (exhaust cam)
If the cam wear exceeds the agreed minimum value of 0.1 mm for H
and H1 , replace the camshaft.
Distribution timing
assemble the camshaft gear by coinciding reference 1 with
reference 2 of the gear (camshaft key).
Distribution timing without following the references
Place piston A at the top dead centre.
Insert the camshaft, thus the intake cam B and the exhaust cam C
are well balanced (while the intake opens, the exhaust closes).
Insert the respective tappets Dand E.
Carry out the check: the intake D and exhaust Etappets laid on their
cams shall be at the same level F.
53
50
51
52
V DISASSEMBLY/REASSEMBLY

DATE
30-11-2001
TECO/ATL AUTHOR BOOKCODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 APPROVAL 17
Speed governor
It has a centrifugal system with 6 balls housed in the gear, which is
directly operated by the drive shaft.
The balls, moved at the gear periphery by a centrifugal force, axially
shift the bell 3, which actuates the fork 2connected to lever 1in
order to determine the injection pump rack rod position. A spring
with two plates 4, energized by the accelerator control 5, opposes
the action of the governor cetrifugal force. The balance between the
two forces keeps the rpm rate constant with the change of load.
Timing of the speed governor
Adjust the injection pump control lever 1 thus, when the governor is
closed, it is placed at distance Aas to the external surface of the
base.
- Loosen the screw 2.
- Close the governor (move the mobile bell 3towards the operator,
picture 55).
- Place lever 1at Adistance, picture 56 (22 mm for 3LD 450, 3LD
510, 3LD 451/S, 3LD 510/S and 28 mm for 4LD 640, 4LD 705, 4LD
820).
- Tighten the screw 2.
54
55 56
DISASSEMBLY/REASSEMBLY V

BOOK CODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 DATE
30-11-2001
APPROVAL
TECO/ATL AUTHOR
18
Lubrication circuit
Details:
1Intake pipe
2 Oil pump
3 Oil filter
4 Pressure switch
5 Crankshaft bearing
6 Pressure adjusting valve
7Tappet rod protection pipe
8Vent and oil filler plug.
Oil pump
Make sure that the gear teeth are intact and check that the
clearance between the gear periphery and the pump case does not
exceed 0.15 mm and that the drive shaft can easily turn with an axial
clearance not exceeding 0.15 mm.
Check that the gear lubrication holes 1and 2are not clogged.
Tighten the pump case at 30 Nm.
Tighten the pump control gear at 20 Nm.
The oil pumps for 3LD 451/S and 3LD 510/S engines, which turn
anticlockwise (from flywheel position), are different, see information
below.
57
58
VI LUBRICATION CIRCUIT
59

DATE
30-11-2001
TECO/ATL AUTHOR BOOKCODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 APPROVAL 19
65
60
62
61
63 64
LUBRICATION CIRCUIT VI
Oil pump, difference between clockwise rotation pump and
anticlockwise pump
The difference between the oil pump on clockwise rotation engines
and the anticlockwise one is the suction duct provided either with
the pump case and with the base.
See picture 60 for anticlockwise rotation engines from flywheel
position (3LD 451/S, 3LD 510/S).
A =Intake
B= Delivery
Picture 61, for clockwise rotation engines, seen from the flywheel
side (3LD 450, 3LD 510, 4LD 640, 4LD 705, 4LD 820)
C = Intake
D = Delivery
Oil filter cartridge
Componens:
1Gasket 5Bowl
2 Assembly 6 By-pass valve
3 Antidrainage rubber cap 7Spring
4 Filter element
Features:
Maximum operating pressure: 7 bars
Maximum operating temperature: -25° + 150°C
Filtering degree: 20 µm
By-pass valve setting: 1÷ 1.4
Total filtering surface: 750 cm2
Oil pressure regulating valve
It is housed in the flywheel side main bearing
For 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S, see picture 63
1 Support 4Sheet metal
2 Valve 5Screw
3Spring
Tighten the support at 25 Nm.
For 4LD 640, 4LD 705, 4LD 820,see picture 64
1 Support 5Spring
2 Gasket 6Flange
3 Valve support 7 Plate
4 Ball 8 Screw
Tighten the support at 40 Nm.
Oil pressure check
After the assembly operation, fill the engine with oil and fuel;
connect a 10 bars pressure gauge to the fitting on the oil filter.
Start the engine and check the pressure reaction according to oil
temperature.
Oil pressure curve with the engine at its maximum speed
It is shown on the filter and obtained with the engine at 3000 rpm
at N power; the pressure is expressed in bars and the temperature
in degrees Celsius. The curve represents the pressure minimum
value, while its maximum value is 5 bars. The minimum oil
pressure (1200 rpm) with the oil temperature at 100° C shall not be
lower than 0.8 bars.
Note: When the engine has been run in, the oil lubrication
maximum temperature shall be lower than the following
addition: ambient temperature + 95° C.

BOOK CODE
1-5302-556
MODEL No.
50839
DATEOFISSUE
01-94 REVIEW 02 DATE
30-11-2001
APPROVAL
TECO/ATL AUTHOR
20
69
66
67
68
70
VII FUEL/INJECTION CIRCUIT
Standard feeding/injection circuit
Components:
1Tank
2 Filter
3Pump
4 Pipe
5Injector
6Injector waste pipe
Fuel filter inside the tank (standard)
Details:
1Spring 6Gasket
2Disk 7 Cover
3Ring 8Ring
4Cartridge 9Bolt
5Gasket
Cartridge features:
Filtering degree = 7 µm
Filtering surface = 390 cm2
Feeding pump (by request)
Features: at 1500 rpm of the control eccentric, the minimum delivery
is 60 l/h, while the automatic adjustment pressure is 4 ÷ 5 m
column of water.
Feeding pump rod projection
Details:
1Feeding pump 3Rod
2Base 4 Oil pump drive shaft eccentric
The check shall be carried out with the eccentric 4at rest.
The projection A of rod 3 is 0.8 ÷ 1.2 mm; it shall be adjusted with
the following supplied gaskets having a thickness of 0.50; 0.80 and
1.0 mm.
Rod length = 65.4 mm for 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S
and 75.2 mm for 4LD 640, 4LD 705, 4LD 820.
Injection pump
Components:
1Delivery fitting 11 Spring
2O-ring 12 Pumping piston
3 Spring 13 Tappet case
4Delivery valve 14 External roller
5 Gasket 15 Internal roller
6 Barrel 16 Pin
7Pump case 17 Lock ring
8Eccentric 18 Rack rod
9Sector gear 19 Lock pin
10 Spring bearing cap 20 Collar
Tighten the pump at its base at 30 Nm.