Lombardini CHD series Instruction manual

CHD series Engine
cod. 1-5302-345
WORKSHOP MANUAL

- 3 -
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 manualwaswrittenby themanufacturer to provide technical andoperatinginformation toauthorised LOMBARDINI
after-sales service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations.
-As well as employing good operating techniques and observing the right timing for operations, operators must read
the information very carefully and comply with it scrupulously.
- Timespentreadingthisinformationwillhelptopreventhealthandsafetyrisksandnancialdamage.
Written information is accompanied by illustrations in order to facilitate your understanding of every step of the
operating phases.
CHD Engine Series
Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05

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CUSE/ATLO
01-12-2009
Drafting
body
Document
code Edition Issue date Review date
Model
N° Revision
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Anymodicationstothisdocumentmustberegisteredbythedraftingbody,bycompletingthefollowingtable.
Endorsed
1-5302-345 50534 31-12-896° 5

- 5 -Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
-
This manual gives the main instructions on how to repair LOMBARDINI diesel engines LDW 1503 - 1603 - 2004 -
2004/T - 2204 - 2204/T,uidcoolingcircuit,updatesasofDecember1st 2009.
INDEX
1 GENERAL REMARKS AND SAFETY INFORMATION.......................................................................... 9 - 11
General safety during operating phases ......................................................................................................................... 11
General Service manual notes.......................................................................................................................................... 9
Glossary and terminology ................................................................................................................................................. 9
Safety and environmental impact.................................................................................................................................... 11
Safety and warning decals .............................................................................................................................................. 10
Safety regulations ........................................................................................................................................................... 10
Warrantycerticate ........................................................................................................................................................... 9
2 TECHNICAL INFORMATION ...............................................................................................................12 - 20
Approval data .................................................................................................................................................................. 14
Characteristicspower,torqueandspecicfuelconsumptioncurves.............................................................................. 20
Manufacturerandmotoridenticationdata..................................................................................................................... 14
Overall dimensions.......................................................................................................................................................... 15
Performance diagrams.................................................................................................................................................... 20
Possible causes and trouble shooting............................................................................................................................. 12
Table of likely anomalies and their symptoms................................................................................................................. 12
Technicalspecications................................................................................................................................................... 18
3 MAINTENANCE - PRESCRIBED LUBRICANT - REFILLING ............................................................22 - 25
ACEA Regualtions - ACEA Sequences........................................................................................................................... 23
API / MIL Sequences .................................................................................................................................................... 23
Aviation fuel..................................................................................................................................................................... 25
Biodiesel fuel................................................................................................................................................................... 25
Coolant............................................................................................................................................................................ 25
Extraordinary maintenance ............................................................................................................................................. 22
Fuel recommendations.................................................................................................................................................... 25
Fuel type ......................................................................................................................................................................... 25
Fuels for low temperatures.............................................................................................................................................. 25
Internationalspecications.............................................................................................................................................. 23
Lubricant ......................................................................................................................................................................... 23
Ordinary maintenance..................................................................................................................................................... 22
Prescribed lubricant ........................................................................................................................................................ 24
Routine engine maintenance .......................................................................................................................................... 22
SAEClassication.......................................................................................................................................................... 23
4 DISASSEMBLY/REASSEMBLY ...........................................................................................................26 - 56
Airltercloggingindicator ............................................................................................................................................... 28
Assembling and tightening the cylinder head on engines with hydraulic tappets ........................................................... 39
Camshaft......................................................................................................................................................................... 51
Camshaft bushing replacement ...................................................................................................................................... 52
Camshaft end play .......................................................................................................................................................... 56
Camshaft gear - Speed governor counter weights ......................................................................................................... 50
Camshaft journals and bushings in model LDW 1503 .................................................................................................... 52
Camshaft journals and bushings in models LDW 2004-2004/T ...................................................................................... 52
Camshaft removal ........................................................................................................................................................... 51
Camshaft timing .............................................................................................................................................................. 54
Center main bearings...................................................................................................................................................... 42
Check clearance between main bearings and journals................................................................................................... 43
Checking camshaft bushing internal diameter ................................................................................................................ 52
Checking main journals and crank pins .......................................................................................................................... 46
Connecting rod................................................................................................................................................................ 40
Connecting rod alignment ............................................................................................................................................... 41
Connecting rod and piston pin ........................................................................................................................................ 40
Connecting rod weights................................................................................................................................................... 40
Connecting rod/piston assemblies .................................................................................................................................. 41
CHAPTER INDEX

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-Chapter index
Cooling fan ...................................................................................................................................................................... 29
Crankshaft end play ........................................................................................................................................................ 44
Crankshaft for engines with dynamic equalizer (only four-cylinder engines). ................................................................. 47
Crankshaft front and rear oil seal .................................................................................................................................... 45
Crankshaft lubrication ducts............................................................................................................................................ 45
Crankshaft timing gear .................................................................................................................................................... 45
Cylinder head .................................................................................................................................................................. 31
Cylinder head gasket ...................................................................................................................................................... 38
Cylinder head tightening for engines without hydraulic tappets ...................................................................................... 39
Cylinder head tightening steps........................................................................................................................................ 39
Cylinder roughness ......................................................................................................................................................... 36
Cylinders ......................................................................................................................................................................... 36
Dimensions for injection pump delivery control yoke adjustement.................................................................................. 49
Driving pulley (2a P.T.O.)................................................................................................................................................. 29
Dry air cleaner................................................................................................................................................................. 27
Dry air components ......................................................................................................................................................... 28
Dynamic balancer (on request) - Adjustment of clearance between teeth D and ring gear A........................................ 47
Engines with hydraulic tappets........................................................................................................................................ 55
Engines with mechanical tappets.................................................................................................................................... 55
Exhaust manifold............................................................................................................................................................. 28
Flywheel .......................................................................................................................................................................... 30
Frame with idling speed governor spring ........................................................................................................................ 50
Front cover ...................................................................................................................................................................... 48
GR 1 and GR 2 hydraulic pump 3rd p.t.o........................................................................................................................ 56
Hydraulic diagram for feeding the tappets ...................................................................................................................... 34
Hydraulic pump p.t.o. ...................................................................................................................................................... 56
Hydraulic tappet components:......................................................................................................................................... 34
Hydraulic tappet operation .............................................................................................................................................. 35
Hydraulic tappet valve control ......................................................................................................................................... 34
Idler gear and hub ........................................................................................................................................................... 48
Injection pump follower ................................................................................................................................................... 35
Intake manifold................................................................................................................................................................ 28
Intake, exhaust and injection cam height for models LDW 2004- 2004/T....................................................................... 53
Intake, exhaust and injecton cam height for model LDW 1503....................................................................................... 53
Main bearing and connecting rod big bearing inside diameter (mm) .............................................................................. 46
Mainbearingcapstimingside-ywheelside................................................................................................................. 42
Main journal and connecting rod big end journal diameter ............................................................................................. 46
Oil seal in the valves guides, (intake and exhaust) ......................................................................................................... 33
Oil-bath air cleaner ......................................................................................................................................................... 27
Oil-bath air cleaner components ..................................................................................................................................... 27
Piston .............................................................................................................................................................................. 36
Piston-Retting.............................................................................................................................................................. 38
Piston availability............................................................................................................................................................. 36
Piston cooling sprayer..................................................................................................................................................... 41
Piston position and clearance ......................................................................................................................................... 38
Piston rings - Clearance between grooves ..................................................................................................................... 37
Piston rings - End gaps ................................................................................................................................................. 37
Piston rings - Fitting sequence........................................................................................................................................ 37
Piston weight................................................................................................................................................................... 37
Precombustion chamber ................................................................................................................................................. 34
Recommendations for disassembling and assembling ................................................................................................... 26
Recommendations for overhauls and tuning................................................................................................................... 26
Rocker arm assemly ....................................................................................................................................................... 31
Rocker arm cover for engines with recirculating vent ..................................................................................................... 30
Rocker arm cover with vent into the air........................................................................................................................... 30
Speed governor............................................................................................................................................................... 49
Speed governor counter springs ..................................................................................................................................... 50
Spring for extra fuel supply at starting............................................................................................................................. 51
Summary tables of the governor equipment according to the speed variation. .............................................................. 51
Table of pin-rocker arm dimensions ............................................................................................................................... 31
Tank................................................................................................................................................................................. 29
Thrust bearing, oversizes................................................................................................................................................ 44
Thrust bearings ............................................................................................................................................................... 43
Timing angles for checking puposes .............................................................................................................................. 55
Timing angles for checking purposes LDW 2004/T ........................................................................................................ 55
Timing angles for operating purposes ............................................................................................................................ 55
Timing angles for operating purposes LDW 2004/T ....................................................................................................... 55

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-
Chapter index
Timing belt operating angles (with valve clearance set to zero)...................................................................................... 55
V belt ............................................................................................................................................................................... 29
Valve guide insertion, after driving .................................................................................................................................. 33
Valve guides and cylinder head ...................................................................................................................................... 32
Valve material.................................................................................................................................................................. 32
Valve recess and sealing surfaces.................................................................................................................................. 33
Valve removal.................................................................................................................................................................. 31
Valve seats and bore....................................................................................................................................................... 33
Valve spring - Check ....................................................................................................................................................... 32
Valve spring - check under load ...................................................................................................................................... 32
Valve timing check .......................................................................................................................................................... 54
Valve timing without considering timing marks................................................................................................................ 54
5 TURBOCHARGER ...............................................................................................................................58 - 59
Checking actuator setting - "Waste gate" valve control rod stroke adjustment ............................................................... 59
Turbocharger................................................................................................................................................................... 58
Turbocharger components .............................................................................................................................................. 58
Turbocharger Testing ...................................................................................................................................................... 58
6 LUBRICATION SYSTEM ......................................................................................................................60 - 62
Lubrication system layout................................................................................................................................................ 60
 Oilltercartridge ............................................................................................................................................................. 61
Oil pressure adjusting valve ............................................................................................................................................ 61
Oil pressure check .......................................................................................................................................................... 62
Oil pressure curve for LDW 1503 - 1603........................................................................................................................ 62
Oil pressure curve for LDW 2004 - 2204........................................................................................................................ 62
Oil pressure curve for LDW 2004/T - 2204/T ................................................................................................................. 62
Oil pump.......................................................................................................................................................................... 61
Oil pump rotor clearance................................................................................................................................................. 61
7 COOLING SYSTEM..............................................................................................................................64 - 65
Cooling system layout ..................................................................................................................................................... 64
Expansion tank and cap.................................................................................................................................................. 65
Checking for cooling system leaks.................................................................................................................................. 65
Coolant circulating pump................................................................................................................................................. 65
Thermostat ...................................................................................................................................................................... 65
8 FUEL SYSTEM .....................................................................................................................................66 - 72
Checking injection pump delivery.................................................................................................................................... 70
Checking low pressure injection timing for engines with hydraulic tappets.................................................................... 71
Checking low pressure injection timing for engines with mechanical tappets................................................................. 71
Electric fuel pump (24V).................................................................................................................................................. 67
Fuel feeding pump .......................................................................................................................................................... 66
Fuel feeding pump drive rod protrusion .......................................................................................................................... 66
Fuel feeding/injection circuit............................................................................................................................................ 66
Fuellter ......................................................................................................................................................................... 66
How to reassemble injection pump components............................................................................................................. 68
How to reassemble injection pump feeding tubes........................................................................................................... 69
How to remove injection pump feeding tubes ................................................................................................................. 68
Injection pump................................................................................................................................................................. 67
Injection pump control rod............................................................................................................................................... 68
Injection pump delivery equalization. .............................................................................................................................. 69
Injection pump disassembly ............................................................................................................................................ 67
Injection pump non-return valve...................................................................................................................................... 68
Injection pump P. No. 6590-249 - Plunger and barrel assembly ..................................................................................... 70
Injection timing correction by changing the pad thickness .............................................................................................. 72
Injector (pin type) ............................................................................................................................................................ 72
Injector setting................................................................................................................................................................. 72
Instrument for equalizing injection pump delivery ........................................................................................................... 69
Test data of injection pump ............................................................................................................................................ 70

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-Chapter index
9 ELECTRIC SYSTEM.............................................................................................................................73 - 82
Alternator type Iskra, AAK3139 14V 80A ..................................................................................................................... 75
AlternatortypeIskra,typeAAK357028V35A(for24Voutts) ..................................................................................... 77
Alternator type Marelli AA 125 R 14V 45A...................................................................................................................... 73
Alternator type Marelli AA 125 R 14V 65A...................................................................................................................... 74
CharacteristiccurvesforalternatortypeAAK357028V35A(for24Voutts) ............................................................... 77
Characteristic curves for alternator type Iskra, AAK3139 14V 80A ............................................................................. 75
Characteristic curves for alternator type Marelli AA 125 R 14V 45A ............................................................................... 73
Characteristic curves for alternator type Marelli AA 125 R 14V 65A ............................................................................... 74
Characteristic curves for starting motor Iskra type AZE 4598 24V 3 kW ....................................................................... 80
Characteristic curves for starting motor type Bosch EV 12V 2.2 kW ............................................................................. 79
Characteristic voltage curve for regulator type AER 1528 .............................................................................................. 75
Characteristic voltage curve for regulator type AER 1528 .............................................................................................. 77
Characteristic voltage curve for regulator type RTT 119 AC ........................................................................................... 73
Characteristic voltage curve for regulator type RTT 119 AC ........................................................................................... 74
Connection diagram for preheating control unit .............................................................................................................. 76
Connection diagram for preheating control unit .............................................................................................................. 78
Coolant high temperature lamp switch............................................................................................................................ 82
Glow plug controller relay with coolant temperature sensor ........................................................................................... 81
Heavy starting conditions (max admitted): ...................................................................................................................... 76
Heavy starting conditions (max admitted): ...................................................................................................................... 78
Key switch electrical layout ............................................................................................................................................. 79
Key switch electrical layout ............................................................................................................................................. 80
Normal starting conditions:.............................................................................................................................................. 76
Normal starting conditions:.............................................................................................................................................. 78
Pre-heating glow plug ..................................................................................................................................................... 81
Spacerangeforstartermotor ....................................................................................................................................... 80
Starting Motor 12V .......................................................................................................................................................... 79
Starting Motor 24V .......................................................................................................................................................... 80
Temperature sensor (Thermistor).................................................................................................................................... 81
Thermistor for electric thermometer ................................................................................................................................ 82
Thermistor for preheating water temperature – Thermal contact for water temperature indicator light .......................... 82
Wiring diagram 24 V with alternator 35A......................................................................................................................... 78
Wiring diagram with alternator 45A / 65A........................................................................................................................ 76
10 SETTINGS ............................................................................................................................................83 - 84
Application diagram for tampering system adjustment screw and
torque gearing device for EPA-approved engines........................................................................................................... 84
Fuel limiting device.......................................................................................................................................................... 84
Fuel limiting device adjustment ....................................................................................................................................... 84
Full speed setting in no-load conditions (standard)......................................................................................................... 83
Idling speed setting in no-load conditions (standard)...................................................................................................... 83
Injection pump delivery limiting and torque adjusting device .......................................................................................... 83
Standard injection pump delivery setting without torque dynamometer.......................................................................... 83
Stop setting ..................................................................................................................................................................... 84
11 ENGINE STORAGE .................................................................................................................................... 85
Engine storage ................................................................................................................................................................ 85
Preparing the engine for operation after protective treatment......................................................................................... 85
Protective treatment ........................................................................................................................................................ 85
12 TORQUE SPECIFICATIONS AND USE OF SEALANT ......................................................................86 - 87
Maintorquespecications............................................................................................................................................... 86
Table of tightening torques for standard screws (coarse thread) .................................................................................... 87
Tableoftighteningtorquesforstandardscrews(nethread) ......................................................................................... 87
13 SPECIAL TOOLS ........................................................................................................................................ 88

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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 rst end user.
- For engines tted 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 tted , 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 correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the
documentation supplied with each engine.
- To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be carried out
by qualied personnel only.
- The list of the Lombardini authorized dealers is reported in the “Service” booklet, supplied with each engine.
- Special applications involving considerable modications to the cooling/lubricating system (for ex.: dry oil sump), ltering
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 afxed 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).
GENERAL REMARKS AND SAFETY INFORMATION
WARRANTY CERTIFICATE
GLOSSARY AND TERMINOLOGY
For clarity, here are the denitions of a number of terms used
recurrently in the manual.
- Cylinder number one: is the piston timing belt side
«viewed from the ywheel side of the engine».
- Rotation direction: anticlockwise «viewed from the
ywheel side of the engine».

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1
•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.
• Theenginehasbeenmadeaccordingtoamachinemanufacturer'sspecications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specicallyestablishedcannotthereforebeconsideredasconformingtotheusedened
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 ope-
ration 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 latter
case,mustonlybecarriedoutbypersonsspecicallytrainedbyLOMBARDINI and who work in compliance with the existing
documentation.
• Variationstothefunctionalparametersoftheengine,adjustmentstothefuelowrateandrotationspeed,removalofseals,
demountingandretting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specications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insufcientventilation.
Combustion creates carbon monoxide, an odourless and highly poisonous gas.
Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death.
• Theenginemustnotoperateinplacescontaininginammablematerials,inexplosiveatmospheres,wherethereisdustthat
caneasilycatchreunlesspecic,adequateandclearlyindicatedprecautionshavebeentakenandhavebeencertiedforthe
machine.
• Topreventre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inammable.Thetankmustonlybelled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soundproongpanelsmadeofporousmaterialaresoakedinfueloroil.
 Makesurethatthegroundoroor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ll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ameswhenrefuelling.
• Theenginemustbestartedincompliancewiththespecic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retted.
•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.
General remarks and safety information
-Important remarks and features of the text are highlighted
using symbols, which are explained below:
Danger – Attention
This indicates situations of grave danger which, if igno-
red, may seriously threaten the health and safety of
individuals.
SAFETY AND WARNING DECALS
Caution – Warning
This indicates that it is necessary to take proper pre-
cautions to prevent any risk to the health and safety of
individuals and avoid nancial damage.
Important
This indicates particularly important technical information
that should not be ignored.
SAFETY REGULATIONS

- 11 -Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
1
General remarks and safety information
Never carry out any operation whilst the engine is running.
• Thecoolantuid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 en-
gine 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lter,makesurethattheoldoilisdisposedofinthecorrectwayinordertosafeguardtheen-
vironment.
 Thespongylteringmaterialinoil-cooledairltersmustnotbesoakedinoil.
 Thereservoiroftheseparatorpre-ltermustnotbelled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.
• Payattentiontothetemperatureoftheoillterwhenthelteritselfisreplaced.
• Onlycheck,topupandchangethecoolantuidwhentheengineisoffandcold.
 Takecaretopreventuidscontainingnitritesfrombeingmixedwithothersthatdonotcontainthesesubstancessince"Nitro-
samine", dangerous for the health, can form.
 Thecoolantuid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 insula-
te 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 SAFETY DURING OPERATING PHASES
– The procedures contained in this manual have been tested and selected by the manufacturer’s technical experts, and hence
are to be recognised as authorised operating methods.
– Some tools are normal workshop ones, while others are special tools designed by the Manufacturer of the engine.
– All tools must be in good working condition so that engine components are not damaged and that operations are carried out
properly and safely.
– It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual.
– Holesmustbelinedupmethodicallyandwiththeaidofsuitableequipment.Donotuseyourngerstocarryoutthis
operation to avoid the risk of amputation.
– Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding
the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.
– Donotuseammableliquids(petrol,diesel,etc.)todegreaseorwashcomponents.Usespecialproducts.
– Use the oils and greases recommended by the manufacturer.
Do not mix different brands or combine oils with different characteristics.
– Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.
– Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.
SAFETY AND ENVIRONMENTAL IMPACT
Every organisation has a duty to implement procedures to
identify,assessandmonitortheinuenceofitsownactivities
(products, services, etc.) on the environment.
Procedures for identifying the extent of the impact on the envi-
ronment must consider the following factors:
- Liquid waste
- Waste management
- Soil contamination
- Atmospheric emissions
- Use of raw materials and natural resources
- Regulations and directives regarding environmental impact
In order to minimise the impact on the environment, the manu-
facturer now provides a number of indications to be followed
by all persons handling the engine, for any reason, during its
expected lifetime.
-All packaging components must be disposed of in accor-
dance with the laws of the country in which disposal is
taking place.
-Keep the fuel and engine control systems and the exhaust
pipesinefcientworkingordertolimitenvironmentaland
noise pollution.
-When discontinuing use of the engine, select all compo-
nents according to their chemical characteristics and dispo-
se of them separately.

- 12 - Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
22
FUEL
CIRCUIT
POSSIBLE CAUSE
ELECTRIC
SYSTEM
MAINTENANCE
SETTINGS REPAIRS
Inadequate performance
High noise level
Overheats
TROUBLE
Engine does not start
Engine starts but stops
No acceleration No n-u n if o rm speed Black smoke White smoke
Too low oil pressure
Excessive oil consumption
Obstructed fuel line
Fuellterclogged
Air or water leaks in fuel system
The tank cap vent hole is clogged
No fuel
Discharged battery
Cable connection uncertain or incor-
rect
Faulty starting switch
Faulty starting motor
Faulty glow plugs
Faulty glow plug control relay
Burnt fuse on preheating spark plugs
Cloggedairlter
Excessive idle operation
Incomplete run-in
Overloaded engine
Incorrect governor linkage
adjustment
Governor spring broken or unhooked
Low idle speed
Rings worn or sticking
Worn cylinder
Worn main con rod-rocker arm be-
arings
Badly sealed intake valve
Damaged cylinder head gasket
Defective timing system
Bent rods
Faulty hydraulic tappets
POSSIBLE CAUSES AND 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

- 13 -Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
2
INJECTION
LUBRICATION
CIRCUIT
COOLING
CIRCUIT
Damaged injector
Injection pump valve damaged
Injector not adjusted
Faulty fuel feeding pump
Hardened pump control rod
Broken or loose supplementary start-
up spring
Worn or damaged pumping element
Incorrecttuningofinjectioncomponents
(delivery balancing advance)
Cracked or broken precombustion
chamber
Oil level too high
Oil level low
Oil pressure valve blocked or dirty
Worn oil pump
Oil sump suction line clogged
Faulty pressure gauge or pressure
switch
Blocked draining pipe
Faulty spray nozzles (Turbo engines
only).
Blocked draining pipe
Alternator fan belt loose or torn
Clogged radiator exchange surface
Insufcientcoolant
Fault fan, radiator or radiator plug
Faulty thermostatic valve
Blockage inside the radiator or the
coolant ducts
Coolant leaking from radiator, hoses,
the crankcase or from the water pump
Faulty or worn water pump
POSSIBLE CAUSE
Inadequate performance High noise level
Overheats
TROUBLE
Engine does not start
Engine starts but stops
No acceleration
No n-u n if o rm speed
Black smoke
White smoke Too low oil pressure
Excessive oil consumption
Technical information

- 14 - Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
2
C
A
F
D
E
B
2 3
4
7
65
1
Theidenticationplateshowninthegurecanbefounddirectly
on the engine.
It contains the following information:
A) Manufacturer’s identity
B) Engine type
C) Engine serial number
D) Maximum operating speed
E) Number of the customer version (form K)
F) Approval data
Approval data
The approval reference directives EC are on the engine plate.
Plate for EPA regulations placed on the recoil starter or the rocker-
arm cap.
It contains the following information:
1) Current year
2) Engine displacement
3) Rated power, measured in kW
4) EPA family ID
5) Injection timing
6) Injection opening preassure
7) Valve clearance
MANUFACTURER AND MOTOR IDENTIFICATION DATA
Technical information

- 15 -Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
2
468
235
233 max
231.3
425.2
208
175
147.5
250.2
154.2
75
220
240
310
171
215.7
81
348
250
187.5
70
356.4
191
283.3
164
266
87
99.6
336
68
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
A1
B1
C1
D1
E1
B C
D
A
GH
F
E
J
K
L
M
N
O
P
Q
R
S
T
U
Z
Y
W
X
V
C1 D1
B1
E1
A1
LDW 1503-1603
Note : Dimensions shown in mm
OVERALL DIMENSIONS
Technical information
DIMENSIONS mm

- 16 - Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
2
468
235
233
231.3
425.2
208
175
156.5
154.2
75
220
240
171
215.7
81
350
187.5
356.3
191
283.3
164
366
133
99.6
436
68A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
A1
B C
D
A
E
FGH
J
K
M
L
NO
P
Q
R
US
T
V
W
X
Y Z A1
TAPPO SCARICO ACQUA
WATER DRAIN PLUG
TAPPO SCARICO OLIO
OIL DRAIN PLUG
Note : Dimensions shown in mm
LDW 2004 - 2204
Technical information
DIMENSIONS mm

- 17 -Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
2
166.7
195
153.5
160
348
350
210
386.1
164
190.5
186.3
366
68
133
468.1
235
233.1
168.7
452.5
208
224.8
156.5
373.2
133.5
220
210
310
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
A1
B1
A
B
C
D
E
G
F
H
J
K
M N
O
L
T
W
V
U
Q R
X
Y
S
P
A1
Z
B1
Note : Dimensions shown in mm
LDW 2004/T - 2204/T
Technical information
DIMENSIONS mm

- 18 - Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
3
88
85
1551
22:1
3000
26.4
24.6
22.2
95.4
@ 2100
39.2
@ 3000
0.024
155
2326
108.3
300
35°
25°
***
1-3-2
4
88
85
2068
22:1
3000
35
33.0
29.6
128
@ 2100
39.2
@ 3000
0.032
190
3100
128
300
35°
25°
***
1-3-4-2
4
88
85
2068
22:1
3000
44.1
42.0
37.8
165.7
@ 2000
39.2
@ 3000
0.04
195
3900
180
300
35°
25°
***
1-3-4-2
N.
mm
mm
Cm³
Nm @ RPM
Nm @ RPM
Kg/h
Kg
l/min
m3/min
Kg
LDW 2004/T
LDW 1503
LDW 2004
LDW 2004/T
2
LDW 1503 LDW 2004
Cylindres
Bore
Stroke
Displacement
Compression ratio
R.P.M.
N 80/1269/CEE-ISO 1585-DIN 70020
Power KW NB ISO 3046 - 1 IFN - DIN 6270
NA ISO 3046 - 1 ICXN - DIN 6270
Max. torque *
Max. torque 3rd + 4th p.t.o.
Oil consumption **
Dry weight
Combustion air volume at 3000 r.p.m.
Cooling air volume at 3000 r.p.m.
Max. permissible driving shaft axial load in both directions
Max. 60 seconds
Max inclination Lasting up to 30 seconds
Permanent
Firing Order
* Referred to max. N power
** At NA power
*** Depending on the application
ENGINE TYPE CHD
TECHINICAL SPECIFICATIONS
Technical information

- 19 -Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
3
88
90.4
1649
22:1
3000
30.0
27.6
25.4
113
@ 1600
39.2
@ 3000
0.019
156
2475
96
300
35°
25°
***
1-3-2
4
88
90.4
2199
22:1
3000
38.0
34,5
32.0
144
@ 2200
39.2
@ 3000
0.025
192
3300
128
300
35°
25°
***
1-3-4-2
4
88
90.4
2199
22:1
3000
49.2
47
42.3
190
@ 1800
39.2
@ 3000
0.04
197
4200
180
300
35°
25°
***
1-3-4-2
N.
mm
mm
Cm³
Nm @ RPM
Nm @ RPM
kg/h
kg
l/min
m3/min
kg
LDW 1603
LDW 2204
LDW 2204/T
2
LDW 2204/TLDW 1603 LDW 2204
Cylindres
Bore
Stroke
Displacement
Compression ratio
R.P.M.
N 80/1269/CEE-ISO 1585-DIN 70020
Power KW NB ISO 3046 - 1 IFN - DIN 6270
NA ISO 3046 - 1 ICXN - DIN 6270
Max. torque *
Max. torque 3rd + 4th p.t.o.
Oil consumption **
Dry weight
Combustion air volume at 3000 r.p.m.
Cooling air volume at 3000 r.p.m.
Max. permissible driving shaft axial load in both directions
Max. 60 seconds
Max inclination Lasting up to 30 seconds
Permanent
Firing Order
ENGINE TYPE CHD PLUS
* Referred to max. N power
** At NA power
*** Depending on the application
Technical information

- 20 - Workshop Manual LDW CHD _ cod. 1.5302.345 - 6° ed_rev. 05
2
LDW 1503 LDW 1603
LDW 2004 LDW 2004/T
CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES
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: Continuous light duty operation with constand speed and
variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOUS RATING WITH OVERLOAD CAPABILITY: continuous heavy duty with constant speed
and constant load.
MN Torque curve (N curve) - MB (NB curve) - MA (NA curve) - C: Specicfuelconsumptioncurve(NB curve)
Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m altitude and by 2% every 5°C above 25°C.
Enginepowercanbeinuencedbythetypeofcouplingusedwiththecoolingfan.
Technical information
PERFORMANCE DIAGRAMS