Lombardini LDW 422 SERIES Instruction manual

1
LDW 422
18-10-2004
00
18-10-2004
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION DATE ENDORSED
COMPILER TECO/ATI
1st Edition
WORKSHOP
MANUAL
LDW 422 engines-
4 Speed - EURO 2 Version
code 1-5302-662

3
18-10-2004
18-10-2004 00
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION ENDORSED
COMPILER TECO/ATI DATE
FOREWORD
We have done all in our power to give up to date and accurate technical information in this manual. Lombardini
engines are, however, constantly developing thus the data in this publication may be liable to modification without
prior notice.
The information in this manual is the exclusive property of Lombardini. Neither partial nor total duplications or
reprints are therefore permitted without the express authorization of Lombardini.
The information in this manual is given on the assumption that:
1- the persons who service Lombardini engines have been adequately trained and outfitted to safely and
professionally carry out the necessary tasks;
2- the persons who service Lombardini engines possess the necessary skills and special Lombardini tools to
safely and professionally carry out the necessary tasks;
3- the persons who service Lombardini engines have read the specific information concerning the above
mentioned Service operations and that they have clearly understood the operations required.
GENERAL SERVICE NOTES
1 - Only use genuine Lombardini spare parts. Use of spurious spares may lead to incorrect performance and
shorten the life of the engines.
2 - The metric system is used to express all data, i.e. the dimensions are given in millimeters (mm), torque is
expressed in Newton-meters (Nm), weight in kilograms (Kg), volume in liters or cubic centimeters (cc) and
pressure in barometric units (bar).

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18-10-2004 00
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
TABLE OF CONTENTS
SAFETY DECALS - SAFETY INSTRUCTIONS ............................................................................ Pag. 8-9
I TROUBLESHOOTING ................................................................................................................. " 10-11
II MAINTENANCE ........................................................................................................................... "12
III MAINTENANCE- RECOMMENDED OIL TYPE - REFILLING........................................................ " 13
IV MODEL NUMBER AND IDENTIFICATION ................................................................................... " 14
V TECHNICAL DATA ...................................................................................................................... " 15
VI LUBRICATION SYSTEM ............................................................................................................. " 16-17
VII COOLING SYSTEM..................................................................................................................... " 18-21
Cooling liquid features ....................................................................................................................................................19
Cooling liquid circulating pump......................................................................................................................................20
Checks on water pump ...................................................................................................................................................20
Checks on thermostat valve............................................................................................................................................20
Check of the coolant temperature switch. ......................................................................................................................21
FORCED LIQUID COOLING SYSTEM WITH AXIAL FAN ................................................................................................19
Thermostatic valve...........................................................................................................................................................20
Sensor for cooling liquid temperature indicator light....................................................................................................21
WATER COOLED SYSTEM DESCRIPTION....................................................................................................................18
VIII FUEL SYSTEM ............................................................................................................................ " 22-24
FUEL SUPPLY CIRCUIT WITH QUICK STOP DEVICE ( QSD ).....................................................................................22
Fuel circuit air bleeding ...................................................................................................................................................24
QSD behaviour with excited electromagnet ...................................................................................................................22
QSD behaviour with de-excited electromagnet..............................................................................................................23
QSD WIRING DIAGRAM ..................................................................................................................................................24
Running engine (excited electromagnet).......................................................................................................................23
Running engine (excited electromagnet).......................................................................................................................22
IX TIMING DIAGRAM ...................................................................................................................... " 25
X PREHEATING SYSTEM............................................................................................................... " 26-27
Distraction time diagram............................................................................................................................................... 27
Preheating system ........................................................................................................................................................ 26
Preheating time diagram according to ambient temperature ( 11V ) .............................................................................. 27
Post heating time diagram............................................................................................................................................ 27
IX DISASSEMBLY / REASSEMBLY
Internal alternator ............................................................................................................................................................32
Internal alternator - features............................................................................................................................................33
Adjustment of pump control rod......................................................................................................................................103
Air shroud, Cooling fan - Disassembly ..........................................................................................................................30
Air shroud, cooling fan – Radiator shroud - Assembly..................................................................................................106
Assembly play - Cylinder-Piston .....................................................................................................................................63
This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled,
indirect injection Diesel engines type LDW 422: updated October 18, 2004.
INDEX

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REG. CODE
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MODEL N°
51092
DATEOFISSUE REVISION ENDORSED
COMPILER TECO/ATI DATE
INDEX
Assembly play - Piston rings ..........................................................................................................................................63
Assembly play - Piston - Piston pin ................................................................................................................................64
Assembly play - Piston slots - piston rings....................................................................................................................64
Assembly play - Small end bush - wrist pin ...................................................................................................................64
Assembly play - Connecting rod small end bush ..........................................................................................................64
Assembly play - Crankshaft - big end.............................................................................................................................65
Assembly play - Valve guide - valve stim........................................................................................................................65
Assembly play - Valve seat..............................................................................................................................................65
Assembly play - Tappet ...................................................................................................................................................66
Assembly play - Valves - spring......................................................................................................................................66
Assembly play - Valves caps...........................................................................................................................................66
Battery recharge curve.....................................................................................................................................................33
Belt tightener - Disassembly ..........................................................................................................................................45
Camshaft - Reassembly .................................................................................................................................................92
Camshaft and tappet support .........................................................................................................................................91
Camshaft extraction ........................................................................................................................................................46
Camshaft oil seal and timing pulley ...............................................................................................................................92
Camshaft support - Disassembly ..................................................................................................................................47
Camshaft timing ..............................................................................................................................................................37
Camshaft: control of size.................................................................................................................................................92
Caption Gearbox shaft 4th speed gear ..........................................................................................................................77
Centrifugal weights assembly - Assembling.................................................................................................................97
Clearance Check .............................................................................................................................................................100
Clutch assembly..............................................................................................................................................................88
Clutch cover, clutch pack - Disassembly .......................................................................................................................36
Clutch-side housing half .................................................................................................................................................84
Clutch-side housing half – Gearbox shaft roller case and multiple gear ball bearing - Disassembling. .................53
Complete governor assembly - Disassembly ...............................................................................................................44
Connecting rod ................................................................................................................................................................76
Cooling fan support - Disassembly................................................................................................................................31
Cooling liquid circulating pump - Assembly ..................................................................................................................96
CRANCKCASE - BEARINGS - CLUTCH SIDE MULTIPLE GEAR BALL BEARING .......................................................67
CRANCKCASE - BEARINGS - CRANKSHAFT - CRANKCASE - BEARING HOUSING .................................................67
CRANCKCASE - BEARINGS - DIFFERENTIAL HOUSING ............................................................................................67
CRANCKCASE - BEARINGS - NEEDLE BEARING HOUSING ......................................................................................67
CRANCKCASE - BEARINGS - REVERSE GEAR............................................................................................................67
Crankcase, half, flywheel side ........................................................................................................................................84
Crankshaft – Reverse shaft – Gearbox shaft – Multiple gear – Differential gear assembly ........................................52
Crankshaft timing ............................................................................................................................................................38
Cylinder – Piston – Wrist pin - Disassembly.................................................................................................................51
Cylinder head...................................................................................................................................................................70
Cylinder head - Disassembly .........................................................................................................................................47
Cylinder head installation - Reassembly.......................................................................................................................91
Cylinder-cylinder head securing studs...........................................................................................................................91
Delivery governor assembly............................................................................................................................................97
Delivery regulator – reassembly .....................................................................................................................................59
Delivery regulator - Disassembly ...................................................................................................................................58
Description of the injection advance regulator...............................................................................................................98
Differential case ..............................................................................................................................................................81
Differential gear box ........................................................................................................................................................81
Dismantling values .........................................................................................................................................................70
Drive shaft and connecting rod .......................................................................................................................................76
Drive shaft, reverse gear shaft, multiple gear, gearbox shaft and differential gear .....................................................85
Driving shaft gear ............................................................................................................................................................49
ELECTRICAL DIAGRAM ..................................................................................................................................................82
Engine gear .....................................................................................................................................................................87
Feeding pump .................................................................................................................................................................104
Fireproof bulkhead and injector - Assembly ..................................................................................................................101
Flywheel - disassembly ..................................................................................................................................................31
Flywheel and cooling fan support - Assembly ...............................................................................................................106
Flywheel-side air shroud - Disassembly .......................................................................................................................30
Flywheel-side housing half – Roller case, multiple gear and roller case, gear - Disassembly .................................53
Fuel exhaust pipe - Assembly.........................................................................................................................................105
FUEL FLOW GOVERNOR DESCRIPTION .....................................................................................................................56

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MODEL N°
51092
DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
INDEX
Fuel pump - Disassembly...............................................................................................................................................47
Fuel pump – Characteristics and components .............................................................................................................104
Fuel pump - Reassembling............................................................................................................................................104
Gear assembly measure check......................................................................................................................................78
Gear cluster ball bearing and drive shaft d.c. roller bearing .........................................................................................84
Gearbox............................................................................................................................................................................80
Gearbox shaft...................................................................................................................................................................77
Glow plug - Disassembly................................................................................................................................................42
Glow plug - Check ...........................................................................................................................................................42
Glow plug - Assembling..................................................................................................................................................102
GOVERNOR’S WORKING DESCRIPTION - ENGINE AT FULL LOAD ..........................................................................61
GOVERNOR’S WORKING DESCRIPTION - ENGINE AT IDLE SPEED ........................................................................60
GOVERNOR’S WORKING DESCRIPTION - ENGINE AT MAX SPEED..........................................................................62
GOVERNOR’S WORKING DESCRIPTION - ENGINE AT PARTIAL LOAD.....................................................................61
GOVERNOR’S WORKING DESCRIPTION - ENGINE STANDING OR AT STARTING ..................................................60
Injection static advance timing........................................................................................................................................108
Injection advance dynamic control - B ............................................................................................................................113
Injection advance variator................................................................................................................................................98
Injection advance variator - Disassembly ......................................................................................................................44
INJECTION EQUIPMENT DESCRIPTION AND FUNTIONING - FUEL FLOW CONTROL ............................................103
INJECTION EQUIPMENT DESCRIPTION AND FUNTIONING - FUEL INJECTION ......................................................103
Injection pump .................................................................................................................................................................68
Injection pump - Assembling ..........................................................................................................................................101
Injection pump - Disassembly........................................................................................................................................43
Injection pump : “MICO” type F 002 F 10 006 - Features of the pump on the bench ....................................................68
Injection pump : “MICO” type F 002 F 10 006 - Test conditions ....................................................................................68
Injection pump control cam - Disassembly ...................................................................................................................45
Injection pump control cam – Assembling ....................................................................................................................97
Injector : MICO F 002 C 6 Z 396 ......................................................................................................................................69
Injector setting .................................................................................................................................................................69
Injector, fireproof bulkhead - Disassembly ....................................................................................................................41
Injector-injection pump connecting pipe - Assembly.....................................................................................................105
Main features of electrical starter....................................................................................................................................82
Measurement to determine the thickness of the head gasket. .....................................................................................90
Min. and max r.p.m. regulation........................................................................................................................................115
Minimum oil pressure switch - Assembly ......................................................................................................................106
Muffler - Assembly ...........................................................................................................................................................107
Muffler - disassembly ......................................................................................................................................................29
Oil dipstick case - Assembly...........................................................................................................................................93
Oil dipstick case - Disassembly .....................................................................................................................................48
Oil level check ..................................................................................................................................................................93
Oil filter - Assembly..........................................................................................................................................................107
Oil filter - Disassembly ....................................................................................................................................................29
Oil pressure regulating valve - Disassembly.................................................................................................................50
Oil pressure switch - Disassembly ................................................................................................................................48
Oil pump ..........................................................................................................................................................................75
Oil pump driving gear and oil pump - Disassembly......................................................................................................50
Oil pump gear and oil pump - reassembling.................................................................................................................86
Oldham union - Assembling ...........................................................................................................................................97
Piston and cylinder ..........................................................................................................................................................89
Precombustion chamber – disassembly and reassembly...........................................................................................74
Primary gearbox ring gear and clutch housing pan.......................................................................................................87
Reassembling the gearbox shaft: tightening the speed coupling spider ....................................................................77
Reassembling the gearbox shaft: tightening the spider clamping ring nut. ................................................................78
Reassembly of valves .....................................................................................................................................................72
Ring gear - Disassembly ................................................................................................................................................49
Sensor for cooling liquid temperature indicator light - Disassembly ..........................................................................42
Sensor for cooling liquid temperature indicator light – Assembling.............................................................................101
Separation of the housing halves...................................................................................................................................52
Shim thickness for tappet gap adjustment ....................................................................................................................100
Speed gear control box ...................................................................................................................................................89
Starting motor - Assembly...............................................................................................................................................106
Starting motor - Disassembly.........................................................................................................................................30
Tappet cover - Assembly .................................................................................................................................................105

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DATEOFISSUE REVISION ENDORSED
COMPILER TECO/ATI DATE
Tappet cover disassembly ..............................................................................................................................................46
Tappets - Disassembly...................................................................................................................................................46
Then check injection advance tining as follows - A. ......................................................................................................112
Thermostat – Assembly ..................................................................................................................................................101
Thermostat - Disassembly .............................................................................................................................................44
Timing belt cover - Assembly..........................................................................................................................................105
Timing belt cover, air shroud and stator support...........................................................................................................32
Timing gear and speed gear control box - Disassembly. .............................................................................................51
Timing pulley and camshaft oil seal ring - Disassembly ..............................................................................................45
Timing system .................................................................................................................................................................37
Toothed camshaft timing pulley - Assembly ..................................................................................................................93
Toothed crankshaft timing pulley - Assembly ................................................................................................................93
Toothed timing belt - Disassembly ................................................................................................................................39
Toothed timing belt - Reassembly .................................................................................................................................39
Toothed timing belt tensioner - Assembly .....................................................................................................................96
Valves grinding ................................................................................................................................................................71
Water pump - Disassembly ............................................................................................................................................48
XII TOOLS ................................................................................................................................................. 117-121
XIII MAIN TORQUE SPECIFICATIONS ...................................................................................................... 122-123

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MODEL N°
51092
DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
Failure to comply with the
instructions could result in
damage to persons and
property
Failure to comply with the
instructions could lead to
technical damage to the
machine and/or system
DANGER
SAFETY AND WARNING DECALS
CAUTION
SAFETY INSTRUCTIONS
•Lombardini Engines are built to supply their performances in a safe and long-lasting way. To obtain these results,
it is essential for users to comply with the servicing instructions given in the relative manual along with the safety
recommendations listed below.
•The engine has been made according to a machine manufacturer's specifications and all actions required to meet
theessentialsafetyand healthsafeguarding requisiteshavebeentaken,asprescribedbythecurrentlawsinmerit.
All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the
use defined by Lombardini which thus declines all liability for any accidents deriving from such operations.
•The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning
engine operation in particular, along with the relative routine maintenance work.
•The user must read these instructions carefully and become familiar with the operations described. Failure to do
thiscouldleadtoseriousdangerforhispersonalsafetyandhealthandthatofanypersonswhomaybeinthevicinity
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 specifically
trained by Lombardini and who work in compliance with the existing documentation.
•Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal
ofseals, demountingandrefitting ofpartsnot describedinthe operationandmaintenance manualbyunauthorized
personnel shall relieve Lombardini from all and every liability for deriving accidents or for failure to comply with the
laws in merit.
•On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the
case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or
dangerous objects, also considering the movements made by the operator. Pull-starting with a free cord (thus
excluding self-winding starting only), is not permitted even in an emergency.
•Make sure that the machine is stable to prevent the risk of overturning.
•Become familiar with how to adjust the rotation speed and stop the engine.
•Never start the engine in a closed place or where there is insufficient ventilation. 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.
SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS

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

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1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
I
STARTINGPROBLEMS
Faulty fuel pump
Presence of air inside the injection system
Faulty glow plug
Faulty starting motor or remote control switch
Faulty or dirty injector
Faulty injection pump
Faulty engine stop solenoid valve
LOWPOWER
Air filter clogged
Diesel fuel filter clogged
Delayed injection
Inadequate diesel fuel delivery
Faulty delivery or advance regulators
THEENGINESTOPS
Low idling speed
Presence of impurities inside the diesel fuel tank
Absence of air
Faulty engine stop solenoid valve
THEENGINEOVERHEATS
Low cooling liquid level
Faulty water thermostat
Narrower water passages in cylinder or hoses
Faulty water pump
Clogged radiator core
One ore more blades of the cooling fan are broken
Low oil level
Check and, if necessary, replace
Purge by operating the fuel pump lever
Replace
Detect the problem and, if necessary, overhaul or replace
Check and, if necessary, replace
Check and, if necessary, replace
Check and, if necessary, replace
Clean and, if necessary, replace
Replace
Check and time correctly
Verify fuel filter, check injection and fuel pumps efficiency
Check the assembly and, if necessary, overhaul it
Work on the appropriate register
Empty the tank and clean it, replace the diesel fuel and the filter
Clean the air filter and, if necessary, replace it
Check and, if necessary, replace
Restore level
Check and replace
Check and clean up
Check and replace
Check and clean up
Check and replace
Restore level
POSSIBLE CAUSES AND TROUBLE SHOOTING
FAULT FINDING REMEDIES
The following table contains the possible causes of some failures which may occur during operation. Always perform these
simple checks before removing or replacing any part.
TROUBLE SHOOTING

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MODEL N°
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DATEOFISSUE REVISION ENDORSED
COMPILER TECO/ATI DATE
I
TROUBLE SHOOTING
WHITEEXHAUSTSMOKE
Cold engine
Faulty injector
High oil level
BLACK EXHAUST SMOKE
Air filter clogged
Incorrect injection pump delivery
Faulty injector
NOISY ENGINE
Wrong injection advance
Faulty injector
Tappets with excessive clearance
Excessive wear of the engine internal parts
LOW OIL PRESSURE
Insufficient oil level
Worn oil pump
Worn or damaged crankshaft or small end bearings
CLUTCH : SLIPPING
Insufficient idle stroke
Weak return spring
Worn or burnt driven disk gasket
SPEED GEAR : SPONTANEOUS GEAR DISENGAGEMENT
Worn or damaged gearbox
Incorrectly adjusted control rod
Wrongly assembled or worn gearbox or coupling spider gears
VIBRATIONS TRANSMITTED FROM ENGINE TO FRAME
The silent-blocks anchoring the engine to the frame are not
locked correctly or are damaged
Heat the engine for few minutes at low speed
Check and, if necessary, replace
Restore the level
Replace
Check and restore
Clean and, if necessary, replace
Check the static and dynamic advance and restore
Clean and, if necessary, replace
Adjust
Overhaul
Restore the level
Overhaul
Overhaul
Adjust the stroke
Replace
Replace the disk
Check and, if necessary, replace
Adjust
Overhaul
Lock or replace
FAULT FINDING REMEDIES

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DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
II
40000200001000050001000 2500
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING
Failuretocarry out theoperations described inthetable may leadto technical damagetothe machine
and/or system
LDW 422 ENGINE - SPECIAL MAINTENANCE
OPERATION
CLEANING
CHECK
REPLACEMENT
Dry-type air filter
Checking cooling liquid level
Valve clearance
Water in the fuel filter
Clutch control and possible adjustment
Bolts and nuts correct fastening
Dinamic Injection Advance
Engine oil
Oil filter
COMPONENT after the first
1000 Km
LDW 422 ENGINE - ORDINARY MAINTENANCE
INTERVAL KM
OPERATION
CLEANING
CHECK
REPLACEMENT
Dry-type air filter
Injector
Checking engine oil level
Checking cooling liquid level
Valve clearance
Water in the fuel filter
Integrity of propeller shaft boot
Low-pressure fuel lines
Clutch control and possible adjustment
Bolts and nuts correct fastening
Glow plug performance
Dinamic Injection Advance
Injector calibration
Engine oil
Oil filter
Fuel filter cartridge
Dry-type air filter cartridge
Timing belt
Cooling liquid
COMPONENT
after the first
5000 Km

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COMPILER TECO/ATI DATE
III
CCMC G- 2
CF CE CD CC CB CA SA SB SC SD SE SF SG
DIESEL BENZINA - ESSENCE - PETROL
BENZIN - GASOLINA
CCMC G- 3 G- 5
CCMC PD - 1 / PD - 2
CCMC D- 2
D- 4 CCMC D- 3
D- 5
MIL - L - 2104 D
MIL - L - 2104 E
MIL - L -46152 C
MIL - L- 46152 D/E
MB 226.1 MB 226.5
MB 227.1 MB 227.5
228.3 MB 228.1
VW 501.01
VW 500.00
SHAPI
G- 4
SJ
VOLVO VDS
MAN QC 13-017
VW 505.00
SAE 20W SAE 30SAE 40
SAE 10W-30
SAE 10W-40
SAE 10W-60
SAE 15W-40 base minerale
SAE 15W-40 base semi-sintetica
SAE 20W-60 base semi-sintetica
SAE 5W-30 base sintetica
SAE 0W-30 base sintetica
SAE 5W-40 base sintetica
-
30 - 25 - 20 -
15 - 10 - 50+
5+ 10 + 15 + 20 +
25 + 30 + 35 +
40 + 45
SAE 10W
+
50
-
35
-
40
RECOMMENDED OIL
SAE 15 W 40 API CF - Viscosity SAE 15W/40 ( for Indian market )
OIL SUPPLY (liters)
filter included 3,5
filter excluded 3,0
ACEA SEQUENCES
A = Gasoline (petrol)
B = Light Diesel fuels
E = Heavy Diesel fuels
Required levels :
A1-96
A2-96
A3-96
B1-96
B2-96
B3-96
E1-96
E2-96
E3-96
The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its
combustion could sharply increase the rotation speed.
Use a suitable oil in order to protect the engine.
The lubrication oil influences the performances and life of the engine in an incredible way.
Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, may make the
compression rings jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine
life will also be notably reduced.
Oil viscosity must suit the ambient temperature in which the engine operates.
Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil
is inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible.
Appropriate protective gloves etc should be wore during this operation.
Old oil is highly polluting and must be disposed of in the correct way. Do not litter.
Engine oil fuelling
Set the engine on a flat surface, then pour in oil up to the max. level mark on the plug dipstick.
MAINTENANCE - RECOMMENDED OIL - FUELS AND LUBRICANTS
GRADE

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DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
IV MODEL NUMBER AND IDENTIFICATION
Displacement (cc)
r.p.m.
Lombardini
Diesel
Water cooled Customer's code
Engine serial number

15
18-10-2004
18-10-2004 00
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION ENDORSED
COMPILER TECO/ATI DATE
V
LDW 422
N°
mm
mm
Cm³
kW
Nm
gr kW/h
l.
l.
Kg
LDW
422
1
83
78
422
23 : 1
1200 ± 100
5000
4500 ± 100
8,8
21,6
315
3,0
3,5
94
TECHNICAL DATA
Number of cylinders
Bore
Stroke
Displacement
Compression ratio
R.P.M./1' min
Max idle R.P.M./1'
Max load R.P.M./1'
Power kW
Max torque at 3200 R.P.M./1'
Fuel consumption
Oil quantity without oil filter
Oil quantity with oil filter
Dryweight
TECHNICAL DATA
LDW 422 ENGINE MAIN SPECIFICATIONS
- 4-stroke single cylinder engine
-Indirect-injectionDiesel-cycletype
- Liquid cooling system with axial fan
-Differentialgearandgearboxassemblyonrearaxle
-OHCaxledrivenbytoothed belt
-Lubricationismadethroughalobepumpcontrolled bydriving-shaftchain
-Injectionsystembyimmersed-typepump, fed by diaphragm fuel pump
-Dry-typecartridgeairfilter
- Oil filter with cartridge
- Oil type SAE 15 W 40 API CF

16 18-10-2004
18-10-2004 00
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
VI LUBRICATION SYSTEM

17
18-10-2004
18-10-2004 00
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION ENDORSED
COMPILER TECO/ATI DATE
VI
CYLINDER VALVE FOR
PISTON
COOLING
CRANKSHAFT
OIL SUMP
CONROD
CAMSHAFT
GOVERNOR
OIL
PRESSURE
VALVE
OIL FILTER
OIL PUMP
OIL PICK UP
LDW 422 OIL CIRCUIT DIAGRAM
CYLINDER
HEAD
CAMSHAFT
SUPPORT
LUBRICATION SYSTEM

18 18-10-2004
18-10-2004 00
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
VII
12 11
10
9
8
7
6
5
4
3
2
1
13
COOLING SYSTEM
Details:
1) Cooling liquid level 8) Thermostat
2) Overflow pipe 9) Liquid circulating pump
3) Plug with calibrated pressurizing valve 10) Engine outlet-radiator inlet hose
4) Compensation tank 11) Radiator outlet-engine inlet hose
5) Breathing pipe 12) Radiator
6) Pipe for the connection to the expansion vessel 13) Cooling fan
7) Liquid temperature monitoring thermostat
FORCEDLIQUIDCOOLINGSYSTEMWITHAXIALFAN

19
18-10-2004
18-10-2004 00
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION ENDORSED
COMPILER TECO/ATI DATE
VIICOOLING SYSTEM
Coolingliquidfeatures
It is recommended to use cooling liquids according to the recommended percentages, because besides lowering the freezing
point as well as the pressure determined by the plug (radiator or expansion vessel), it determines the rise of the liquid boiling
point inside the circuit.
Furthermore, it protects the whole circuit from corrosion, deposits, and cavitations can also be easily avoided.
In case radiators with aluminium cores are used, it is strictly necessary to use a solution of 50% H2O and 50% glycol
solution.
It's mandatory the use for the cooling system of the correct percentage of mixture water and glycole.
The lack to the above prescription will result in warranty avoidance
PLUG SETTING WATER SOLUTION WITH 30 % ÷ 50 % GLYCOL
0,50 bar 98° C 102° ÷ 105° C
0,70 bar 102° C 107° ÷ 110° C
0,90 bar 105° C 110° ÷ 112° C
1,00 bar 106° C 112° ÷ 114° C
Thermostatic valve features
- Opening starting point 80° C ± 2° C
- Max opening 95° C with 7 mm stroke
WATERCOOLEDSYSTEMDESCRIPTION
The engine cooling is carried out by means of liquid (50% of water and 50% of glicole) by the centrifugal pump, driven
by the timing belt.
Until the temperature of the liquid is 84-87 °C, the water is recirculated through a by-pass circuit. After, the thermostat
valve provided on the cylinder head allows the recirculation and the cooling through the radiator.

20 18-10-2004
18-10-2004 00
REG. CODE
1-5302-662
MODEL N°
51092
DATEOFISSUE REVISION DATE ENDORSED
COMPILERTECO/ATI
VII COOLING SYSTEM
Checks on thermostat valve
Dip the thermostat valve into a metal container ( a pan ) filled with water.
Procure a thermometer with max reading of 150 °C and dip in also in the same container to monitor the water temperature.
Heat up water and check – by means of the thermometer – that the thermostat valve starts opening at the required temperature
of 80° ±2° C.
If the valve opening temperature is different replace the thermostat.
With the previously described setting, keep heating the water up to 95 °C : at this temperature the valve must be completely
open, meaning that the lift is 7 mm.
Make sure that in cold water the valve is definitely closed.
In cased the thermostat valve would not open, the result is a substantial increase of the coolant temperature with abundant
overflow of the coolant itself out of the expansion tank.
Checks on water pump
Water pump is provided with two drain channels located in the upper part to the purpose of unveiling possible liquid leakages
thus indicating an incipient failure of the pump seal.
Particularly during the engine run-in period small leakages of fluid are to considered normal.
Make sure the pump shaft does not show any axial clearance and can turn freely without undue localised friction.
Check that the impeller is free from dents, cracks or – worse – some blade is broken or missing at all.
If anyone of these checks is negative, just replace the water pump.
When re-assembling, replace the O-ring seals, tighten the fixing screws with a torque wrench at the indicated torque of 12÷15
Nm and check for a free turning of the pump after the tightening.
Replace the gasket of the inlet fitting of the pump.
Replace the timing belt.
Coolingliquidcirculatingpump
Components:
1 Water pump case
2 Snap ring
3 Water pump bearing
4 Water pump sealing
5 Water pump impeller
6 Pulley
7 Shaft
Thermostatic valve
1 Case
2 Airvent
3 Valve head with wax sensor
Features:
Opening temperature: ...... 80° ± 2° C
Max stroke at 95° C: .......... 7 mm
Liquid return ...................... 30/80 lt/h
The following operation must be performed with the utmost
attention. The water temperature reaches very high values –
near boiling (about 100°C). Serious burns can result from
contact.
Payattentiontosplashesandoverflows.Becareful not toknock
over the container