Lombardini Ldw 502 User manual

SERVICE MANUAL

code 1.5302.727

- 2 -

service manual mod. 051135

REGISTERINGDOCUMENTMODIFICATIONS

This document is made up of 98 pages (-sides - excluding

the cover and title page). Pages are numbered in progressive

order

from 051135.01 to 051135.98.

Any modifications to this document must be registered by the

drafting body and approved by the head of the Quality

Management System, with completion of the table below.

Copyright 2005 - Lombardini. Reproduction, even partial, of this document is subject to the manufacturer’s written authorisation. The manufacturer is committed to a policy of continuing improvement and reserves the

right to modify the document, with no obligation to notify, providing that omission to do so constitutes no safety risk. The text may be reproduced in part or in whole, providing that the author is cited. Text and

graphics by: IDM Esperti in Comunicazione Tecnica - Forlì

Drafting body Document

Code Edition Issue date Review date Replaced

Pages Added

Pages Eliminated

pages

ATLO 1-5302-727 1° 30/06/05

- 3 -

service manual mod. 051135

1 GENERAL REMARKS AND SAFETY

1.1 PURPOSE OF THE MANUAL ....................................5

1.2 USING THISMANUAL................................................5

1.3 MANUFACTURERAND ENGINEIDENTIFICATION ..5

1.4 GLOSSARYANDTERMINOLOGY .............................6

1.5 WARRANTYCLAUSES ..............................................6

1.6 GENERALSAFETYREGULATIONS ..........................6

1.7 GENERAL SAFETYDURING OPERATING PHASES 6

1.8 SAFETYAND ENVIRONMENTALIMPACT .................7

1.9 PRECAUTIONS WHEN THE ENGINE IS INSTALLED

ON THE MACHINE .....................................................7

1.10 PRECAUTIONS WHEN THE ENGINE IS ON THE

ROTATING STAND......................................................7

2 TECHNICAL INFORMATION

2.1 GENERAL DESCRIPTION OF THE ENGINE ............9

2.2 TECHNICALSPECIFICATIONS ...............................10

2.3 CHARACTERISTIC CURVEDIAGRAMS .................12

2.4 ALTERNATORLOAD CURVEDIAGRAMS...............13

2.5 LUBRICANTS...........................................................14

2.5.1 SAE Classification ...................................................14

2.5.2 API/MIL sequences..................................................14

2.5.3 ACEAStandards .......................................................14

2.5.4 Recommended oil ...................................................14

2.6 OPERATING PRINCIPLE FOR LUBRICATION .......15

2.7 OPERATING PRINCIPLE FOR COOLING...............15

2.8 OPERATING PRINCIPLE FOR FUEL INJECTION..16

2.9 WIRING DIAGRAM....................................................17

2.10 SPECIALTOOLSAND EQUIPMENT FOR

MAINTENANCE ........................................................19

2.11 TABLE OFTIGHTENING TORQUES .......................19

2.12 TABLE OFSEALANTS..............................................21

2.13 ROUTINEENGINEMAINTENANCE ........................21

3 MALFUNCTIONS

3.1 LOOKING FOR MALFUNCTIONS ...........................23

4 STORING THE ENGINE

4.1 HANDLINGAND LIFTING ........................................25

4.2 STORING THE ENGINE (UNINSTALLED) ..............25

4.3 STORING THE ENGINE (INSTALLED) ...................25

4.4 PROTECTIVETREATMENT .....................................26

4.5 PREPARINGTHE ENGINE FOR OPERATION

(UNINSTALLED).......................................................26

4.7 PREPARINGTHE ENGINE FOR OPERATION

(INSTALLED) ............................................................27

5 REMOVING THE ASSEMBLIES

5.1 RECOMMENDATIONSFORREMOVINGTHE

ASSEMBLIES ...........................................................29

5.2 REMOVINGTHEEXHAUST AND INTAKE

MANIFOLDS .............................................................29

5.2.1 Disassembling the intake manifold .......................29

5.2.2 Disassembling the exhaust manifold ....................30

5.3 REMOVING THE COOLINGFAN BELTDRIVE........30

5.3.1 Disassembling the cooling fan belt

(with external alternator) ..........................................31

5.3.2 Disassembling the cooling fan belt

(with internal alternator)...........................................31

5.4 REMOVING THETIMING BELT DRIVE....................31

5.4.1 Disassembling the timing belt casing ...................31

5.4.2 Disassembling the timing belt ...............................32

5.4.3 Disassembling the pulleys

(camshaft and crankshaft) ......................................32

5.5 REMOVING THE CYLINDER HEAD ........................33

5.5.1 Disassembling the rocker arm cover .....................33

5.5.2 Disassembling the rocker arms.............................33

5.5.3 Disassembling the fuel pump ................................33

5.5.4 Disassembling the injection-pumps......................34

5.5.5 Disassembling the precombustion chamber........34

5.5.6 Disassembling the speed governor

and flow limiter.........................................................35

5.5.7 Disassembling the camshaft..................................36

5.5.8 Disassembling the cylinder head...........................36

5.6 REMOVING THE CRANKGEAR

AND CRANKCASE ...................................................36

5.6.1 Disassembling the flywheel....................................36

5.6.2 Disassembling the oil pump ..................................37

5.6.3 Disassembling the crankcase and crankshaft ......38

5.6.4 Disassembling the connecting rod and piston......39

5.7 DISASSEMBLINGTHE VALVES ...............................39

5.8 DISASSEMBLING THEPISTON ..............................40

6 OVERHAULS AND TUNING

6.1 RECOMMENDATIONSFOROVERHAULS

AND TUNING ...........................................................41

6.1.1 Shaft seals ...............................................................41

6.1.2 O-rings .....................................................................41

6.1.3 Bearings...................................................................41

6.2 OVERHAULING THE CRANK GEARSAND

CRANKCASE ...........................................................41

6.2.1 Overhauling cylinders and pistons .........................41

6.2.2 Dimensional check and overhaul of cylinders .......42

6.2.3 Dimensional check and overhaul of pistons..........42

6.2.4 Dimensional check of sealing rings.......................43

6.2.5 Dimensional check and overhaul of crankshaft.....44

6.2.6 Dimensional check and overhaul of

connecting rods .......................................................45

6.2.7 Checking parallelism of the connecting rod axes..45

6.2.8 Checking and overhauling the fuel pump ..............46

6.2.9 Overhauling the decanting device...........................47

6.3 OVERHAULOF CYLINDER HEADAND RELATED

COMPONENTS ........................................................47

6.3.1 Checking and overhauling the cylinder head .........47

6.3.2 Checking and overhauling the rocker arm pin .......48

6.3.3 Checking and replacing the camshaft....................49

6.3.4 Checking and replacing the fuel pump drive rod ...50

6.3.5 Checking and overhauling the valves .....................51

6.3.6 Adjusting valve-rocker arm clearance.....................52

6.3.7 Checking clearance volume....................................52

6.3.8 Calibrating the injector ............................................53

6.3.9 Checking and overhauling the speed governor .....53

6.4 CHECKING TIMING BELT RATING .........................54

6.4.1 Valve adjustments ...................................................54

6.5 DIAGRAMOFTIMINGBELTRATES.........................55

6.6 ADJUSTING STATIC INJECTIONTIMING................55

6.7 BALANCING INJECTION-PUMPDELIVERY ...........58

GENERALINDEX

- 4 -

service manual mod. 051135

GENERALINDEX

6.8 ADJUSTING MINIMUMAND MAXIMUM

IDLE SPEED RPMS .................................................60

6.9 ADJUSTING INJECTION DELIVERY .......................60

6.9.1 Adjusting injection delivery (without dyno brake) ...60

6.9.2 Adjusting injection delivery (with dyno brake).........61

6.10 CHECKING OIL PRESSURE ..................................61

7 INSTALLATION OF ASSEMBLIES

7.1 RECOMMENDATIONSFOR INSTALLINGTHE

ASSEMBLIES ...........................................................63

7.2 PRE-ASSEMBLYOF

SEALING RINGS – PISTONS .................................63

7.3 PRE-ASSEMBLYOF

CONNECTING RODS – PISTONS ..........................64

7.4 INSTALLINGVALVES ...............................................64

7.4.1 Assembling the valves ............................................64

7.5 INSTALLATION OF CRANKGEAR

AND CRANKCASE … ..............................................65

7.5.1 Installing piston/connecting rod - engine block .....65

7.5.2 Assembling the crankshaft .....................................66

7.5.3 Assembling the crankcase .....................................66

7.5.4. Measuring crankshaft axial clearance ....................67

7.5.5 Assembling the crankshaft flange (flywheel side) .67

7.5.6 Installing the oil pump .............................................68

7.5.7 Assembling the flywheel .........................................69

7.6 INSTALLATIONOF CYLINDER HEADAND

COMPONENTS….....................................................70

7.6.1 Assembling the precombustion chamber..............70

7.6.2 Assembling the cylinder head ................................71

7.6.3 Assembling the camshaft .......................................71

7.6.4 Assembling the speed governor and flow limiter ..72

7.6.5 Assembling injection – pumps...............................73

7.6.6 Assembling the mechanical fuel pump..................74

7.6.7 Assembling the rocker arms...................................75

7.6.8 Assembling the rocker arm cover ...........................75

7.7 INSTALLINGTHE TIMINGBELTDRIVE ..................76

7.7.1 Assembling the timing belt pulley...........................76

7.7.2 Assembling the timing belt .....................................76

7.7.3 Assembling the belt drive cover ..............................77

7.8 INSTALLATION OFTHECOOLING FAN

BELT DRIVE .............................................................78

7.8.1 Assembling the fan belt drive pulleys .....................78

7.8.2 Assembling the fan belt drive..................................79

7.8.3 Assembling the cooling fan.....................................80

7.9 INSTALLINGINTAKEAND EXHAUSTMANIFOLDS 80

7.9.1 Assembling the exhaust manifold ..........................80

7.9.2 Assembling the intake manifold .............................80

8 REPLACING PARTS

8.1 RECOMMENDATIONSFORREPLACING PARTS ..83

8.2 REPLACING THEALTERNATOR – FAN BELT ........83

8.3 REPLACING THE TIMING BELT ..............................85

8.4 REPLACING THE OIL FILTER .................................85

8.5 REPLACING THEAIR FILTER .................................86

8.6 REPLACING THEALTERNATOR.............................87

8.7 REPLACING THESTARTER MOTOR......................87

8.8 REPLACING THE FLYWHEEL RING GEAR............88

8.9 REPLACINGTHE COOLANTTHERMOSTAT ..........88

8.10 REPLACING THE COOLANT PUMP .......................89

8.11 REPLACINGTHETHERMOSTATICVALVE ….........89

8.12 REPLACING THE NEGATIVE-PRESSURE VENT

VALVE........................................................................90

8.13 REPLACING THE PRE-HEATING GLOW PLUGS ..90

8.14 REPLACING INJECTOR PUMPPARTS ..................91

8.14.1 Pumping element replacement ..............................91

8.14.2 Replacing the nozzle-injector ..................................93

8.15 REPLACINGTHE COOLING FAN SUPPORT .........93

INDEX................................................................ 95

- 5 -

service manual mod. 051135

GENERAL REMARKS AND SAFETY

1.1 PURPOSE OF THE MANUAL

- Thismanual was written by the manufacturertoprovide

technical and operating information to authorised

LOMBARDINI after-sales service centres to carry out

assembly, disassembly, overhauling, replacement and

tuningoperations.

- This information is provided by the manufacturer in its

own language (Italian) and may be translated into other

languages to satisfy legislative and/or commercial

requirements.

- As well as employing good operating techniques and

observingtherighttimingforoperations,operatorsmust

read the information very carefully and comply with it

scrupulously.

- Time spent reading this information will help to prevent

health and safety risks and financial damage.

- Written information is accompanied by illustrations in

ordertofacilitateyourunderstandingofeverystepinthe

operatingphases.

-Importantremarksandfeatures of the textarehighlighted

using symbols, which are explained below.

Danger – Attention

This indicates situations of grave danger, which, if

ignored, may seriously threaten the health, and safety

of individuals.

Caution – Warning

This indicates that it is necessary to take proper

precautionstopreventany risk tothehealth and safety

of individuals and avoid financial damage.

Important

This indicates particularly important technical

information that should not be ignored.

1.2 USING THIS MANUAL

- Thismanualis divided into several chapters.

- The first chapter gives general information and details

about safety (purpose of the manual, safety, etc.).

- The second, third and fourth chapters provide general

technicalinformation(technicalspecifications,diagrams,

tightening torques, malfunctions, etc.).

- Thefifth,sixth,seventhandeighthchapters describe the

mostimportantoperatingprocedures(removal,overhaul

and tuning, installation, replacements, etc.).

- This final section, which is reserved specifically for

LOMBARDINI after-sales service centres, has been

prepared with technical and practical considerations in

mind.

- However, the actual sequence of operations that

LOMBARDINI service centres must use may in some

casesbedifferent fromtheonesdescribed inthismanual.

For this reason, the reader should refer to the index to

find his/her topic of interest quickly.

1.3 MANUFACTURERANDENGINEIDENTIFICATION

Theidentificationplateshown in thefigurecan

be found directly on the engine. It contains

themodel, engine identity and all information

needed to operate safely.

A) Manufacturer’sidentity

B) Enginetype

C) Engineserialnumber

D) Maximumspeed

E) Customercode

E) Approvaldata

- 6 -

service manual mod. 051135

GENERAL REMARKS AND SAFETY

1.4 GLOSSARYAND TERMINOLOGY

For clarity, here are the definitions of a number of terms

used recurrently in the manual. -Pistonnumberone: firstpiston“viewedfromtheflywheel

sideof the engine”.

-Rotation direction: clockwiseoranticlockwise“viewed

from the timing belt side of the engine”..

1.5 WARRANTYCLAUSES

LOMBARDINI issuesawarrantycertificateforeachengine

givingdetailsofall relevant general terms.

1.6 GENERALSAFETYREGULATIONS

- Indesigningandbuilding its product, the manufacturer

haspaid particular attention to thoseaspects posing a

risk to the health and safety of persons handling the

engine.Inadditiontolegislativerequirements,all “rules

forgoodtechnicalconstruction”havebeenapplied.

- Thepurpose of this information is to invite operators to

pay particular attention in order to prevent any form of

risk. Caution is always the best policy. Safety is also

theresponsibilityof alloperatorswhohandle theengine.

- Allpersonscarryingoutworkonthe engine at anypoint

in its life must possess precise technical qualifications

andskills,aswellas experiencerecognisedandgained

in the specific sector. Non-compliance with these

requirements may cause damage to the health and

safetyofindividuals.

- Do not tamper with, sidestep, eliminate or bypass the

installed safety devices. Non-compliance with this

requirementmaybehazardoustothe health andsafety

ofindividuals.

- The procedures contained in this manual have been

tested and selected by the manufacturer’s technical

experts,andhencearetoberecognisedasauthorised

operatingmethods.

- A number of procedures must be carried out with the

aid of equipment and tools that simplify and improve

the timing of operations.

- Some of these tools are normal workshop equipment,

while others are specific instruments that have been

constructedbytheengine manufacturer.

- All tools must be in good working condition so that

engine components are not damaged and that

operationsare 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.

- Holesmustbelinedupmethodicallyandwiththeaidof

suitable equipment. Do not use your fingers to carry

out this operation to avoid the risk of amputation.

- Somephasesmayrequiretheassistanceofmorethan

oneoperator. If so, itisimportanttoinformandexercise

themregardingthetypeofactivitytheywillbeperforming

in order to prevent risks to the health and safety of all

personsinvolved.

- Do not use flammable liquids (petrol, diesel, etc.) to

degreaseor wash components. Use specialproducts.

- Keep flames away from the engine to avoid the risk of

fire.

- Replacewornor damagedpartsexclusivelywithoriginal

LOMBARDINI spare parts. This will contribute to

ensuringbetterperformanceandlongerproductlife.

1.7 GENERALSAFETYDURING OPERATINGPHASES

- 7 -

service manual mod. 051135

GENERAL REMARKS AND SAFETY

- Use the oils and greases recommended by the

manufacturer. Do not mix different brands or oils with

differentcharacteristics.

- Useatorquewrench to tighten the main fixing points of

engine components. Stick to the tightening torques

indicatedbythe manufacturer.

- Discontinue use of the engine if any irregularities

arise, particularly in the case of unusual vibrations.

- The engine has been designed and built to satisfy

all the operating conditions described by the

manufacturer.

- Do not tamper with any devices to alter the level of

performanceguaranteedbythemanufacturer.

In order to minimise the impact on the environment, the

manufacturernow provides a number ofindicationsto be

followedbyall personshandlingtheengine, foranyreason,

during its expected lifetime.

- All packaging components must be disposed of in

accordance with the laws of the country in which

disposal is taking place.

- Keep exhaust pipes in efficient working order to limit

thenoiseleveloftheengineand reduce environmental

pollution.

- When discontinuing use of the engine, select all

componentsaccordingtotheir chemical characteristics

anddispose of separately.

- Alloperations,except whereexpresslystatedotherwise,

mustbecarriedoutwhentheengineisnotrunningand

has cooled sufficiently to avoid the risk of burns.

- Donotkeeptheenginerunninginareasthatareclosed

and inadequately ventilated. Take all necessary

precautionsto prevent a build up ofexhaust fumes.

Everyorganisation has a duty to implement procedures to

identify,assessandmonitortheinfluenceofitsownactivities

(products,services, etc.) on the environment.

Procedures for identifying the extent of the impact on the

environmentmustconsiderthefollowingfactors:

- Liquidwaste

- Wastemanagement

- Soilcontamination

- Atmosphericemissions

- Useof raw materials and natural resources

- Regulationsanddirectivesregardingenvironmental

impact

-Beforeremovingtheenginefromthemachineonwhich

it is installed, disconnect the electric current, the fuel

supply,coolantandall connectionsincludingmechanical

ones.

-To lift the engine, attach the lifting device at the points

(eyebolts)specifiedbythemanufacturer.

-Close all engine openings carefully (exhaust, intake,

etc.)washtheoutsideanddrywitha jet of compressed

air.

-Anchor the engine to the rotating stand to facilitate

alloperations.

Note: the engine may also be placed on the

workbench, depending on the type of work to

be carried out.

1.10 PRECAUTIONS WHEN THE ENGINE IS ON THE ROTATING STAND

1.8 SAFETYAND ENVIRONMENTAL IMPACT

1.9 PRECAUTIONS WHEN THE ENGINE IS INSTALLED ON THE MACHINE

- 8 -

service manual mod. 051135

. ..........................................................................................................................................................................

...........................................................................................................................................................................