Lombardini LGA 340 OHC Instruction manual

WORK SHOP
MANUAL
LGA 280-340 OHC Series engines,code 1-5302- 528
SERVICE
LGA 280 OHC
LGA 340 OHC
COMPILER TECO/ATI REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSEDDATE
31.07.2001
1st Edition
1

SERVICE
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 continuos. 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 persons performing service work on Lombardini series engines is properly trained and equipped to
safely and professionally perform the subject operation;
2- The person or persons 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 persons performing service work on Lombardini series engines has read the pertinent information
regarding the subject service operations and fully understands the operation at hand.
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).

COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 3
WARRANTY CERTIFICATE
WARRANTY CERTIFICATE
Engine manufactured by Lombardini S.r.l., are warranted to be free of defects in workmanship or materials for 12
months from the date of delivery to the first purchaser or non more than two (2) years from date of engine delivery to
the Original Equipment Manufacturer as defined by Lombardini invoicing, whichever occurs firsts, except as defined
below.
Stationary applications, working at constant speed and/or slightly variable speeds, are excluded from the above
terms. Stationary/fixed speed applications will be warranted to be free of material/workmanship defects for a
maximum operational period of 1000 hours or 12months from the date of first purchase, whichever occurs first. The
two (2) year limitation from date of Lombardini invoice will remain intact as described above.
Modification of Lombardini products by the Original Equipement Manufacturer or the end user with respect to cooling
systems, filtration systems, induction systems, exhaust systems, lubrication system, fuel system, fuel system
settings, etc., will require special written warranty agreements. A test certificate/approval by the R&D/Application
engineering department of Lombardini or associated Lombardini companies concerning modified Lombardini products
will entitle Warranty as defined above. Warranty will not be granted on any modified Lombardini product without
special written approval by Lombardini.
Within the above stated periods Lombardini will replace and/or repair, at the option of Lombardini, any part or
component that, upon examination by Lombardini or an authorized Lombardini agent, is found to be defective in
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 replacemnt of any component will not extend or renew the warranty period. Direct labor required to make
repairs or to replace components found to be defective in materials or workmanship will be completed at no cost to
the end user. Lombardini in not responsible however for indirect costs of removing/installing the engine assembly.
Further, Lombardini is not responsible for the costs of transportation of the machine or components requiring repair or
for service supplies such as lubricating oils and filters.
Lombardini Warranty obligations will be cancelled if:
- Lombardini engines are applied to a given machine causing working engine parameters outside Lombardini
application guidelines.
- Lombardini engines are not serviced and maintained according to the "USE and MAINTENANCE" booklet.
- Any seal affixed to the engine by Lombardini has been tampered with or removed.
- Engines have been disassembled, repaired or altered by any party other than an authorized Lombardini agent.
- Spare parts used are not original Lombardini.
- Fuel injection system/component failures caused by the use of unauthorized fuel types or poor quality fuels are
not covered under the Lombardini warranty policy.
- Electrical system failures due to the modification of Lombardini supplied harnesses, modification of Lombardini
supplied control panels, OEM/end user supplied/installed relays, controls, etc. are not covered under warranty.
Following expiration of the above stated warranty period(s) and limitations, Lombardini will have no further
responsibility for warranty and will consider our obligation for warranty complete.
The above warranty certificate will be in effect starting July 1, 1993 and cancels/replaces any and all explicit or implicit
warranty policies on the part of Lombardini. The above warranty conditions can from this date forward be modified only
in writing.

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
4
INDEX
I TROUBLE SHOOTING
II WARNING SIGNS - SAFETY INSTRUCTIONS
III ENGINE IDENTIFICATION
IV TECHNICAL FEATURES
V CHARACTERISTICS
VI OVERALL DIMENSION
VII MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING
VIII DISASSSEMBLY/REASSEMBLY
General information for correct repairs
Engine disassembly
Engine preparation
Flywheel extraction
Head disassembly
Disassembly of camshaft-tappets valves
Timing pulley removal
Timing cover removal
Crankshaft extraction
Cylinder head
Camshaft
Valves - guides - seats - valve spring - tappets
Valves and valve-guides dimensions after assembly in the head
Valves and valve-guides gap
Valve guide
Oil seal ring on valve guide
Valve seats
Valve springs
Tappets
Breather valve
Cylinder
Connecting rod
Piston and rings
Crankshaft
Main journals and crank pin diameter (mm)
Governor and balancing shaft gear command
Balancing shaft
Speed governor
Bearings
Crankcase and timing cover
Recoil starter
Rope and return spring replacement
Oil watch device (optional)
Crancshaft and oil seal rings
Piston and connecting rods
Speed governor
Timing cover
This manual gives the main instructions on how to repair LOMBARDINI LGA 280-340 OHC
gasoline-fuelled engines, updated as of 31.07.2001.
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INDEX
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COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 5
INDEX
Timing pulley assembling
Cylinder head assembling
Camshaft assembling and valve clearance adjustment
Timing adjustement and assembling of the toothed belt
Flywheel assembly and coil gap adjustment
Carburetor
Lubrication
IX ELECTRONIC IGNITION
Electronic ignition
Spark plugs
X ELECTRIC STARTING
Electric starting
Electrical start system standard
System checks
Alternator
Rectifier
Starting motor
Battery
Starting panel
Lighting system with alternator
Characteristics with alternator 180 W (optional)
XI REGISTRAZIONI
Engine assembling
Governor lever adjustment
Engine test
Starting with the recoil starter
Electric starting
Carburetor and R.P.M. adjustment
XII STORAGE
Storage
Temporary inactivity
Preparation for starting
XIII INSTALLATION - INCLINATION AND OPERATING LIMITS
Axial load - radial load and maximum overhang
Installation
Inclination and operating limits
XIV TORQUE SETTING
Main torque specifications
Standard bolt torque specifications
XV SPECIAL TOOLS
Special tools
XVI PISTON-CYLINDER OVERSIZE TABLE - TOLERANCES OF CRANKSHAFT JOURNAL
GRINDINGS - TABLE OF CLEARANCES AND ADJUSTMENTS
Piston-cylinder oversize table
Tolerances of crankshaft journal grindings
Table of clearances and adjustments
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○○○ ○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○ ○ ○ ○ ○ ○ ○ ○ ○ ○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○ ○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
6
NOTE

COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 7
TROUBLE SHOOTING I
Listed below are some of the possible causes of engine operating defects.
Carry out simple tests before proceeding with disassembly operations or making substitutions.
TROUBLE SHOOTING
Tank plug breather clogged
Tap clogged
Fuel filter clogged
Dirty carburetor
Carburetor needle valve blocked
Speed governor rod blocked
Grounded spark plug
Broken spark plug lead
Defective coil
Clogged air filter
Low oil level (oil watch alerted)
Air filter chocked
Blocked valves
Worn piston rings
Excessive valve play
Defective oil seals
Worn valve guides
Worn governor spring
Piston seizure
Loose head locking-nuts
Low idling rate
Driving belt broken
POSSIBLE CAUSES
TROUBLE
Noisy
No power
Starts and stops
Does not start
Light or white smoke
Dark or black smoke
Hunts
Consumes oil
Overheats
Does not accel.
Spark plug fails to spark
•
•
•••
••• ••• ••
••
••
•• ••••
•
••
••• •
•• ••
••• •••• • ••
••••
•
•
••
•

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
8
II WARNING SIGNS - SAFETY INSTRUCTIONS
Failure to comply with these
instructions may result in
damages to persons and
property.
Failure to comply with these
instructions can lead to
technical damage to the
machine and/or installation.
DANGER
WARNING SIGNS
CAUTION
•Lombardini engines are built to provide safe and longlasting performances, but in order to obtain these results it is
essential that the maintenance requirements described in the manual are observed along with the following safety
recommendations.
•The engine has been built to the specifications of a machine manufacturer, and it is his responsibility to ensure that
all necessary action is taken to meet the essential and legally prescribed health and safety requirements. Any use
of the machine other than that described cannot be considered as complying with its intended purpose as specified
by Lombardini, which therefore declines all responsibility for accidents caused by such operations.
•The following instructions are intended for the user of the machine in order to reduce or eliminate risks, especially
those concerning the operation and standard maintenance of the engine.
•The user should read these instructions carefully and get to know the operations described. By not doing so he
may place at risk his own health and safety and that of anyone else in the vicinity of the machine.
•The engine may be used or mounted on a machine only by personnel suitably trained in its operation and aware of
the dangers involved. This is particularly true for standard and, above all, special maintenance work. For special
maintenance contact personnel trained specifically by Lombardini. This work should be carried out in accordance
with existing literature.
•Lombardini declines all responsibility for accidents or for failure to comply with the requirements of law if changes
are made to the engine’s functional parameters or to the fuel flow rate adjustments and speed of rotation, if seals
are removed, or if parts not described in the operating and maintenance manual are removed and reassembled by
unauthorized personnel.
•In addition to all other machine specifications, ensure that the engine is in a near horizontal position when starting.
lf starting manually, ensure that the necessary operations can be performed without any risk of striking against
walls or dangerous objects. Rope starting (except for recoil rope starting) is not permitted even in emergencies.
•Check that the machine is stable so that there is no risk of it overturning.
•Get to know the engine speed adjustment and machine stop operations.
•Do not start the machine in closed or poorly ventilated environments. The internal combustion process generates
carbon monoxide, an odourless and highly toxic gas, so spending too long a time in an environment where the
engine discharges its exhaust products freely can lead to loss of consciousness and even death.
•The engine may not be used in environments containing flammable materials, explosive atmospheres or easily
combustible powders, unless adequate and specific precautions have been taken and are clearly stated and
certified for the machine.
•To prevent the risk of fire, keep the machine at a distance of at least one metre from buildings or other machines.
•Children and animals must be kept at a sufficient distance from the machine to prevent any danger resulting from
its operation.
SAFETY INSTRUCTIONS

COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 9
WARNING SIGNS - SAFETY INSTRUCTIONS II
•Fuel is flammable, so the tank must be filled only when the engine is turned off. Dry carefully any fuel that may
have spilled, remove the fuel container and any cloths soaked in fuel or oil, check that any sound-absorbing panels
made of porous material are not soaked with fuel or oil, and make sure that the ground on which the machine is
located has not absorbed fuel or oil.
•To start the engine follow the specific instructions provided in the engine and/or machine operating manual. Do not
use auxiliary starting devices not originally installed on the machine (e.g. Startpilot systems which utilise ether etc.)
•Before starting, remove any tools that have been used for carrying out maintenance work to the engine and/or the
machine and check that any guards removed have been replaced. In cold climates it is possible to mix kerosene
with the diesel fuel to make the engine easier to start. The liquids must be mixed in the tank by pouring in first the
kerosene and then the diesel fuel. Consult Lombardini technical office for mixture proportions. Petrol may not be
used because of the risk of it forming flammable vapours.
•During operation the surface of the engine reaches temperatures that may be dangerous. Avoid in particular all
contact with the exhaust system.
•Before carrying out any work on the engine, turn it off and allow it to cool down. Do not perform any operation while
the engine is running.
•The liquid cooling circuit is under pressure. Do not carry out any checks before the engine has cooled down, and
even then open the radiator cap or the expansion tank cautiously. Wear protective clothing and glasses. lf there is
an electric fan, do not approach the engine while it is still hot as the fan may come on even when the engine is not
running. Clean the cooling system with the engine turned off.
•While cleaning the oil bath air filter, check that the oil is disposed of in such a way as not to harm the environment.
Any filtering sponges in the oil bath air filter should not be soaked with oil. The cyclone pre-filter cup must not be
filled with oil.
•Since the oil must be emptied out while the engine is still hot (approx. 80°C), particular care should be taken in
order to avoid burns. In any case make sure that oil does not come into contact with your skin because of the
health hazards involved.
•Check that the discharged oil, the oil filter and the oil contained in the oil filter are disposed of in such a way as not
to harm the environment.
•Close the fuel tank filler cap carefully after each fílling operation. Do not fill the tank right up to the top, but leave
sufficient space to allow for any expansion of the fuel.
•Fuel vapours are highly toxic, so fill up only in the open air or in well ventilated environments.
•Do not smoke or use naked flames while filling.
•Take care when removing the oil filter as it may be hot.
•The operations of checking, filling up and replacing the cooling liquid must be carried out with the engine turned off
and cold. Take particular care if liquids containing nitrites are mixed with others not containing these compounds
as this may give rise to the formation of nitrosamines which are a health hazard. The cooling liquid is polluting, so
dispose of in a manner that does not damage the environment.
•During operations which involve access to moving parts of the engine and/or removal of the rotary guards, disconnect
and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter
motor.
•Check the belt tension only when the engine is turned off.
•In order to move the engine use exclusively the eyebolts fitted for this purpose by Lombardini. These lifting points
are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer.

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
10
III ENGINE IDENTIFICATION
LOMBARDINI
ENGINE TYPE
SWEPT VOLUME
CUSTOMER CODE
ENGINE IDENTIFICATION NUMBER
Í
Í
Í
Í
Î
Ï

COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 11
IV
TECHNICAL FEATURES
Cylinder
Bore
Stroke
Swept volume
Compression ratio
Standard R.P.M. N DIN 70020
Rating kW NB DIN 6271 ISO 3046
NA DIN 6271 ISO 3046
Max torque
Specific fuel consumption
Tank capacity
Housing oil capacity
Dry weight
Spark plug
Ignition system
Cooling system
Type of engine
TECHNICAL FEATURES LGA 280-340 OHC
ENGINE TYPE
N.
mm
mm
cc.
RPM
kW/HP
kW/HP
kW/HP
Nm-Kgm
g/kW h - g/HP h
l.
l.
Kg.
LGA 280 LGA 340
1
74
64
275
8.5 - 1
3000 - 3800
6.0/8.1 - 6.6-9.0
5.6/7.6 - 6.3/8.5
5.2/7.1 - 5.9/8.0
19 - 1.94
329 - 242
6
1.2
30
112-2100-067
Electronic
Forced air
4-stroke
integral
camshaft
1
82
64
338
8.5 - 1
3000 - 3800
7.4/10 - 8.1/11
6.9/9.4 - 7.7/10.4
6.6/8.9 - 7.3/9.9
23.7 - 2.4
342 -251
6
1.2
30
112-2100-067
Electronic
Forced air
4-strokes
integral
camshaft
LGA 280
LGA 340

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
12
CHARACTERISTICS
V
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 constant 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 (at Npowe)r.
MB (in NB curve)
MA (in NA curve)
CCurve of specific fuel consumption measured at power N.
The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of 20°C
and 1 bar.
Max. power tolerance is 5%.
Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 20°C.
Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.
LGA 280 LGA 340

COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 13
VI
OVERALL DIMENSIONS - OPTIONAL P.T.O. AND FLANGES
POWER TAKEOFFS AND SPECIAL FLANGING
OVERALL DIMENSIONS
Note: The values are given in mm

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
14
MAINTENANCE - RECOMMENDED OIL - FUELS AND LUBRICANTS
VII
10 20 25 50 100 300 500 1000 2500
MAINTENANCE
CLEANING
INSPECTION
REPLACEMENT
INTERVAL (HOURS)
COMPONENT
OPERATION
Air filter cartridge
Fuel filter
Cylinder and head fins
Oil level in housing
Distance of glow plug electrodes
Valve play
Timing belt
Oil in housing
Paper cartridge of air filter
Timing belt
•
•
•
•
•
•
•
•
•
•
Failuretocarryouttheoperationsdescribedinthetablemayleadtotechnicaldamagetothemachine
and/or system
To avoid explosions or fire outbreaks, do not smoke or use naked flames during the operations.
Fuel vapours are highly toxic. Only carry out the operations outdoors or in a well-ventilated place.
Keep your face well away from the plug to prevent harmful vapours from being inhaled. Dispose of fuel in the
correct way and do not litter as it is highly polluting.
FUEL
When refuelling, it is advisable to use a funnel to prevent fuel from spilling out. The fuel should also be filtered to
prevent dust or dirt from entering the tank.
Use PREMIUM gasoline or UNLEADED PREMIUM gasoline of the type used in cars. Use of other types of fuel could
damage the engine.
The octane rating of the fuel must be higher than 95 to prevent difficult starting.
Do not use old, dirty gasoline or oil-gasoline, water-gasoline mixtures since this would cause serious engine faults.
The tank capacity is: 6 l.

COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 15
RECOMMENDED OIL
AGIP SINT 2000 5W40 specification API SJ/CF ACEA A3-96 B3-96
MIL-L-46152 D/E.
ESSO ULTRA 10W40 specification API SJ/CF ACEA A3-96 MIL-L-
46152 D/E.
In countries where AGIP and ESSO products are not available, use
API SJ/CF oil for gasoline-fuelled engines or oil that complies with
military specification MIL-L-46152 D/E.
OIL SUPPLY (liters) LGA 280 - LGA 340
Standard oil sump lt 1.2
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
VII
MAINTENANCE - RECOMMENDED OIL - FUELS AND LUBRICANTS
Theenginecould bedamagedif allowedtooperate withinsufficientoil. Itisalsodangerous toaddtoomuchoil asits combustion
couldsharply increase therotationspeed.
Useasuitable oilinorder to protectthe engine.
Thelubrication oil influencestheperformances andlifeof theenginein an incredibleway.
Useofaninferiorquality oilorfailure toregularlychangetheoil willincreasethe riskofpistonseizure,maymakethecompression
ringsjam andwill leadtorapid wearon thecylinder liner,the bearingsandall othermoving parts.Engine lifewill alsobenotably
reduced.
Oilviscositymust suit theambienttemperature in whichtheengine 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,youare advised tothoroughly wash yourhandswith soap andwater as soonaspossible.
Appropriateprotective gloves etcshould beworeduring thisoperation.
Oldoilis highly polluting andmustbe disposed of inthecorrect way.Donot 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.
If the engine has an oil-cooled filter, check the oil level in the filter sump and if necessary, top up with the same type of oil as used to
lubricate the engine.
GRADE
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 mineral based
SAE 15W-40 semi-synthetic based
SAE 20W-60 semi-synthetic based
SAE 5W-30 synthetic based
SAE 0W-30 synthetic based
SAE 5W-40 synthetic based
-
30 - 25 - 20 -
15 - 10 - 50+
5+ 10 + 15 + 20 +
25 + 30 + 35 +
40 + 45
SAE 10W
+
50
-
35
-
40

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
16
NOTE

COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 17
DISASSEMBLY/REASSEMBLY VIII
DISASSEMBLY AND REASSEMBLY
Besides disassembly and reassembly operations this chapter also
includes checking and setting specifications, dimensions, repair and
operating instructions. Always use original LOMBARDINI spare parts
for repair operations.
GENERAL INFORMATION FOR CORRECT REPAIRS
- In order to work quickly and safely, strictly observe the instructions in the manual and the following general rules:
-Lockthemachinein positionbeforedisassemblingtheengine.
-Disconnect the batterycables (iftheengine isequipped with electricstarting).
-Alwaysusesuitabletools inordertoavoiddamaging engineparts.
- Use a plastic mallet to separate connected parts.
- When disassembling the engine, mark the parts that are not provided with reference marks in order to facilitate successive
assembly operations.
- Clean disassembled parts with petrol and compressed air
- Always replace gaskets, oil seals, washers and locknuts. Before re-assembling, lubricate moving parts and contact
surfaces.
- Respect torque wrench settings when tightening screws.
- Use always LOMBARDINI original spare parts.
ENGINEDISASSEMBLY
lf the engine is mechanically worn-out but the outside parts are still in good condition (tank, casing, flywheeI, coil, carburetor,
air filter, exhaust, fan cowl, cylinder head), the use of a “Short-Blocks” is advised (composed of crankcase, crankshaft,
connecting rod, piston, timing cover) already enclosed and prepared to be completed by the outside parts. Once assembly
operations have been completed, proceed with setting up.
ENGINE PREPARATION
After having drained off the oil from the engine and emptied the fuel tank, place the engine on a work bench and
disassemblethe outsideparts:tank, exhaust,air filter, carburetor,casing, recoilstarterand fancowl.
During the demounting phases, pay particular attention to
prevent the flywheel from dropping as this could seriously injure
the operator.
Wear protective goggles when removing the flywheel ring.
FLYWHEEL EXTRACTION
Loosen the flywheel locknut (remember that the thread is RIGHT
HANDED), remove the washer and pulley belt. Using the puller
CODE 3595.048 on page 42, remove the flywheel (fig. 1).
HEAD DISASSEMBLY
Do not disassemble when hot to avoid deformation.
Remove the belt cover casing, loosen the tightener and timing belt, remove the timing pulley loosening the screw that fixes it
to the camshaft, and the relative key, remove the toothed belt internal protective casing.
Using a allen wrench, loosen the 4 screws M 10 that fix the casing to the engine.
WARNING:itis advisedtoreplace thetimingbeltafterremoval,evenifthismeansanticipatingtheexpiryterm.
(See tab. pag. 14)
1
WARNINGS!
During repair operations, when using
compressed air, wear eye protection.

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
18
DISASSEMBLY/REASSEMBLY
VIII
3
2
DISASSEMBLY OFCAMSHAFT- TAPPETS VALVES
Remove the tappet cover, rotate the camshaft so that the cams face
upward, remove the side support, extract the camshaft (fig.2).
Removethetappetsand,withtoolCODE1460.113 onpage42 ,remove
the valve cotters; then extract the valves from the valve guides.
TIMING PULLEY REMOVAL
UseextractorCODE 1460.114 on page42 and remove thetimingpulley
as shown in fig. 3.
TIMING COVER REMOVAL
Loosen the M 8 screws that fix the timing cover to the crankcase, using puller CODE 3595.048 on page 42, position the central
screw on the opposite side from that used to extract the flywheel, tighten the two screws in the threaded holes on the timing cover
(fig. 4a).
DRIVESHAFTEXTRACTION
After the completion of operations, loosen the connecting rod screws, slide out the piston and extract the drive shaft.
Do not demount and remount when hot to avoid deformations.
CYLINDER HEAD
Made in die-cast aluminium alloy with inserted valve seats which are
made of special cast iron of high nickel-chromium content. They are
introduced with negative allowance into the relative seats on the head.
The valve guides are inserted and replaceable; special cast iron for the
intake valve and bronze for the exhaust valve. Clean all carbon deposits
from the head and check that the head face Pfig. 4b is not deformed.
lfdeformed, grindtheworking faceby removingnot morethan0.25 mm.
4a 4b

COMPILER TECO/ATL REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 ENDORSED
DATE
31.07.2001 19
DISASSEMBLY/REASSEMBLY VIII
CAMSHAFT
Checkthatthecamsandpinsarenotwornorscored.Slightindentations
or scoring can be taken up using a fine file and finished with the same
type of emery cloth. The pin diameter values and other main camshaft
dimensions are shown in the table in fig. 5.
All engines are fitted with centrifugal compression release; check the
smoothness of the counter-weight and the correct position of the spring
(fig.6).
The protusion of the pin from the cam contour must be between 0.50
÷ 0.60 mm with the device engaged.
N.B.: up to serial No. 11276 the protusion of the pin from the cam was
0.65-0.75 mm. Camshaft with protusion of the pin between 0.50-
0.60 mm will be delivered as spare parts.
VALVES- GUIDES -SEATS -VALVE SPRINGS-TAPPETS
After disassembly and cleaning with a metal brush, check that the
valves heads are not deformed, burned or worn in the seats: replace
the valves if damaged.
If the general condition is good, reset the face track Pin the seat with
a grinding of:
90' exhaust - 90' intake for engine LGA 280 OHC
90' exhaust - 121' intake for engine LGA 340 OHC
Check the guides, valves, seats after assembly.
N.B.: Valve seats with angles of 90° (exhaust) and 121° (intake) will be
used in the LGA 280 OHC too.
Please check tecknical informative sheet for introdution date
Valves and valve-guides dimensions after assembly in the head.
nominal D. (mm)
A Inlet valve 7 -0.013
-0.035
B Exhaust valve 7 -0.030
-0.045
C Inlet valve-guide 7 -0.025
+0.015
D Exhaust valve-guide 7 +0.025
+0.015
7
5
6
8

REG. CODE
1-5302-528
MODEL N°
50805
DATE OF ISSUE
31.07.2001 REVISION 00 DATE
31.07.2001
ENDORSED
COMPILER TECO/ATL
20
DISASSEMBLY/REASSEMBLY
VIII
Valves and valve-guides gap
NOMINAL LIMIT
C - A 0.028 - 0.070 0.14
D - B 0.045 - 0.080 0.14
VALVEGUIDES
Check that the valve guides are not scored, show signs of seizing or
carbon deposits. Cheeking of the valve guides wear (fig. 10) can be
carried out using a plug go-no-go gauge with pitch code 1460.103 on
page 42.
Internal valve-guides diameter after assembly in the head:
min 7.015 mm - max 7.025 mm
valve-guides gauge diameter:
7.010 mm passes - 7.097 mm does not pass
lf the diameter of the guide exceeds the plug diameter, replace the
guide. In order to extract the valve guide from the seat, use puller code
1460.104 on page 42, after having removed the safety ring.
OILSEALRINGONVALVEGUIDE:
Check that the rings are intact and still sufficiently elastic before re-
assembling. It is advised to replace these parts. For the assembling,
(fig. 11) use the tool code 1460.108 on pag. 42.
9
10
11