Lombardini LGW 523 Series Instruction manual

WORKSHOP
MANUAL
Series LGW 523-627 and LGW 627 GPL engines
code 1-5302-509
SERVICE
1
LGW 523
LGW 627
1st Edition
COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99

SERVICE
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).

COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 3
WARRANTY CLAUSE
Lombardini S.r.l., guarantees its engines for a period of 12 months from the date of delivery to the first user, and
no later than 24 months from the date of delivery to the manufacturer or building site. Of the two alternatives, the
one that occurs first shall be considered valid.
Stationary assemblies (with use at constant load and constant speed and/or with load and speed that slightly vary
within the regulating limits) are not covered by this clause. For these assemblies, the guarantee is recognized up
to a maximum one thousand (1000) hours service if the above mentioned periods have not been exceeded.
In the case of special applications requiring considerable modifications to the cooling, lubricating (example: dry
sump systems), supercharging and filtering circuits, either the special warranty clauses explicitly established in
writing shall be valid or the above mentioned general clauses if an approval test of the application issued by the
Technical Management of Lombardini motori is exhibited.
Within the above mentioned terms, Lombardini undertakes to supply, free of charge, spare parts for those
components which are recognized by Lombardini or by one of its authorized representatives as possessing
manufacturing or material defects or, at its discretion, to either carry out repairs itself or by means of authorized
workshops.
All other total and partial liability and obligation for other direct or indirect expenses, damages or losses deriving
from use or the impossibility to use the engines shall, however, remain excluded.
Repairs or supply of substitutions shall in no way extend or renew the length of the warranty period.
Expenses sustained to remove the engine from the machine or hull and to remount it again, plus transport
expenses and those for expendable materials (filters, lubricating oils, etc.) shall be at the user's charge.
Lombardini's obligations established in the previous paragraphs shall become void if:
- The engines are not used in compliance with Lombardini's instructions in the operation and maintenance
manual;
- The seals affixed by Lombardini are tampered with;
- The engines are repaired, dismantled or modified by workshops that have not been authorized by Lombardini;
- Use has been made of spares that are NOT genuine Lombardini parts;
- The injection systems have been damaged by unsuitable or polluted fuel;
- The electrical systems become faulty owing to components such as remote control relays, for which the
manufacturer's warranty is applicable.
Lombardini shall consider itself released from all liability and from the obligations described in the previous
paragraphs once the twelve month period from the date on which the engine was delivered to the first users has
elapsed and/or the thousand (1000) hours service have terminated.
This warranty, which runs from 1st July 1993, voids and substitutes all other expressed or implicit warranties and
may only be modified in writing.
WARRANTY CLAUSE

REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
4
TABLE OF CONTENTS
I TROUBLESHOOTING
II SAFETY DECALS - SAFETY INSTRUCTIONS
III CODE AND IDENTIFICATION
IV TECHNICAL SPECIFICATIONS
V CHARACTERISTIC CURVES
VI OVERALL DIMENSIONS
VII MAINTENANCE- RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS
VIII DISASSEMBLY / REASSEMBLY
Bearing half-rings, oversizes
Belt tightening guide pulley
Cam height inspection
Camshaft and housings, pin dimensions (mm)
Camshaft, demounting
Camshaft, inspection of pin diameters and housings
Central main bearing caps
Checking for play between bearings and main journals
Connecting rod (big-end bearing)
Connecting rod complete with bearings and pin
Connecting rod, weight
Connecting rod alignment
Cooling fan
Cooling fan and alternator belt
Cylinder head, removal
Cylinders
Cylinders, class
Cylinders, roughness
Crank shaft float
Crank shaft front and rear oil retention seals
Crank shaft, lubrication ducts
Crank shaft, main journal and crank inspection
Demounting and remounting the pin stop rings
Demounting the oil pump
Diameters of main journal and big-end journals
Driving pulley
Exhaust manifold
Flywheel
Head gasket
Head torquing
Hydraulic pump drive (for LGW 627)
Inner diameters of main and big-end bearings
Intake, exhaust cam height - LGW 523 - LGW 627
LGW 523 - LGW 627 remote dry air filter
LGW 523 - LGW 627 valve springs
LGW 523 - LGW 627 valve/rocker clearance
LGW 523 Dry air filter
This manual contains information on how to repair LOMBARDINI LGW 523, LGW 627 gasoline
fuelled engines and LOMBARDINI LGW 627 LPG fuelled engines and is up to date as of
10.06.1999.
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COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 5
TABLE OF CONTENTS
LGW 523 bleed
LGW 523 dry air filter
LGW 523 rocker cap
LGW 523-627 head torquing phases
LGW 627 air filter support
LGW 627 dry air filter
LGW 627 rocker cap
LGW 627 speed governor
LGW 627 speed governor components
LGW 627 speed governor levers
Oil pump
Oil retainer seal in valve guide, removal
Oil sump, removal
Operative timing system tuning angles (valve clearance = 0.26 mm) for LGW 523
Operative timing system tuning angles (valve clearance = 0.26 mm) for LGW 627
Piston
Piston protrusion test
Piston rings - Distance between the tips
Piston rings, assembly order
Piston rings, play between slots (mm)
Piston, class and logotype
Piston, demounting and inspection
Piston, refitting
Pistons, weight
Pulley on crank shaft
Rear and front main bearing caps
Remounting the LGW 627 speed governor
Remounting the oil pump
Removing the timing belt
Rocker cap and recirculated oil vapour bleeding system for engine LGW 627
Rocker shaft
Rocker shaft, demounting and refitting
Supporting half-rings
Tank (on request)
Third drive, components (for LGW 627)
Timing belt and gears
Timing belt guard
Timing pulley - Disassembly/Reassembly
Timing pulley - Timing system tuning reference marks
Transmission pulley
Tuning angles to check the timing system (valve clearance = 2 mm) for LGW 523
Tuning angles to check the timing system (valve clearance = 2 mm) for LGW 627
Tuning the timing system - Angles
Tuning the timing system - Belt tightening tool
Tuning the timing system - Inspection
Tuning the timing system - Refitting the timing belt
Tuning the timing system - Tightening the timing belt and tightener torque
Valve guides and housings
Valve guides, assembly
Valve recessing and width of housing seal
Valves
Valve springs
Valves, seats and housings
Valves, specifications
IX LUBRICATION CIRCUIT
Internal oil filter and engine oil return tube
Lubrication circuit
Oil filter cartridge
Oil pressure check
Oil pressure regulating valve
Oil pump
Oil pump, play between rotors
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REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
6
TABLE OF CONTENTS
X COOLING CIRCUIT
Cooling circuit
Cooling fluid pump, components
Radiator and compensation chamber plug - Inspections and tightness
Thermostatic valve
XI FUELLING CIRCUIT
Adjustments
Adjustments and calibration
Calibrated parts
Carburetor
Carburetor 32TLF/250
Carburetor FHCD22.18E
Carburetor LGW 523
Carburetor vacuum adjustment
Carburetor vacuum adjustment
Carburetor vacuum balancing test
Carburetor with variant to keep the engine idling when cold
Cold starting
Enrichment adjustments - with analyzer
Float chamber level
Fuel filter detached from tank
Fuel pump
Fuel pump rod projection
Higt and idling speed adjustment
Idling adjustment
Idling speed
Fuelling circuit
Inspections and adjustments
Mixture adjuster screw regulation (idling rate)
Normal speed
Partial air powered opening of the ignition throttle
Pick-up
Pick-up pump delivery
Positive opening
Preliminary conditions
Speed adjuster screw regulation (idling rate)
XII IGNITION
523 ignition process
Introduction
LGW 523 coil
LGW 523 cut-off
LGW 523 ignition system
LGW 627 ignition system
Main components of the LGW 523 ignition system
Main components of the LGW 627 ignition system
Operating principle
Operating principle
Phase sensor
Spark plug (type Champion RC 12YC)
Technical specifications of the ignition module
XIII ELECTRICAL CIRCUIT
Alternator housed in the flywheel
Alternator Iskra 14V 33A
Battery
Battery recharging curve for 12V 20A alternator
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COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 7
TABLE OF CONTENTS
Battery recharging curve for 12V 30A alternator
Characteristic curve of alternator Marelli AA 125 R 14V 45A
Characteristic curve of starter motor Bosch type DW 12V 1.1 kW
Characteristic curve of the Iskra 14V 33A alternator
Ignition module of gasoline (petrol) and LPG fuelled engine LGW 627 with spark lead variation
device serial N° 122.2193.114
Ignition module of gasoline (petrol) fuelled engine LGW 523 with idling back-up device serial N°
122.2193.113
Ignition module of gasoline (petrol) fuelled engine LGW 523 without idling back-up device serial N°
122.2193.108
Ignition module of gasoline (petrol) fuelled engine LGW 627 with spark lead variation device serial
N° 122.2193.109
Ignition module of gasoline (petrol) fuelled engine LGW 627 with spark lead variation device serial
N° 122.2193.114
Marelli alternator, type AA 125 R 14V 45A
Pressure switch for oil pressure indicator
Sensor for coolant fluid temperature indicator
Starter motor, Bosch type DW 12V 1.1 kW
Voltage regulator connection
Wiring diagram of gasoline (petrol) fuelled engine LGW 523 with idling back-up device, with internal
alternator and module serial N° 122.2193.113
Wiring diagram of gasoline (petrol) fuelled engine LGW 523 withour idling back-up device, with
internal alternator and module serial N° 122.2193.108
Wiring diagram of gasoline (petrol) fuelled engine LGW 627 with external alternator and module
serial N° 122.2193.109
Wiring diagram of gasoline (petrol) fuelled engine LGW 627 with external alternator and module
serial N° 122.2193.114
Wiring diagram of LPG fuelled engine LGW 627 with external alternator and module serial N°
122.2193.114
XIV STORAGE
Permanent protection (longer than 6 months)
Preparing for operation
Storage
Temporary protection (1/6 months)
XV LPG fuelled ENGINE LGW 627
Carburation test with exhaust gas analyzer
Change-over switch Mod. 093
Components of the LPG conversion unit
Connecting the mixer to the regulator
Electrical system
Gasoline (petrol) solenoid valve
How to regulate the sensitivity of reducer SE 81 SIC
Liquid phase LPG shut-off solenoid valve
Mod. 093 change-over switch installation
Operation of the ignition system for gasoline (petrol) or LPG fuelled engines
Operation of the LPG conversion unit
Positioning the regulator
Regulator heating circuit connection
Regulator installation
Regulator/atomizer
Regulating procedure with reducer SE 81 SIC
Technical specifications
The mixer
76
75
77
74
69
73
71
65
67
75
77
77
77
75
72
70
64
66
68
" 78
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78
78
" 79
88
87
83
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86
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82
80
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86
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REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
8
TABLE OF CONTENTS
XVI MAIN DRIVING TORQUES
Driving torques for standard screws
Main driving torques
Use of sealing agents
XVII SPECIFIC TOOLS
Specific tools
90
91
90
90
" 92
92
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
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○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○

COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 9
The table gives the causes of some of the faults that may occur during operation.
Proceed systematically with the simplest inspections before removing or replacing any parts.
DISASSEMBLY / REASSEMBLY
ADJUSTMENTS MAINTE-
NANCE ELECTRICAL
CIRCUIT LUBRICATION
CIRCUIT FUEL
CIRCUIT
PROBABLE CAUSES AND THEIR REMEDIES
Clogged tubes
Fuel filter clogged
Air in the fuel circuit
Tank plug venting hole clogged
Defective fuel pump
Fuel dirty or containing water
Carburetor incorrectly regulated
Dirty carburetor
Oil level too high
Pressure regulating valve jammed or dirty
Worn oil pump
Air in oil intake pipe
Defective pressure gauge or pressure switch
Oil intake pipe clogged
Oil filter clogged
Electronic module defective
"Hall" module sensor faulty
Battery low
Wiring uncertain or incorrect
Defective ignition switch
Defective starter motor
Defective coil
Spark plug grounded or defective
Spark plug cable disconnected
Cut-Off defective or disconnected
Air filter clogged
Coolant fluid radiator clogged
Coolant fluid level low or containing air
Engine overloaded
Speed governor levers incorrectly timed
Speed gov. spring broken, released or unsuitable
Idling rate too low
Piston rings worn or jammed
Cylinders worn or scored
Valve guides worn
Faulty valve housings
Valves jammed
Worn connecting rod journal bushes
Governor levers not free to slide
Drive shaft not free to slide
Damaged big-end seals
Timing belt broken
PROBABLE CAUSE
FAULTS
Irregular speed
Fails to accelerate Starts then stops
Fails to start
Black smoke
White smoke
Low oil pressure
High oil pressure
Excessive oil consumption
Oil and fuel drip from exhaust
Coolant fluid overheats
TROUBLESHOOTING I
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REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
10
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
theessentialsafetyandhealthsafeguardingrequisiteshavebeentaken,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 ofpartsnotdescribedin theoperationandmaintenancemanual byunauthorized
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.
II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS

COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 11
·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 II

REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
12
III CODE AND IDENTIFICATION
é
ç
Max speed
setting
(r/min)
Type of engine
Serial N°
Performance approval
N° of version
(K modulus)
Exhaust approvals
Note: The Performance Approval and Exhaust Approvals are
only stamped for Diesel engines

COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 13
Cylinders
Bore
Stroke
Displacement
Compression ratio
r/min N 80/1269/EEC - 88/195/EEC - ISO 1585
Power kW/HP NB 80/1269/EEC - ISO 1585
NA ISO 3946/1 - ICXN
Maximum torque
No-load idling speed r/min
Water pump flow rate
Max. tolerated inclination for intermittant service ***
Specific fuel consumption
Standard oil sump capacity (filter included)
Standard oil sump capacity (filter excluded)
Oil consumption (measured at N power rating) *
Oil consumption (measured at NA power rating) **
Recommended battery
Dry weight
IV
TECHNICAL SPECIFICATIONS
LGW 523-627 SPECIFICATIONS
TYPE OF ENGINE
N°
mm
mm
cc.
Nm
l/min
g/kW
l.
l.
g/kWh
g/kWh
V/ah
Kg
* In N power
SELF-DRIVING POWER: Discontinuous service at variable rate and load.
** In NA power
CONT. OVERLOADABLE POWER: Continuous heavy-duty service at constant rate and load.
*** Depending on application
LGW523 LDW 627
2
72
62
505
8.7 : 1
5000
15 / 20.4
37 @ 2200
1100
52 (~)
at 5000 rpm
25° (35°)
300
1.5
1.4
0.007
12/44
52
2
72
75
611
9 : 1
3600
14.5 / 19.7
12.3/16.7
44.5 @ 2400
1100
40 (~)
at 3600 rpm
25° (35°)
310
1.7
1.6
0.007
12/44
60
LGW 523
LGW 627

REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
14
CHARACTERISTIC CURVES
V
CHARACTERISTIC POWER, DRIVING TORQUE AND SPECIFIC CONSUMPTION CURVES
N (80/1269/CEE - ISO 1585) SELF-DRIVING POWER: Discontinuous service at variable rates and loads.
NB (ISO 3046 - 1 IFN) NON-OVERLOADABLE POWER: Continuous light service at constant rate and with variable loads.
NA (ISO 3046 - 1 ICXN) CONTINUOUS OVERLOADABLE POWER: Continuous heavy-duty service at constant rates and loads.
MN Torque curve (in curve N)
Mt (in curve N)
MA (in curve NA)
CSpecific consumption curve measured at power NB
Cse Specific consumption curve measured at power N
The indicated power ratings refer to engines equipped with air filter, standard silencer and fan, with the running-in period terminated and at
environmental conditions of 20°C and 1 bar.
Maximum power is guaranteed with a 5% tolerance.
The power ratings drop by about 1% for every 100 m of altitude and by 2% for every 5°C above 25°C.
Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.
LGW 523 LGW 627
Remember that all variations to the intake or exhaust systems during the application phase of engines LGW 523 and
LGW 627 will involve a variation in the carburation.
Optimizing must be checked beforehand in the Lombardini test departments. Failure of Lombardini to approve this type
of modification relieves the same from all liability for any damage the engine may sustain.

COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 15
VI
OVERALL DIMENSIONS
Note : The values are in mm
LGW 627
LGW 523

REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
16
VII
10 50 80 100 175 250 350 500 1000 2000 5000
FREQUENCY HOURS
PARTOPERATION
SUMP OIL LEVEL
RADIATOR FINS
ALTERNATOR BELT TENSION
VALVE AND TAPPET PLAY
AIR FILTER
CARBURETOR
SUMP OIL LEVEL
ANTI-FREEZE (****)
OIL FILTER CARTRIDGE
FUEL FILTER
AIR FILTER CARTRIDGE
TIMING BELT (**)
FAN (ALTERNATOR) BELT
SPARK PLUG
PARTIAL (***)
GENERAL
CARBURETOR
First change
(*) In very dusty environments
(**) When the timing belt is removed it must be changed even though it has not terminated its period of use.
(***) Check the cylinders, piston rings, guides, springs and valve seat honing; descale cylinder head and cylinders.
(****) Every two years or after 1000 hours service.
INSPECTION
REPLACEMENT
OVERHAUL
Failureto carry out the operations described in the table may lead to technical damage to the machine
and/or system
MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS
LGW 523 ENGINE MAINTENANCE
10 50 80 100 175 250 350 500 1000 2000 5000
FREQUENCY HOURS
PART
OPERATION
OIL-COOLED AIR FILTER
FUEL TANK AIR FILTER OIL
LEVEL SUMP OIL
BATTERY FLUID
RADIATOR FINS
ALTERNATOR BELT TENSION
VALVE AND TAPPET PLAY
AIR FILTER
CARBURETORS
AIR FILTER (*)(**)
SUMP
ANTI-FREEZE (*****)
OIL FILTER CARTRIDGE
FUEL FILTER
AIR FILTER CARTRIDGE
TIMING BELT (***)
ALTERNATOR BELT
SPARK PLUG
PARTIAL (****)
GENERAL
CARBURETORS
First change
(*) In very dusty environments
(**) See recommended type of oil
(***) When the timing belt is removed it must be changed even though it has not terminated its period of use.
(****) Check the cylinders, piston rings, guides, springs and valve seat honing; descale cylinder head and cylinders.
(*****) Every two years or after 1000 hours service.
CLEANING
INSPECTION
REPLACEMENT
OVERHAUL
OIL
LGW 627 ENGINE MAINTENANCE
(*)
(*)
(*)
(*)
(*)

COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 17
GRADE
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 ) 523
Standard oil sump
filter included 1.5
filter excluded 1.4
OIL SUPPLY ( liters ) 627
Standard oil sump
filter included 1.7
filter excluded 1.6
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
-
30 - 25 - 20 -
15 -
10 - 50+
5+ 10 + 15 + 20 +
25 +
30 + 35 +
40 + 45
SAE 20W
SAE 10W
+
50
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
VII
MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS
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
VOLVO VDS
MAN QC 13-017
VW 505.00
SHAPI
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.
G- 4
SJ
SAE 0W-30 synthetic based
SAE 5W-40 synthetic based
-
35
-
40

REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
18
VII MAINTENANCE - RECOMMENDED OIL - COOLANT FLUID - FUELS AND LUBRICANTS
The fluid coolant circuit is pressurized. Inspections must only be made when the engine has cooled and even in this
case, the radiator or expansion chamber plug must be unscrewed with the utmost caution.
If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the engine is at
a standstill.
Coolant fluid is polluting. It must therefore be disposed of in the correct way. Do not litter.
COOLANT FLUID
Remember to use anti-freeze and protective fluids (e.g. (es. AGIP ANTIFREEZE, ESSO PERMANENT ANTIFREEZE, etc.)
mixed with decalcified water for preference.
The freezing point of the coolant fluid mixture depends on the concentration of the product in water: at -15° ( 30% ), at -20° C
( 35 % ), at -25° C ( 40 % ), at -30° C ( 45 % ), at -35° C ( 50 % ).
Besides lowering the freezing point, permanent liquid also raises the boiling point. This passes from 100°C (point at which
water boils) to temperatures of over 110°C. The boiling point varies according to the characteristics of the fluid and depending
on the pressure in the circuit itself.
It is therefore advisable to use a mixture diluted by 50% to ensure a general degree of protection.
COOLANT FLUID SUPPLY ( liters )
With standard radiator LGW 523 - 627 l. 2.3

COMPILER TECO/ATL REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 ENDORSED
DATE
10.06.99 19
DISASSEMBLY/REASSEMBLY VIII
DISASSEMBLY AND REASSEMBLY
Besides describing how to dismantle and reassemble the various
parts, this chapter also includes instructions on how to check and
tune the engines, dimensions, repairs and hints on operation.
Always use genuine LOMBARDINI spares to correctly repair the
engines.
LGW 523 Dry air filter
The dry air filter of engine LGW 523 consists of a single unit (casing
and cartridge) which cannot be separated.
Since the internal cartridge cannot be cleaned, the whole filter must
be changed.
To remove the old filter, unscrew screw 1(clamp that fixes it to the
carburetor) and screw 2( clamp that fixes the breather pipe).
To fix seal 3(see fig. 1), thoroughly clean and and degrease the
housing on the carburetor and apply Loctite 401 adhesive.
Consult page 16 for the maintenance (replacement) instructions.
Never clean the filtering element using solvents with a low
flash point. This could cause an explosion !
It is inadvisable to blow compressed air on to the paper filter
element.
If necessary, lightly and repeatedly tap the element on a hard
surface to eliminate any excess dirt.
LGW 627 Dry air filter
Parts: 1Cover
2Filtering cartridge
3Support
4Vent
Cartridge specifications:
Filtering degree = 13 to 14 micron m.
Filtering area = 4470 cm²
See page 16 for the maintenance or replacement instructions.
LGW 627 Air filter support
The exhaust manifolds are built into the support.
To remove the support, unscrew the 4 nuts 1 and disconnect the
bleed pipe between the manifold and the rocker cover.
When remounting the parts, re-connect the bleed pipe, tighten the
relative clamps and then torque the 4 nuts 1to 4 Nm.
3
1
2
Always wear protective goggles during repair
work, when compressed air is used

REG. CODE
1-5302-509
MODEL N°
50778
DATE OF ISSUE
10.06.99 REVISION 00 DATE
10.06.99
ENDORSED
COMPILER TECO/ATI
20
LGW 627 Air filter support
1Air filter support
2Oil vapour venting tube from the tappet cap to the air filter support
3Tube that returns the vapour, re-converted into liquid oil, back to
the sump
Whenever the intake manifold is demounted, make sure that there
are no traces of dust either in the manifold itself or in the intake
pipes.
Replace the seals between the carburetors and manifold whenever
the support is demounted.
LGW 523 - LGW 627 Remote dry air filter
Configuration example of remote air filters for the two engines in
question.
4 or 5 inch filtering elements can be used.
LGW 523: 1 Remote air filter (4 or 5 inches)
2Clamp
3Connection pipe from the carburetor cap to the air filter
4Clamp
5Carburetor cap
LGW 627: 1 Remote air filter (4 or 5 inches)
2Clamp
3Connection pipe from the intake manifold to the air
filter
4Clamp
5Intake manifold
6Bleed pipe from the intake manifold to the rocker cap
Allow the exhaust manifold to cool before demounting it in
order to prevent scorching and burns.
Exhaust manifold
When the exhaust manifold is demounted, make sure that the
interior is perfectly clean and free from cracks or fractures.
Replace the seals whenever the manifold is remounted.
Torque the fixing nuts to 25 Nm when the parts are remounted.
DISASSEMBLY/REASSEMBLY
VIII
6
5
4
When engines LGW 523 and LGW 627 are being installed, remember that any variation to the intake system (type of
air filter, length and diameters of the pipes leading from the intake manifold to the air filter) will involve a modification to
the carburation.
The carburation must be tested beforehand in the Lombardini test department. Failure of Lombardini to approve this
type of modification shall relieve the same of all liability for deriving operating faults and any damage to which the
engine may be subjected.
When engines LGW 523 and LGW 627 are being mounted, remember that any variations to the exhaust system (type
of exhaust silencer, length and diameters of the pipes that lead from the exhaust manifold to the silencer) will involve a
variation to the carburation.
The carburation must be tested beforehand in the Lombardini test department. Failure of Lombardini to approve this
type of modification shall relieve the same of all liability for deriving operating faults and any damage to which the
engine may be subjected.