workshop manual · 2014-10-01 · - attach the engine to a suitable lifting device (lifting beam)....

WORKSHOP MANUAL

cod. ED0053022860

9 LD Engine Series

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PREFACE

- Everyattempthasbeenmadetopresentwithinthisservicemanual,accurateanduptodatetechnicalinforma-tion.

However,developmentontheLOMBARDINIseriesiscontinuous. Therefore,theinformationwithinthismanualissubjecttochangewithoutnoticeandwithoutobligation.

- TheinformationcontainedwithinthisservicemanualisthesolepropertyofLOMBARDINI. Assuch,noreproductionorreplicationinwholeorpartisallowedwithouttheexpresswrittenpermissionofLOM-

BARDINI.

Informationpresentedwithinthismanualassumesthefollowing:

1- ThepersonorpeopleperformingserviceworkonLOMBARDINIseriesenginesisproperlytrainedandequip-pedtosafelyandprofessionallyperformthesubjectoperation;

2- ThepersonorpeopleperformingserviceworkonLOMBARDINIseriesenginespossessesadequatehandandLOMBARDINIspecialtoolstosafelyandprofessionallyperformthesubjectserviceoperation;

3- ThepersonorpeopleperformingserviceworkonLOMBARDINIseriesengineshasreadthepertinentinforma-tionregardingthesubjectserviceoperationsandfullyunderstandstheoperationathand.

- ThismanualwaswrittenbythemanufacturertoprovidetechnicalandoperatinginformationtoauthorisedLOM-BARDINIafter-salesservicecentrestocarryoutassembly,disassembly,overhauling,replacementandtuningoperations.

- Aswellasemployinggoodoperatingtechniquesandobservingtherighttimingforoperations,operatorsmustreadtheinformationverycarefullyandcomplywithitscrupulously.

- Timespentreadingthisinformationwillhelptopreventhealthandsafetyrisksandfinancialdamage. Writteninformationisaccompaniedbyillustrationsinordertofacilitateyourunderstandingofeverystepofthe

operatingphases.

9 LD Engine Series

9LD Workshop Manual _ cod. 1.5302.286 - 4° ed_rev. 03

- 4 -

CUSE/ATLO

-

4° 06-883 01.09.2014

Drafting body

Document code Edition Issue date

Review date

ModelN° Revision

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Anymodificationstothisdocumentmustberegisteredbythedraftingbody,bycompletingthefollowingtable.

Endorsed

9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03

ED0053022860 50494

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-CHAPTER INDEX

TABLE OF CONTENTS

1 GENERAL REMARKS AND SAFETY INFORMATION ______________________________________ 9-11

CaliforniaProposition65WARNING..................................................................................................................................11Generalsafetyduringoperationgphases..........................................................................................................................11Generalservicemanualnotes............................................................................................................................................ 9Glossaryandterminology................................................................................................................................................... 9Regulationsforliftingtheengine......................................................................................................................................... 9Safetyandenvironmentalimpact.......................................................................................................................................11Safetyregulations............................................................................................................................................................. 10Warrantycertificate............................................................................................................................................................. 9

2 TECHNICAL INFORMATION _________________________________________________________ 12-21

Approvaldata.................................................................................................................................................................... 14Maincomponents.............................................................................................................................................................. 15Manufacturerandengineidentification............................................................................................................................. 14Overalldimension............................................................................................................................................................. 20Performancediagram................................................................................................................................................... 18-19Tableoflikelyanomaliesandtheirsymptoms................................................................................................................... 12Technicalspecifications................................................................................................................................................ 16-17Troubleshooting........................................................................................................................................................... 12-13

3 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING _____________________________ 22-25

ACEARegulations-Sequences....................................................................................................................................... 23API/MILSequences....................................................................................................................................................... 23Extraordinarymaintenance............................................................................................................................................... 22Fuelrecommendations...................................................................................................................................................... 25Internationalspecifications................................................................................................................................................ 23Lubricant........................................................................................................................................................................... 23Ordinarymaintenance...................................................................................................................................................... 22Prescribedlubricant.......................................................................................................................................................... 24Routineenginemaintenance............................................................................................................................................ 22SAEClassification............................................................................................................................................................ 23

4 DISASSEMBLY / REASSEMBLY ______________________________________________________ 26-51

Aircleaner......................................................................................................................................................................... 26Camshaft........................................................................................................................................................................... 45Camshaftendplay............................................................................................................................................................ 46Camshafttiming................................................................................................................................................................ 46Centermainbearingsupport,locatingscrew.................................................................................................................... 42Checkingmainjournalsandcrankpins............................................................................................................................ 43Clearancebetweenmainjournals/crankpinsandconnectingrodbearings..................................................................... 44Cloggingindicator............................................................................................................................................................. 28Compressionrelease....................................................................................................................................................... 32Connectingrod.................................................................................................................................................................. 39Connectingrodalignment................................................................................................................................................. 40Connectingrodbigendbearing........................................................................................................................................ 40Connectingrodsmallendbushing.................................................................................................................................... 40Connectingrodweight...................................................................................................................................................... 40Coolingfan........................................................................................................................................................................ 30Crankshaft......................................................................................................................................................................... 42Crankshaftcentermainbearingsupport........................................................................................................................... 42


ThismanualcontainspertinentinformationregardingtherepairofLOMBARDINIair-cooled,directinjectionDieselenginestype9 LD 625-2 - 625-2 EPA - 626-2 - 626-2 NR.

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- Chapter index

Crankshaftendplay.......................................................................................................................................................... 45Crankshaftjournalradius.................................................................................................................................................. 43Crankshaftlubricationducts.............................................................................................................................................. 42Crankshaftremoval........................................................................................................................................................... 42Crankshafttiminggear...................................................................................................................................................... 41Cylinder............................................................................................................................................................................. 36Cylinderhead.................................................................................................................................................................... 33Dimensionsandclearancebetweenguidesandvalves................................................................................................... 35Dimensionsofcamshaftjournalsandhousings................................................................................................................ 45Dryaircleaner................................................................................................................................................................... 27Dryaircleaner,Donaldsontype........................................................................................................................................ 27Electronicspeedgovernor................................................................................................................................................ 49Exhaustmanifold............................................................................................................................................................... 28Externalalternatorblowercontrolbelt-Disassembly....................................................................................................... 29Externalalternatorblowercontrolbelt-Reassembly........................................................................................................ 29Externalalternatorblowercontrolbelt–Tensioncheck.................................................................................................... 29Externalalternatorcontrolbelt.......................................................................................................................................... 29Flywheel............................................................................................................................................................................ 31Fueltank........................................................................................................................................................................... 29Governorspringswithrockerarmsystem......................................................................................................................... 49Governorspringswithsingle-springsystem..................................................................................................................... 49Headsealthickness.......................................................................................................................................................... 39Howtomeasurecamshaftjournalsandhousings............................................................................................................ 45Howtomeasureintake/exhaustcamheight..................................................................................................................... 46Howtomeasuremainbearinginsidediameter................................................................................................................. 43Hub.................................................................................................................................................................................... 30Hydraulicpump................................................................................................................................................................. 47Hydraulicpumpcomponents(1P).................................................................................................................................... 48Hydraulicpumpp.t.o......................................................................................................................................................... 47Injector.............................................................................................................................................................................. 32InjectorforEPAand97/68CEengines............................................................................................................................. 33Injectorprojection.............................................................................................................................................................. 33Intakemanifold.................................................................................................................................................................. 28Internalalternator.............................................................................................................................................................. 30Mainbearingandconnectingrodbigendbearinginsidediameter................................................................................... 44Mainbearinghousings...................................................................................................................................................... 44Mainbearingsupport,flywheeIside.................................................................................................................................. 41Mainbearingsupport,gearside........................................................................................................................................ 41Mainbearingsupports....................................................................................................................................................... 41Mainbearíngsupports-Dimensions................................................................................................................................ 44Mainjournalandcrankpindiameter................................................................................................................................. 43Manifolds,intake/exhaust.................................................................................................................................................. 28Mechanicalspeedgovernor.............................................................................................................................................. 48Mechanicalspeedgovernorcomponents......................................................................................................................... 48Oilvapourseparator......................................................................................................................................................... 28Oil-bathaircleaner............................................................................................................................................................ 26Piston................................................................................................................................................................................ 37Piston-Refitting................................................................................................................................................................ 39Pistonclearance................................................................................................................................................................ 39Pistonrings-Endgaps(mm)............................................................................................................................................ 38Pistonrings-Fittingsequence.......................................................................................................................................... 38Pistonweight..................................................................................................................................................................... 38Pistonsrings-Clearancebetweengrooves(mm)............................................................................................................ 38Pulleyguard-Shroud-Sideplates.................................................................................................................................. 30Pushrodtube..................................................................................................................................................................... 36Recommendationsfordisassemblingandassembling..................................................................................................... 26Recommendationsforoverhaulsandtuning..................................................................................................................... 26Rockerarmassembly....................................................................................................................................................... 32Rockerarms...................................................................................................................................................................... 31Shroudsupport(Gearcoverplate).................................................................................................................................... 31Speedgovernorwiringdiagram........................................................................................................................................ 50Table“Clearancebetweenmainbearingsandmainbearinghousings”........................................................................... 45Table“Pistonandcylindertypesandsizes"...................................................................................................................... 37Valve/Rockerarmclearance........................................................................................................................................... 31Valveguideinsertion......................................................................................................................................................... 35Valveguidesandvalveguidehousings............................................................................................................................ 35


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-Chapter index

Valvematerial.................................................................................................................................................................... 34Valveseatgrinding............................................................................................................................................................ 36Valveseatsandhousings................................................................................................................................................. 36Valvesprings..................................................................................................................................................................... 34Valvestemsealingrings-Reassembly........................................................................................................................... 34Valvetiming-Angles......................................................................................................................................................... 47Valvetimingcheck............................................................................................................................................................ 47Valvetimingwithoutconsideringtimingmarks.................................................................................................................. 46Valves................................................................................................................................................................................ 34

5 LUBRICATION SYSTEM ____________________________________________________________ 52-55

Lubricationsystemandbreatherrecirculationsystem...................................................................................................... 52Lubricationsystemwithoilradiatorcircuit......................................................................................................................... 53Oilfiltercartridge(external)............................................................................................................................................... 54Oilpressurecheck............................................................................................................................................................ 55Oilpressurecurvewithengineatfullspeed..................................................................................................................... 55Oilpressurecurvewithengineatidlespeed.................................................................................................................... 55Oilpressurereliefvalve..................................................................................................................................................... 54Oilpump............................................................................................................................................................................ 53Oilradiator......................................................................................................................................................................... 55Standardlubricationsystemcircuit................................................................................................................................... 52

6 FUEL SYSTEM ____________________________________________________________________ 56-65

Fuelfeeding/injectioncircuitwithexternalfuelfilter........................................................................................................ 56Fuelfeeding/injectioncircuitwithexternalfuelfilteranddoublesolenoidvalve............................................................. 56Fuelfeeding/injectioncircuitwithexternalfuelfilterandQSD(QuickStopSystem)...................................................... 57Fuelfeeding/injectioncircuitwithfuelfilterinsidethefueltank....................................................................................... 56Fuelfeeding/injectioncircuitwithfuelfilterinsidethefueltankanddoublesolenoidvalve............................................ 56Fuelfeeding/injectioncircuit............................................................................................................................................. 56Fuelfeedingpumpcomponents........................................................................................................................................ 58Fuelfilter........................................................................................................................................................................... 57Fuelfilter(insidefueltank)................................................................................................................................................ 57Fuelfilter,external............................................................................................................................................................. 57Fuelliftpump..................................................................................................................................................................... 57Howtocheckinjectionpumpdeliveryvalvesealing......................................................................................................... 60Howtocheckplungerandbarrelforinternalleakage....................................................................................................... 59Howtomountinjectionpumpontheengine..................................................................................................................... 61Howtoreassembleinjectionpumpcomponents............................................................................................................... 61Injectionadvanceadjustment............................................................................................................................................ 63Injectionpump................................................................................................................................................................... 58InjectionpumpforEPAengines........................................................................................................................................ 59InjectionpumpforStandardand97/68CEengines......................................................................................................... 58Injectionpump/mechanicalspeedgovernortiming........................................................................................................... 62Injectionstaticadvanceadjustment.................................................................................................................................. 62Injector.............................................................................................................................................................................. 64Injectorsetting................................................................................................................................................................... 65Pistonfuelliftpump(onrequest)...................................................................................................................................... 58PlungerandBarrelAssembly............................................................................................................................................ 59SizePinjector,for97/68CEandEPAengines................................................................................................................. 65SizePnozzle,for97/68CEandEPAengines.................................................................................................................. 65SizeSInjector,onlyforstandardengines......................................................................................................................... 64SizeSNozzle,onlyforstandardengines......................................................................................................................... 64(Static)injectiontiming...................................................................................................................................................... 62Table“Conversionforestablishingadvance”.................................................................................................................... 63Testdataforinjectionpumpdelivery................................................................................................................................. 60

7 ELECTRIC SYSTEM ________________________________________________________________ 66-75

Alternator......................................................................................................................................................................... 67Alternator-12V,14A..................................................................................................................................................... 68


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- Chapter index

Alternator-12V,18A........................................................................................................................................................ 67Alternator-24V,6A....................................................................................................................................................... 67Alternatorbatterychargercurve-24V,6A...................................................................................................................... 68Alternatorbatterychargercurve-external,12V,33A...................................................................................................... 69Alternatorbatterychargercurve(12V,18A).................................................................................................................... 67Alternatorbatterychargercurvestandard-12V,14A.................................................................................................... 68Alternator,external-12V,33A......................................................................................................................................... 69CharacteristiccurvesforstartingmotortypeBosch-12V,1.7kW.................................................................................. 72Characteristiccurvesofthe24V1.6kWstartingmotor................................................................................................... 73Checkingforcablecontinuity............................................................................................................................................ 69Directstopelectromagnet................................................................................................................................................. 75Directstopelectromagnets............................................................................................................................................... 74Electricstartinglayoutwithinternalalternator................................................................................................................... 66Electricalstartinglayoutwithexternalalternator............................................................................................................... 66Howtocheckvoltageregulatorforproperoperation........................................................................................................ 70Magnetizationcheckingtool.............................................................................................................................................. 68Pre-heatingglowplug....................................................................................................................................................... 74Reverseelectromagnet–FIREversion............................................................................................................................ 74Startingmotor.................................................................................................................................................................... 72StartingmotortypeBoschDW(R)12V,1.7kW............................................................................................................... 73Voltageregulator............................................................................................................................................................... 70Voltageregulator-12V,30A........................................................................................................................................... 71Voltageregulator-12V,26A,with“W”terminal............................................................................................................... 71Voltageregulator-12V,30A,with“W”terminal............................................................................................................... 71

8 SETTINGS _______________________________________________________________________ 76-79

Fullspeedsettinginno-loadconditions(standard)........................................................................................................... 76Idlingspeedsettinginno-loadconditions......................................................................................................................... 76Injectionpumpdeliverysetting.......................................................................................................................................... 76Injectionpumpdeliverysettingwithdynamometricbrake................................................................................................. 77lnjectionpumpdeliverylimitingandextrafueldevice....................................................................................................... 76lnjectionpumpdeliverysettingwithoutdynamometricbrake............................................................................................ 77Requiredsettings(asmostcommonlyapplies)................................................................................................................ 78Settingthestoplimitstop.................................................................................................................................................. 78Speedadjustments........................................................................................................................................................... 76

9 STORAGE ________________________________________________________________________ 80-81

Enginestorage.................................................................................................................................................................. 80Preparingtheengineforoperationafterprotectivetreatment........................................................................................... 81Protectivetreatment.......................................................................................................................................................... 80

10 TORQUE SPECIFICATIONS AND USE OF SEALANT ____________________________________ 82-84

Tableoftighteningtorquesforstandardscrews(coarsethread)...................................................................................... 84Tableoftighteningtorquesforstandardscrews(finethread)........................................................................................... 84Tableoftighteningtorquesforthemaincomponents.................................................................................................. 82-83

11 SPECIAL TOOLS _____________________________________________________________________85

Specialtoolsandequipmentformaintenance.................................................................................................................. 85


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1GENERAL REMARKS AND SAFETY INFORMATION

WARRANTY CERTIFICATE

GLOSSARY AND TERMINOLOGY

Forclarity,herearethedefinitionsofanumberoftermsusedrecurrentlyinthemanual.

- Cylinder number one: isthetimingbeltsidepiston.- Rotation direction: anticlockwise«viewedfromtheflywheelsideoftheengine».

Regulations for lifting the engine-Beforeremovingtheenginefromthevehicleonwhichitisinstalled,disconnectthepowersupply,detachthefuelandcoolantsupply,andallconnectionsincludingthemechanicalones.

-Attachtheenginetoasuitableliftingdevice(liftingbeam).-Tomovetheenginesimultaneouslyusetheeyeboltsinstalled,theseliftingpointsarenotsuitablefortheentiremachine,thenusetheeyeboltsinstalledbythemanufacturer.

-Beforelifting,makesuretheweightiscorrectlybalancedbycheckingitsbarycentre.-Closeallengineopeningsaccurately(exhaust,intake,etc.),thenwashtheoutsideanddrywithajetofcompressedair.


- TheproductsmanufacturedbyLombardiniSrlarewarrantedtobefreefromconformitydefectsforaperiodof24monthsfromthedateofdeliverytothefirstenduser.

- Forenginesfittedtostationaryequipment,workingatconstantloadandatconstantand/orslightlyvariablespeedwithinthesettinglimits,thewarrantycoversaperioduptoalimitof2000workinghours,iftheabovementionedperiod(24months)isnotexpired.

- Ifnohour-meterisfitted,12workinghourspercalendardaywillbeconsidered.- Forwhatconcerns thepartssubject to wearanddeterioration(injection/feedingsystem,electricalsystem,coolingsystem,sealingparts,non-metallicpipes,belts)warrantycoversamaximumlimitof2000workinghours,iftheabovementionedperiod(24months)isnotexpired.

- Forcorrectmaintenanceandreplacementoftheseparts,itisnecessarytofollowtheinstructionsreportedinthedocumentationsuppliedwitheachengine.

- Toensuretheenginewarrantyisvalid,theengineinstallation,consideringtheproducttechnicalfeatures,mustbecarriedoutbyqualifiedpersonnelonly.

- ThelistoftheLombardiniauthorizeddealersisreportedinthe“Service”booklet,suppliedwitheachengine.- Specialapplicationsinvolvingconsiderablemodificationstothecooling/lubricatingsystem(forex.:dryoilsump),filteringsystem,turbo-chargedmodels,willrequirespecialwrittenwarrantyagreements.

- WithintheabovestatedperiodsLombardiniSrldirectlyorthroughitsauthorizednetworkwillrepairand/orreplacefreeofchargeanyownpartorcomponentthat,uponexaminationbyLombardiniorbyanauthorizedLombardiniagent,isfoundtobedefectiveinconformity,workmanshipormaterials.

- Anyotherresponsibility/obligationfordifferentexpenses,damagesanddirect/indirectlossesderivingfromtheengineuseorfromboththetotalorpartialimpossibilityofuse,isexcluded.

- Therepairorreplacementofanycomponentwillnotextendorrenewthewarrantyperiod.

Lombardiniwarrantyobligationshereabovedescribedwillbecancelledif:

- Lombardinienginesarenotcorrectlyinstalledandasaconsequencethecorrectfunctionalparametersarenotrespectedandaltered.

- Lombardinienginesarenotusedaccordingtotheinstructionsreportedinthe“UseandMaintenance”bookletsuppliedwitheachengine.

- AnysealaffixedtotheenginebyLombardinihasbeentamperedwithorremoved.- SparepartsusedarenotoriginalLombardini.- Feedingandinjectionsystemsaredamagedbyunauthorizedorpoorqualityfueltypes.- Electricalsystemfailureisduetocomponents,connectedtothissystem,whicharenotsuppliedorinstalledbyLombardini.- Engineshavebeendisassembled,repairedoralteredbyanypartotherthananauthorizedLombardiniagent.

- Followingexpirationoftheabovestatedwarrantyperiodsandworkinghours,Lombardiniwillhavenofurtherresponsibilityforwarrantyandwillconsideritshereabovementionedobligationsforwarrantycomplete.

- Anywarrantyrequestrelatedtoanon-conformityoftheproductmustbeaddressedtotheLombardiniSrlserviceagents.

GENERAL SERVICE MANUAL NOTES

1- UseonlygenuineLombardinirepairparts. FailuretousegenuineLombardinipartscouldresultinsub-standardperformanceandlowlongevity.

2 - All data presented are in metric format. That is, dimensions are presented in millimeters (mm), torque is presented inNewton-meters (Nm),weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) andpressureispresentedinbarometricunits(bar).

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1 General remarks and safety information

Thismanualcontainssafetyprecautionswhichareexplainedbelow.

WARNINGWarningisusedtoindicatethepresenceofahazardthatcancause severe personal injury, death, or substantial propertydamageifthewarningisignored.

Safety regulation


GENERAL NOTES

. Lombardini engines are built to provide safe andlonglasting performances, but in order to obtain theseresults it is essential that the maintenance requirementsdescribed in the manual are observed along with thefollowingsafetyrecommendations.

.Theenginehasbeenbuilttothespecificationsofamachinemanufacturer, and it is his responsibility to ensure that allnecessaryactionistakentomeettheessentialandlegallyprescribedhealthandsafetyrequirements.Anyuseofthemachine other than that described cannot be consideredas complying with its intended purpose as specified byLombardini,which therefore declines all responsibility foraccidentscausedbysuchoperations.

. The following instructions are intended for the user of themachine in order to reduce or eliminate risks, especiallythoseconcerningtheoperationandstandardmaintenanceoftheengine.

.Theusershouldreadtheseinstructionscarefullyandgettoknow the operations described. By not doing so hemayplaceatriskhisownhealthandsafetyandthatofanyoneelseinthevicinityofthemachine.

. The engine may be used or mounted on a machine onlybypersonnelsuitably trained in itsoperationandawareofthedangers involved.This isparticularly true for standardand, above all, special maintenance work. For specialmaintenance contact personnel trained specifically byLombardini.Thisworkshouldbecarriedoutinaccordancewithexistingliterature.

. Lombardini declines all responsibility for accidents or forfailure to comply with the requirements of law if changesaremade to the engine’s functional parameters or to thefuel flow rate adjustments and speed of rotation, if sealsareremoved,orifpartsnotdescribedintheoperatingandmaintenance manual are removed and reassembled byunauthorizedpersonnel.

WARNING

. In addition to all othermachine specifications, ensure thatthe engine is in a near horizontal position when starting.lf startingmanually, ensure that the necessary operationscanbeperformedwithoutanyriskofstrikingagainstwallsordangerousobjects.Ropestarting(exceptforrecoilropestarting)isnotpermittedeveninemergencies.

.Checkthatthemachineisstablesothatthereisnoriskofitoverturning.

.Gettoknowtheenginespeedadjustmentandmachinestopoperations.

. Do not start the machine in closed or poorly ventilated

environments. The internal combustion process generatescarbon monoxide, an odourless and highly toxic gas, sospendingtoolongatimeinanenvironmentwheretheenginedischarges its exhaust products freely can lead to loss ofconsciousnessandevendeath.

. The engine may not be used in environments containingflammable materials, explosive atmospheres or easilycombustible powders, unless adequate and specificprecautions have been taken and are clearly stated andcertifiedforthemachine.

.Topreventtheriskoffire,keepthemachineatadistanceofatleastonemetrefrombuildingsorothermachines.

.Childrenandanimalsmustbekeptatasufficientdistancefromthemachinetopreventanydangerresultingfromitsoperation.

. Fuel is flammable, so the tank must be filled only when theengine is turned off. Dry carefully any fuel that may havespilled, remove the fuel container and any cloths soakedin fuel or oil, check that any sound-absorbing panels madeof porousmaterial arenot soakedwith fuel or oil, andmakesurethatthegroundonwhichthemachineislocatedhasnotabsorbedfueloroil.

. Before starting, remove any tools that have been used forcarrying out maintenance work to the engine and/or themachine and check that any guards removed have beenreplaced. In cold climates it is possible tomix kerosenewiththediesel fuel tomaketheengineeasier tostart.The liquidsmustbemixedinthetankbypouringinfirstthekeroseneandthen the diesel fuel. ConsultLombardini technical office formixture proportions. Petrolmay not be used because of theriskofitformingflammablevapours.

. During operation the surface of the engine reachestemperatures thatmay be dangerous. Avoid in particular allcontactwiththeexhaustsystem.

.The liquidcoolingcircuit isunderpressure. Donot carryoutany checks before the engine has cooled down, and eventhen open the radiator cap or the expansion tank cautiously.Wear protective clothing and glasses. lf there is an electricfan,donotapproachtheenginewhile it isstillhotasthefanmaycomeonevenwhentheengineisnotrunning.Cleanthecoolingsystemwiththeengineturnedoff.

. While cleaning the oil bath air filter, check that the oil isdisposed of in such a way as not to harm the environment.Any filtering sponges in the oil bath air filter should not besoakedwithoil. Thecyclonepre-filtercupmustnotbefilledwithoil.

.Since theoilmustbeemptiedoutwhile theengine isstillhot(approx. 80°C), particular care should be taken in order toavoidburns.Inanycasemakesurethatoildoesnotcomeintocontactwithyourskinbecauseofthehealthhazardsinvolved.

.Fuelvapoursarehighlytoxic,sofilluponlyintheopenairorinwellventilatedenvironments.

CAUTIONCautionisusedtoindicatethepresenceofahazardthatwillorcancauseminorpersonalinjuryorpropertydamageifthecautionisignored.

IMPORTANT This indicates particularly important technical information thatshouldnotbeignored.

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1General remarks and safety information

California Proposition 65WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

GENERAL SAFETY DURING OPERATING PHASES– Theprocedurescontainedinthismanualhavebeentestedandselectedbythemanufacturer’stechnicalexperts,andhence

aretoberecognisedasauthorisedoperatingmethods.– Anumberofproceduresmustbecarriedoutwiththeaidofequipmentandtoolsthatsimplifyandimprovethetimingof

operations.– Alltoolsmustbeingoodworkingconditionsothatenginecomponentsarenotdamagedandthatoperationsarecarriedout

properlyandsafely. Itisimportanttowearthepersonalsafetydevicesprescribedbyworksafetylawsandalsobythestandardsofthismanual.– Holesmustbelinedupmethodicallyandwiththeaidofsuitableequipment.Donotuseyourfingerstocarryoutthis

operationtoavoidtheriskofamputation.– Somephasesmayrequiretheassistanceofmorethanoneoperator.Ifso,itisimportanttoinformandtrainthemregarding

thetypeofactivitytheywillbeperforminginordertopreventriskstothehealthandsafetyofallpersonsinvolved.– Donotuseflammableliquids(petrol,diesel,etc.)todegreaseorwashcomponents.Usespecialproducts.– Usetheoilsandgreasesrecommendedbythemanufacturer. Donotmixdifferentbrandsorcombineoilswithdifferentcharacteristics.– Discontinueuseoftheengineifanyirregularitiesarise,particularlyinthecaseofunusualvibrations.– Donottamperwithanydevicestoalterthelevelofperformanceguaranteedbythemanufacturer.

SAFETY AND ENVIRONMENTAL IMPACT

Everyorganisationhasadutytoimplementprocedurestoidentify,assessandmonitortheinfluenceofitsownactivities(products,services,etc.)ontheenvironment.Proceduresforidentifyingtheextentoftheimpactontheenvironmentmustconsiderthefollowingfactors:

- Liquidwaste -Atmosphericemissions - Wastemanagement -Useofrawmaterialsandnaturalresources - Soilcontamination -Regulationsanddirectivesregardingenvironmentalimpact

Inordertominimisetheimpactontheenvironment,themanufacturernowprovidesanumberofindicationstobefollowedbyallpersonshandlingtheengine,foranyreason,duringitsexpectedlifetime.

- Allpackagingcomponentsmustbedisposedofinaccordancewiththelawsofthecountryinwhichdisposalistakingplace.- Keepthefuelandenginecontrolsystemsandtheexhaustpipesinefficientworkingordertolimitenvironmentalandnoise

pollution.- Whendiscontinuinguseoftheengine,selectallcomponentsaccordingtotheirchemicalcharacteristicsanddisposeofthem

separately.


.Duringoperationswhich involveaccess tomovingpartsoftheengineand/orremovaloftherotaryguards,disconnectand insulate the positive cable of the battery so as topreventaccidentalshortcircuitsandactivationofthestartermotor.

.Checkthebelttensiononlywhentheengineisturnedoff.

IMPORTANT

.Tostart theengine follow thespecific instructionsprovidedin the engine and/or machine operating manual. Do notuseauxiliarystartingdevicesnotoriginally installedonthemachine(e.g.Startpilotsystemswhichutiliseetheretc.)

.Beforecarryingoutanyworkon theengine, turn itoffandallow it tocooldown. Donotperformanyoperationwhiletheengineisrunning.

. Check that the discharged oil, the oil filter and the oilcontained intheoilfilteraredisposedof insuchawayasnottoharmtheenvironment.

. Close the fuel tank filler cap carefully after each fílling

operation. Do not fill the tank right up to the top, but leavesufficientspacetoallowforanyexpansionofthefuel.

.Donotsmokeorusenakedflameswhilefilling.

.Takecarewhenremovingtheoilfilterasitmaybehot.

.Theoperationsofchecking,fillingupandreplacingthecoolingliquidmustbecarriedoutwiththeengineturnedoffandcold.Takeparticularcareifliquidscontainingnitritesaremixedwithothersnotcontaining thesecompoundsas thismaygiveriseto the formation of nitrosamines which are a health hazard.Thecooling liquid ispolluting,sodisposeof inamannerthatdoesnotdamagetheenvironment.

. In order tomove the engine simultaneously use the eyeboltsfittedforthispurposebyLombardini.Theseliftingpointsarehowever not suitable for the entiremachine, so in this caseusetheeyeboltsfittedbythemanufacturer.

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2

Obstructedfuelline

Fuelfilterclogged

Airorwaterleaksinfuelsystem

Thetankcapventholeisclogged

Nofuel

Faultyfuelfeedingpump

Extrafuelcontrollevelsticking

TROUBLE SHOOTING

FUEL

CIR

CU

IT

POSSIBLE CAUSE

SETT

ING

S R

EPA

IRS

Inad

equa

te p

er-

form

ance

Hig

h n

oise

leve

l

Ove

rhea

ts

THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:1) -Theenginerpmssuddenlyincreaseanddecrease;2) -Asuddenandunusualnoiseisheard;3) -Thecolouroftheexhaustfumessuddenlydarkens;4) -Theoilpressureindicatorlightturnsonwhilerunning.

TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMSThefollowingtablecontainsthepossiblecausesofsomefailureswhichmayoccurduringoperation.Alwaysperformthesesimplechecksbeforeremovingorreplacinganypart.

PROBLEMEn

gine

doe

s no

t sta

rt

Engi

ne s

tart

s bu

t sto

ps

No

acce

lera

tion

Non

-uni

form

sp

eed

Bla

ck s

mok

e

Whi

te s

mok

e

Oil

prea

ssur

e to

o lo

w

Exce

ssiv

e oi

l co

nsum

ptio

n

CO

OLI

NG

C

IRC

UIT

Incorrectgovernorlinkageadjustment

Governorspringbrokenorunhooked

Lowidlespeed

Ringswornorsticking

Worncylinder

Wornmainconrod-rockerarmbearingsBadlysealedintakevalve

Headtighteningnutsloose

Damagedcylinderheadgasket

Excessivevalve-rockerarmclearance

NoclearancebetweenvalvesandrockerarmsValvesstickingordamaged

Defectivetimingsystem

Bentrods

Crankshaftnotturningfreely

Cloggedairfilter

Coolingcircuitclogged

TECHNICAL INFORMATION


- 13 -

2

Dischargedbattery

CableconnectionuncertainorincorrectFaultystartingswitch

FaultystartingmotorELEC

TRIC

SYST

EMM

AIN

TEN

AN

CE

INJE

CTI

ON

LUB

RIC

ATIO

NC

IRC

UIT

POSSIBLE CAUSE

Inad

equa

te

perf

orm

ance

Hig

h n

oise

leve

l

Ove

rhea

ts

PROBLEM

Engi

ne d

oes

not s

tart

Engi

ne s

tart

s bu

t sto

ps

No

acce

lera

tion

No

n-u

nif

orm

sp

eed

Bla

ck s

mok

e

Whi

te s

mok

e

Too

low

oi

l pr

essu

re

Exce

ssiv

e oi

l co

nsum

ptio

n

Excessiveidleoperation

Incompleterun-in

Overloadedengine

Non-conformingengineoil

Damaged,blockedordirtyinjector

Injectionpumpvalvedamaged

Injectornotadjusted

Hardenedpumpcontrolrod

Brokenorloosesupplementarystart-upspringWornordamagedpumpingelement

Incorrecttuningofinjectioncomponents(deliverybalancingadvance)

Extrafuelcontrollevelsticking

Oilleveltoohigh

Oillevellow

Oilpressurevalveblockedordirty

Oilpressureregulatornotadjusted

Wormoilpump

Oilsumpsuctionlineclogged

FaultypressuregaugeorpressureswitchBlockeddrainingpipe

Technical information


- 14 -

2

A

F

D

E

B

C

2 34

76 5

1

24

65

13


MANUFACTURER AND ENGINE IDENTIFICATION

The identificationplateshown in thefigurecanbe founddirectlyontheengine.Itcontainsthefollowinginformation:

A)Manufacturer’sidentityB)EnginetypeC)EngineserialnumberD) MaximumoperatingspeedE) Numberofthecustomerversion(formK)F)Approvaldata

Approval data

TheapprovalreferencedirectivesECareontheengineidentificationplate.

ThedataplateforEPAStandardsisappliedontheairintakecowling.Itcontainsthefollowinginformation:

1)Currentyear2)Enginedisplacement3)Ratedpower,measuredinkW4)EPAfamilyID5) Injectiontiming6) Injectionopeningpreassure7)Valveclearance


- 15 -

2

1 2 3

4

5

6

7

8 9 10

11

12


MAIN COMPONENTS

Components:

1)Fueltank2)Injectors3)Aircleaner4)Startingmotor5)Oilfilter6)Rockerarmcover

7)Oildipstick8)Throttleandstopcontrols9)Oildrainplug10)Fuelfeedingpump11)Flywheel12)Injectionpump


- 16 -

180°

n°mmcm3

Kg

kW/CV

Nm/KgmKg

n°

g/kWh-g/CV1hKg/h

253-1860.013

11035°25°160026300

11035°25°160026300

11035°25°160026300

3000-

18.8/25.516.9/2367/6.8300

300020.7/2818.8/25.516.9/2373./7.4300

3000-

18.8/25.516.9/2368/6.9300

258-1900.013

258-1900.013

95x88124820.0:1

95x88124817.5:1

95x88124821.0:1

2

625-2 625/626-2 NR CE

625-2EPA

*2200rpmx9LD625-2;2000rpmx9LD625/626-2NR/CEand1700rpmx9LD625-2EPA

MomentaryUpto1hour

l/minl/min

2percylinder

SidecamshaftinthecrankcaseMechanicDirect

RodsandrockerarmsDrivingshaftdegrees

OilbathaircleanerwithcyclonicprefilterordryaircleanerAir(fanintegraltotheflywheel)

Counter-clockwise(fromflywheelside)

2inline

Four-strokediesel

POWER AND TORQUE

CONSUMPTION AT MAXIMUM POWER

GENERAL DETAILSOperatingcycleCylindersBorexstrokeDisplacementsCompressionrateIntakeCoolingCrankshaftrotationCombustionsequenceTiming system

ValvesShaftTappets

FuelinjectionDryweightofengineMaximumtiltwhileoperatingMaximumtiltwhileoperatingCombustionairvolumeat3000r.p.m.Coolingairvolumeat3000r.p.m.

Maximumoperatingspeed N(80/1269/CEE)ISO1585Maximumpower NBISO3046IFN NAISO3046ICXNMaximumtorque*Axialloadallowedoncrankshaft

SpecificfuelonsumptionOilconsumption

r.p.m.

TECHINICAL SPECIFICATIONS



9 LD engine type

- 17 -

cm2

µm

cm2

µmbar

bar

barbarµmbarcm2

VVVAAAkWkW

3.12.80.6

0.3

132015

1.5÷1.7745

3.12.80.6

0.3

132015

1.5÷1.7745

3.12.80.6

0.3

132015

1.5÷1.7745

122412146331.71.6

122412146331.71.6

122412146331.71.6

4607

PF90450002÷34

4607

PF90450002÷34

4607

PF90450002÷34

2

625-2 625/626-2 NR CE

625-2EPA

FUEL SUPPLY CIRCUITFueltypeFuelsupplyFuel filter, internal Filtering surface Filter capacityFuel filter, external Filtering cartridge Filtering surface Filter capacity Maximum operating pressure

Alternator,InternalStandard(nominalvoltage)Alternator,InternalOptional(nominalvoltage)Alternator,ExternalOptional(nominalvoltage)Alternator,InternalStandard(nominalcurrent)*Alternator,InternalOptional(nominalcurrent)*Alternator,ExternalOptional(nominalcurrent)*Startermotorpower(BoshGF)Startermotorpower(BoshDW(R))

TypeoflubricationCircuitsupplyMaximumoilquantityMaximumoilquantityOilpressureatmin.speed(oiltemperature:120°C)Oil pressure switchOperating pressure (min. value)Oil filter cartridge, external Maximum operating pressure

Maximum combustion pressure Filter capacity By-pass valve setting Filtering surface

includingfilter(l)excludingfilter(l)

bar

CompletelyforcedGearpump

LUBRICATION CIRCUIT

ELECTRICAL SYSTEM

Automotivedieselfuel(minimumcetane:51)Mechanicalfuelliftpump(diaphragmorpistons)

*(see“Alternatorbatterychargercurve”page66÷69)

Unipolarsystem



9 LD engine type

- 18 -

2

9 LD 625-2 EPA @ 3000 r.p.m. 9 LD 625 NR @ 2800 r.p.m.

9 LD 625 @ 3000 r.p.m. 9 LD 626-2 @ 3000 r.p.m.


PERFORMANCE DIAGRAM


- 19 -

2

9 LD 626-2 B2 NR @ 2800 r.p.m. 9 LD 626 NR @ 3000 r.p.m.



N (80/1269/CEE - ISO 1585):Automotiverating,intermittentoperationwithvariablespeedandvariableload.NB (ISO 3046/1 - IFN):Ratingwithnooverloadcapability, continuous lightdutyoperationwith constant speedandvariableload.NA (ISO 3046/1 - ICXN): Continuousratingwithoverloadcapability,continuousheavydutywithconstantspeedandconstantload.

C (NB) :SpecificfuelconsumptionatNBpowerMn :TorqueatN.

Theabovepowervaluesrefertoanenginefittedwithaircleanerandstandardmuffler,aftertestingandattheenvironmentalconditionsof20°Cand1bar.Max.powertoleranceis5%.Powerdecreasesbyapproximately1%every100mdialtitudeandby2%every5°Cabove25°C.

Note: ConsultLOMBARDINIforpower,torquecurvesandspecificconsumptionsatratesdifferingfromthosegivenabove.

Important

Non-approval by Lombardini for any modifications releases the company from any damages incurred by the engine.

- 20 -

2

A

B

C

D

198

425

E

F

434

397

I

L

340

168

G

H

O

P

421

178

207

542

599

633

557

217

DIMENSIONI mm - MESURES mm - DIMENSION mm - EINBAUMAßE mm - DIMENSIONE mm - DIMEN0ÇÕES (mm)

M

N

9 LD 561-29 LD561-2/L9 LD 625-2

9 LD 626-29 LD 626-2 NR

OVERALL DIMENSION



- 21 -

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

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

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

2Technical information


- 22 -

10 125 250 500 1000 2500 5000

(***)

(***)

(**)

(***)

(*)

(*)

(*)

(**)

(**)

(***)

(***)

3

ENGINEOILLEVEL

OILBATHAIRCLEANER

DRYAIRCLEANER

FUELPIPES

EXTERNALALTERNATORBELTTENSION

COOLINGSYSTEMCLEANING

VALVE-ROCKERARMSCLEARANCEADJUSTMENT

SETTINGANDINJECTORSCLEANING

RUBBER INTAKEHOSE (DRYAIRCLEANER- INTAKEMANIFOLD)

FUELTANKCLEANING

ALTERNATORANDSTARTINGMOTOR

ENGINEOIL

EXTERNALOILFILTER

FUELFILTER

EXTERNALALTERNATORBELT

RUBBER INTAKEHOSE (DRYAIRCLEANER- INTAKEMANIFOLD)

FUELPIPES

DRYAIRCLEANEREXTERNALCARTRIDGE

DRYAIRINTERNALEXTERNALCARTRIDGE

PARTIAL

TOTAL

Engine oil replacement. Oil filter replacement.

EXTRAORDINARY MAINTENANCE

AFTER THE FIRST50 WORKING HOURS

ORDINARY MAINTENANCE

OPERATION DESCRIPTION FREQUENCY x HOURS

OVERHAUL

REPLACEMENT

CHECK

AFTER 6 CHECKS WITH CLEANING

(*) - In case of low use: every year.(**) - In case of low use: every 2 years.(***) - The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates.

The air filter must be cleaned and replaced more frequently In very dusty conditions.

AFTER 3 CHECKS WITH CLEANING

ImportantFailure to carry out the operations described in the table may lead to technical damage to the machine and/or system

ROUTINE ENGINE MAINTENANCE

MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING


- 23 -

API CH-4 CG-4 CF-4 CF-2 CF CE CD CC

MIL L- 46152 D / E

- 40

- 35

- 30

- 25

- 20

- 15

- 10

- 5 0 +

5+ 10

+ 15

+ 20

+25

+30

+ 35

+ 40

+ 45

+ 50

SAE 10W-30**SAE 10W-40**

SAE 10W-60**SAE 15W-40 **

SAE 15W-40 **SAE 20W-60 **

SAE 5W-30 ***SAE 5W-40 ***

SAE 0W-30 ***

3Maintenance - Recommended oil type - Refilling

International specifications

Theydefinetestingperformancesandproceduresthatthelubricantsneedtosuccessfullyrespondtoinseveralenginetestingandlaboratoryanalysissoastobeconsideredqualifiedandinconformitytotheregulationssetforeachlubricationkind.

A.P.I :(AmericanPetroleumInstitute)MIL :EngineoilU.S.militaryspecificationsreleasedforlogisticreasonsACEA :EuropeanAutomobileManufacturersAssociation

Tablesshownonthispageareofusefulreferencewhenbuyingakindofoil.Codesareusuallyprinted-outontheoilcontainerandtheunderstandingoftheirmeaningisusefulforcomparingdifferentbrandsandchoosingthekindwiththerightcharacteristics.Usuallyaspecificationshowingafollowingletterornumberispreferabletoonewithaprecedingletterornumber.AnSFoil,forinstance,ismoreperformingthanaSEoilbutlessperformingthanaSGone.

LUBRICANT

SAE Classification

IntheSAEclassification,oilsdifferonthebasisoftheirviscosity,andnootherqualitativecharacteristicistakenintoaccount.Thefirstnumberreferstotheviscositywhentheengineiscold(symbolW=winter),whilethesecondconsidersviscositywiththeengineatrégime.Thecriteriaforchoosingmustconsider,duringwinter,thelowestoutsidetemperaturetowhichtheenginewillbesubjectandthehighestfunctioningtemperatureduringsummer.Single-degreeoilsarenormallyusedwhentherunningtemperaturevariesscarcely.Multi-degreeoilislesssensitivetotemperaturechanges. * Mineral base

** Semi-synthetic base*** Synthetic base

SAE- Grade

API / MIL SEQUENCES

ACEA REGULATIONS - SEQUENCES

LIGHT DUTY DIESEL ENGINESB1 = Low-viscosity,forfrictionsreductionB2 = StandardB3 = Highperformances(indirectinjection)B4 = Highquality(directinjection)

HEAVY DUTY DIESEL ENGINESE2 = StandardE3 = Heavyconditions(Euro1-Euro2engines)E4 = Heavyconditions(Euro1-Euro2-Euro3engines)E5 = Highperformancesinheavyconditions(Euro1-Euro

2-Euro3engines)


- 24 -

3.1

2.8

AGIP SUPERDIESELMULTIGRADE

10W40

API CF4 / SGACEA B2 - E2

MIL - L-4165 D/E

3

Litres

Litres

specifications

InthecountrieswhereAGIPproductsarenotavailable,useoilAPISJ/CFforDieselenginesoroilcorrespondingtothemilitaryspecificationMIL-L-4165D/E.Foratemperatureof-10°Canoilwitha5W40 viscosityisrecommended.Foratemperatureof-15°Canoilwitha0W30 viscosityisrecommended.

OIL VOLUME AT MAX LEVEL (OIL FILTER INCLUDED)

OIL VOLUME AT MAX LEVEL (WITHOUT OIL FILTER)

Danger - Attention- The engine may be damaged if operated with insufficient lube oil.- It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused

by its combustion.- Use proper lube oil preserve your engine. Good quality or poor quality of the lubricating oil has an affect on engine performance and life.- If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking, and

accelerated wear of the cylinder liner, bearing and other moving components increases significantly. - Always use oil with the right viscosity for the ambient temperature in which your engine is being operated.

Danger - Attention- The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.- Do not disperse the oil in the ambient, as it has a high pollution power.

PRESCRIBED LUBRICANT

Maintenance - Recommended oil type - Refilling


9 LD ENGINES OIL CAPACITY

- 25 -

10

3

Capacities standard fuel tank Litres

Maintenance - Recommended oil type - Refilling

API CF4 - CG4

API CF

Purchasedieselfuelinsmallquantitiesandstoreinclean,approvedcontainers.Cleanfuelpreventsthedieselfuelinjectorsandpumpsfromclogging.Donotoverfillthefueltank.Leaveroomforthefueltoexpand.Immediatelycleanupanyspillageduringrefueling.

Neverstoredieselfuelingalvanizedcontainers;dieselfuelandthegalvanizedcoatingreactchemicallytoeachother,producingflakingthatquicklyclogsfiltersorcausesfuelpumporinjectorfailure.

Highsulfurcontentinfuelmaycauseenginewear.Inthosecountrieswheredieselhasahighsufurcontent,itsisadvisabletolubricatetheenginewithahighalkalineoiloralternativelytoreplacethelubricatingoilrecommendedbythemanufacturermorefrequently.TheregionsinwhichdieselnormallyhasalowsulfurcontentareEurope,NorthAmerica,andAustralia.

FUEL TYPEForbestresults,useonlyclean,fresh,commercial-gradedieselfuel.Dieselfuelsthatsatisfythefollowingspecificationsaresuitableforuseinthisengine:ASTMD-975-1Dor2D,EN590,orequivalent.

FUELS FOR LOW TEMPERATURES

Itispossibletoruntheengineattemperaturesbelow0°Cusingspecialwinterfuels.Thesefuelsreducetheformationofparaffinindieselatlowtemperatures.Ifparaffinformsinthediesel,thefuelfilterbecomesblockedinterruptingtheflowoffuel.

Fuelcanbe: -Summer upto 0°C -Winter upto -10°C -Alpine upto -20°C -Arctic upto -30°C

BIODIESEL FUELFuels containing less than 20%methyl ester orB20, are suitable for use inthisengine.BiodieselfuelsmeetingthespecificationofBQ-9000,EN14214orequivalentare recommended. DONOTusevegetableoilasabiofuel for thisengine.Anyfailuresresultingfromtheuseoffuelsotherthanrecommendedwillnotbewarranted.

AVIATION FUELAviationfuelssuitableforuseinthisengineincludeJP5,JP4,JP8and,JET-A(if5percentoilisadded).

FUEL RECOMMENDATIONS

EMISSION CONTROL INFORMATION

LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY

EPA /CARB emission label must be attached near the fuel inlet.

Fuelwithlowsulphurcontent

Fuelwithhighsulphurcontent

PRESCRIBED LUBRICANT


Asforfilters,tanksandspecialcrankcasespleaserefertoLOMBARDINIinstructions.

- 26 -

1

4 DISASSEMBLY / REASSEMBLY

RECOMMENDATIONS FOR OVERHAULS AND TUNING

ImportantTo locate specific topics, the reader should refer to the index.

– Before any intervention, the operator should lay out allequipmentandtoolsinsuchawayastoenablehimtocarryoutoperationscorrectlyandsafely.

– The operatormust comply with the specificmeasuresdescribedinordertoavoiderrorsthatmightcausedamagetotheengine.

– Before carrying out any operation, clean the assembliesand/orcomponentsthoroughlyandeliminateanydepositsorresidualmaterial.

– Washthecomponentswithspecialdetergentanddonotusesteamorhotwater.

– Do not use flammable products (petrol, diesel, etc.) todegreaseorwashcomponents.Usespecialproducts.

– Dryallwashedsurfacesandcomponentsthoroughlywithajetofairorspecialclothsbeforereassemblingthem.

– Applyalayeroflubricantoverallsurfacestoprotectthemagainstoxidation.

– Checkallcomponentsforintactness,wearandtear,seizure,cracksand/or faults tobesure that theengine is ingoodworkingcondition.

– Somemechanicalpartsmustbereplaceden bloc,togetherwith their coupled parts (e.g. valve guide/valve etc.) asspecifiedinthesparepartscatalogue.

AIR CLEANER

Oil-bath air cleaner

Checkgasketsandreplaceifnecessary.Checkthatflangeweldisfreeofporosityordefectivespots.Carefully cleanbowl and filteringelement withDiesel oil andblowthroughwithcompressedair.Topupwithengineoiltothemark.

Whenrefittingtightennutsat25Nm.

Seepage22forperiodicmaintenancedetails.

RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING


ImportantTo locate specific topics, the reader should refer to the index.

– Besidesdisassemblyandreassemblyoperationsthischapteralso includes checkingand setting specifications, dimen-sions,repairandoperatinginstructions.

– Alwaysuseoriginal LOMBARDINI spareparts for properrepairoperations.

– Theoperatormustwash,cleananddrycomponentsandassembliesbeforeinstallingthem.

– Theoperatormustmakesurethatthecontactsurfacesareintact,lubricatethecouplingpartsandprotectthosethatarepronetooxidation.

– Beforeanyintervention,theoperatorshouldlayoutallequi-pmentandtoolsinsuchawayastoenablehimtocarryoutoperationscorrectlyandsafely.

– Forsafetyandconvenience,youareadvisedtoplacetheengineonaspecialrotatingstandforengineoverhauls.

– Beforeproceedingwithoperations,makesurethatappro-priatesafetyconditionsareinplace,inordertosafeguardtheoperatorandanypersonsinvolved.

– Inordertofixassembliesand/orcomponentssecurely,theoperatormusttightenthefasteningpartsinacriss-crossoralternatingpattern.

– Assemblies and/or componentswith a specific tighteningtorquemust initiallybe fastenedata level lower than theassignedvalue,andthensubsequentlytightenedtothefinaltorque.

- 27 -

2

3

4

4Disassembly / Reassembly

Components:

1Bowl2Oillevelmark3Filteringelement4Sealring5Internalsealring6Cover7Clamp8Prefilter

Dry air cleaner, Donaldson type

Danger - AttentionNever clean the filter element using highly flammable solvents.It could cause an explosion!

Inordertoknowhowoftenyoushouldcheckandreplacetheairfiltercartridgeandtherubberhose(airfilter–intakemanifold)seepage22.

1Maincartridge2Safetycartridge3 Axialcover4Scavengingvalve5Capcompletewithclamp

Scavengingvalve4mustbepositionedasinfigure4.

Danger - AttentionDuring repair operations, when using compressed air, wear eye protection.

Thecartridgecanbecleanedbyblowingcompressedairbreadthwaysoutside and inside the cartridge, at a pressure not greater than 5atmospheres,orinnecessitycasebyknockingthefrontofthecartridgeseveraltimesagainstaflatsurface.Usealamptocheckthatthefilterelementisnotdamagedorinspectitagainstthelightwhileslanted.Incaseofdoubt,installanewcartridge.

Dry air cleaner

Components:1Handwheel2Cover3Cartridge4Sealring5 Bracket6Cloggingindicator

ImportantReplace cartridge immediately when indicator shows that is clogged.


- 28 -

5

6

8

9

7

4Clogging indicator

Components:1Resetbutton2Transparentindicator

Note: Indicatoriscalibratedat600÷650mmcolumnofwater.

Disassembly / Reassembly

Exhaust manifold

Checkthattheinsideisclean.Toavoidflangebreakagecheckthatheadsareinlinebeforetighteningnuts.Replacegaskets.

Tightennutsat20Nm.

MANIFOLDS, INTAKE/EXHAUST

Intake manifold

Toavoidflangebreakagecheckthatheadsareinlinebeforetighteningnuts.Checkflangesurfaceforwarpageandcorrectifnecessary.Replacegaskets.

Tightennutsat25Nm.

Note: Incaseof lowtemperaturestartingwecansupplyamanifoldwithpossibilityoffittingaglowplugwithairpreheating.

Oil vapour separator

Fittedonengineswithdryaircleaner.Screwitoutoftheairconveyorsupport,carefullywashwithgasolineinsideandblowoutwithcompressedair.Whenrefittingreplacethecoppergasketandconnecttheoilvapourseparatorwithintakemanifoldbymeansofthespecialrubberhose.


- 29 -

10

11

12

13


EXTERNAL ALTERNATOR CONTROL BELT(only for engines with external alternator)

External alternator blower control belt - Disassembly

Releasethetwoalternatorfasteningbolts.Unscrewthefasteningnutsofthebeltguardandremoveit.RemovetheVbelt.

Seepage22forperiodicmaintenancedetails.

External alternator blower control belt – Tension check

ImportantCarry out checks only after isolating the positive battery cable to prevent accidental short-circuiting and, consequently, the activation of the starter motor.

Tension the belt if it flexesmore than 1 cm exerting a pressure of10kg.

External alternator blower control belt - Reassembly

Installthebeltandthebeltguard.Force the alternator outwards and temporarily tighten the fasteningbolts.Makesurethatthebelttensioniswithintherequiredparameters(see“Externalalternatorblowercontrolbelt–Tensioncheck”,Fig.11).

Tightenthefasteningboltstoafinaltorqueof30Nm(8x1.25)and50Nm(10x1.50).

FUEL TANK

After disconnecting the fuel pipes unscrew the anchoring brackets'screwsandremovethefueltank.Completelyemptythetankandcheckthatnoimpuritiesarefoundinside.If thefuel tankisfittedwthaninternal fuelfilterremoveandreplacethecartridge.Checkthatcapbreatherholeisnotclogged.Removethetanksupport.

Whenrefittingtightenthesupportscrewsat40Nmandthebracketscrewsat8Nm.

Seepage57forrefittinginternalfuelfilter.


- 30 -

15

16

17

14

4

Hub

Components:1Hub2Alternatorrotor3Fan4Bolt

Thehubholdsthealternatorrotorandthecoolingfan.

Unscrewtheboltclockwiseandtightenat160Nmwhenrefitting.


Internal alternator

Removestatorandplaceitinsidetherotortopreventmetalparticlesfrombeingattractedbythemagnets.

Whenrefittingtightenrotorscrewsandstatorboltsat10Nm.

Seepage67÷69foralternatorcharacteristics.

Cooling fan

Carefullycleanandcheckallbladesandinserts.Replacethefanevenifthereisonlyasingledamagedbladeoronlyasinglereleasedinsert.

Seepage16forcoolingairflow.

Tightenthefan'sfixingscrewsatatorqueof10Nm.

Pulley guard - Shroud - Side plates

Components:1Pulleyguard2Shroud3Sideplates

Thepulleyguardismadeofsounddeadeningmaterial:itreducesthenoisethatboththepulleyandthefantendtoamplify.ShroudandsideplatesaremadeofANTIFON,anelasticIayerwhichabsorbsthenoisecausedbytheplatevibrations.


- 31 -

19

21 22

20

18

4

FLYWHEEL

Removeflywheelwithpuller1 (partN°.7271-1460-119).Checkstarterringgearandtaperedcrankshaftmatingsurfaces.

Whenrefittingtightenboltal300Nm.

Inorder to replace the ringgear, it isnecessary todisassemble theflywheel.

Cuttheringgearinseveralplacesusingachiselandremoveit.

ImportantRemove any debris and carefully clean the ring gear.

Heatthenewringgearuniformlyandkeepitatatemperatureof300°Cfor15÷20minuti.

Danger – AttentionRisk of burning: be careful of hot surfaces.

Inserttheringgearintoitsseatandplaceitcarefullyontherimoftheflywheel.Leavetotheringgeartocoolgentlybeforereassemblingtheflywheel.


Shroud support (Gear cover plate)

Loosen screws and remove shroud support very carefully to avoiddamagetotheoilsealring.WhenrefittingcheckthatgasketsAandoilsealringBarewellinsidetheirhousings.

Tightenscrewsat25Nm.

ROCKER ARMS

Valve / Rocker arm clearance

ImportantSetting should be performed when the engine is cold.

Removerockerarmcoverandcheckgasketsforbreakage.

Bring each cylinder piston to top dead center on the compressionstrokeandsetclearanceAal0.15÷0.20mmforintakeand0.30÷0.35mmforexhaust.

Whenrefittingtightencoverscrewsby20Nm.


- 32 -

24

26

25

23

4

INJECTOR

Cleaninjectorandcheckcalibratedpressureasindicatedonpage65.Whenrefittingcheckthatitcorrectlyprotrudesfromthecylinderheadplane.

Tightenthefixingnutsat10Nm.

Tightenthehigh-pressurepipeunionat25Nm.


Rocker arm assembly

Components:1Bore2Lubricationtube

Dimensions (mm):A=18.032÷18.050B=17.989÷18.000

Ifclearance(A - B)exceeds0.135mmreplaceshaftandrockerarms.

Caution – WarningWhen retitting check that lubrication tube perfectly matches with the journal bore.

Onslowengines,whicharesetto1,500–1,800rpm,therockerarmsdiffer from the standard version in the upper part of the lubricationchannel.

Tightentherockerarmshaftfasteningscrewstotheheadatatorqueof25Nm.

Compression release (optional)

Bringpistontotopdeadcenteronthecompressionstroke.UnscrewrockerarmcoversideplugandmeasureclearanceA betweenleverandrockerarm,whichmustbe0.30÷0.40mm.Forsettingpurposesremovetherockerarmcover,unscrewthelocknutCandsetclearanceAbychangingtheheightoftheshimsundertheplateB.Setthevalve/rockerarmclearance,see"Valve/Rockerarmclearance"onpage31.Reassembletherockerarmcoverandcheckthedecompressionleverclearanceagain.


- 33 -

28

29

27


CYLINDER HEAD

ImportantDo not remove it when hot to avoid deformation.The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up.

lfcylinderheadisdeformedlevelitoffbyremovingamaximumof0.3mm.Whenrefitting tightenonly ifsure that rockerarm lubrication tube iswellinsideitsholes,andthattherubbersealsofthetappethoseareassembledandinsertedcorrectlyintotheirseats.Alwaysreplacecopperheadgasket:seepage39forchoosingtherightthickness.

Progressivelytightennutsinthe1,2,3,4sequenceat55Nm.

Injector projection

Theendofnozzle Ashouldproject3.0÷3.5mm.fromthecylinderheadplane.AdjustinjectorprojectionbymeansofcoppershimsBmeasuring0.5,1.00and1.50mminthickness.

Injector for EPA and 97/68 CE engines

Theinjectorisattachedtothecylinderheadviaaforkedbracket.

Tightenthefixingbracketscrewat10Nm.

Fixthehigh-pressurehoseuniontotheinjectorunionat25Nm.


- 34 -

30 31

32 33

34

35 36

4 Disassembly / Reassembly

Valves

Components:1 Intakevalve2Springseat3Valvestemsealring4Spring5Retainer6Halfcollets

Toremovehalfcolletsfirmlypressdownasshowninthefigure.

Valve stem sealing rings - Reassembly

Lubricate the inside of the sealing ringwithMolikoteBR2Plus andinsertthemallthewayontotheguidesusingtool1460-108.Topreventdeformationofthesealingring1asitisinsertedontothevalveguide2insertitontotool3.Lubricatevalvestemwiththesametypeofgrease;insertthevalvesinto the guides rotating them particularly as they enter the sealingring.

Valve springs

Measurefreelengthwithagauge.Usingadynamometercheckthatthespringlengthundertwodìfferentloadscorrespondstothevaluesbelow:

Freelength A=52mmLength Bcompressedbya210.6N=35.8mmLengthCcompressedbya340.6N=25.8mm

Replacespringiflengthis1mmormorebelowthestatedvalues.

Valve material

Intake valves AMaterial:X45CrSi9-3UNIEn100901Chromium-platedportiona45.5°÷45.75°

Exhaust valve BShaftandheadaremadeof2differentmaterials.2Weldedportion3Chromium-platedportion4PortionmadeofX45CrSi9-3UNIEN100905PortionmadeofX55CrMnNiN20-8UNIEN10090a45.5°÷45.75°


- 35 -

A 02,13÷08,03

B 02,52÷08,42

A *040,8÷520,8550,0÷520,0 51,0

B 000,8÷589,7

38

39

37

A 0.24

B 84

C 810.41÷000.41

D 650.41÷540.41

4Valve guides and valve guide housings

StartingfromengineNo.2883619intakeandexhaustvalveguidesarebothmadeofphosphoriccastiron.

Components:1 = Exhaustvalveguide2 = Intakevalveguide

Valve guideswithoutsidediameterincreasedby0.5mm.arealsoavailable;insuchcasesvalveguidebore Cshouidalsobeincreasedby0.5mm.

Valve guide insertion

Heatcylinderheadupto160÷180°CPressguidesconsideringtheAandBdistancesfromtheheadplane.

Dimensions and clearance between guides and valves

*withdrivenguide.


Ref. Dimensions (mm)

Clearance(mm)

Limit value(mm)

Dimensions(mm)Ref.



- 36 -

A 610.04÷000.04

B 590.04÷180.04

C 610.43÷000.43

D 590.43÷180.43

40

41

43

42

44

125° ÷ 135°


Valve seats and housings

Pressvalveseatsintothehousingsandcutat45°.INTAKE vALvE

ExHAuSTvALvE


Pushrod tube

WhenrefittingcheekthatgasketsAandrockerarmlubricatíontubeCarewellinsidetheirseats.

Valve seat grinding

Aftercuttinggrindvalveseatswithfineemerypasteinoilsuspension.ThesealingsurfaceSshouldnotexceed2mm.Valve recessaftergrindingD=0.75÷1.25mm;maximumworn limit1.65mm.

CYLINDER

Checks and cylinder roughness

Finsmustbeintact.Cross hatch patternmust rangebetween125°÷135°: theymust beuniformandclearinbothdirections.Averageroughnessshouldrangebetween0.35and0.60µm.


- 37 -

47 48

45 46

A *39.49÷29.4 *10.59÷00.59

90.0÷70.0B *49.49÷39.4 *20.59÷10.59

C *59.49÷49.4 *30.59÷20.599

9

9

*


Measurediametersizebetween twodiametricallyopposedpointsatthreedifferentheights.

As per the cylinder sizes, see Table “Piston and cylinder typesandsizes".

* Incaseofdiameterwearabove0.05mmreplacepistonandpistonrings.

** Incasewearexceeds0.10mm,borethecylinderandfitoversizepistonandrings. Incaseoflesswearreplacepistonringsonly.

Note: Oversizepistonsof0.5and1.0mmareavailable(onlyforstandardand97/68CEengines).

ImportantThe cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up.The cylinder and piston must be replaced with a new cylinder and piston of the same class.

PISTON

Removecirclipsandremovepistonpin.Removepistonringsandcleangrooves.Measurediameterat17mmfromthebottomofskirt.

Table “Piston and cylinder types and sizes"

Clearance (mm)Ø Cylinder (mm)Ø Piston (mm)Class


- 38 -

A

°1 mm56.0÷mm04.0

°2 mm56.0÷mm04.0

°3 mm06.0÷mm03.050

51

53

52

49

A 0,07÷0,11 0,20B 0,05÷0,09 0,16C 0,04÷0,08 0,15


Chromium-platedring

Torsionalinternaltaperedring

Oilcontrolring

Limit value(mm)

Dimensions(mm)Ref.

Piston rings - Fitting sequence

A=1°Chromium-platedringB=2°Torsional(internaltapered)ringC=3°Oilcontrolring

ImportantBefore fitting the piston into the cylinder stagger the ring gaps at 120°.

Pistons rings - Clearance between grooves (mm)

Piston rings - End gaps (mm)

Placepistonringssquarelyintotheunwornpartofthelowercylinderandmeasuretheendgap.

Piston weight

Weighpistonswhenreplacingtheminordertoavoidunbalance.

ImportantThe difference in weight should not exceed 6 g.


- 39 -

56

58

57

59

54 55

4

Distance between the piston at the top dead centre and the cylinder surface

Head seal thickness


CONNECTING ROD

Removetheoilsump.Removetheconnectingrodcap.

ImportantBoth connecting rod/piston units should be fitted back into the corresponding cylinders; mark them so as to identify the correct combination during reassembly.

Seepage40forspecificationsastothetighteningoftheconnectingrodbigendbearing.

Piston clearance

Pistonclearance =0.65÷0.70mm,forstandardengines =0.55÷0.60mm,for97/68CEandEPAengines

Thepiston in theTDC (topdeadcentre)positionmayextendorbeshortoftheuppersurfaceofthecylinder.Use a dial indicator to measure the difference between the twosurfaces (piston crown and upper cylinder surface) and use asuitablethicknesscoppergasketBforthecylinderheadtoadjusttheclearancevolumeA.

(Seeimagebelow)

Piston - Refitting

Connectpistontoconnectingrodinawaythatthecombustionchambercentrebisatrightangleundernozzletipa.Lubricatepistonpinandintroduceitintothepistonbyexertingpressurewithyourthumb.Checkthatbothcirclipsarewellinsidetheirseats.


- 40 -

61

62

63 64

60


Connecting rod big end bearing

BothcenteringnotchesofthebearingsAandBmustbeonthesamesidewhenrefitting.

Tightenboltsat40Nm.

Seepage44fordimensions.

Connecting rod weight

Weighconnectingrodswhenreplacingtheminordertoavoidunbalance.

ImportantThe difference in weight should not exceed 10 g.

Connecting rod alignment

Checkalignmentofsmallendandbigendbearingboresusingfittedmandrels;axialmis-alignmentA=0.02mm;maximumlimit=0.05mm.

Connecting rod small end bushing

Dimensions and clearance (mm):C=25.020÷25.030(withmachinedbushinginplace)D=24.995÷25.000(C-D)=0.020÷0.035(C-D)maximumwornlimit=0.070


- 41 -

66

67

65

1

2


Main bearing support, flywheeI side

RemoveitbymeansoftwoM8x1.25screwswithfullythreadedlengthof40mm.Checkoilsealringandreplaceifwarped,hardenedorworn-out.

Whenrefitting,tightennutsat30Nm.

Seeendfloatonpage45forgasketreplacementdetaiis.

Seepage44÷45fordimensions.

MAIN BEARING SUPPORTS

Main bearing support, gear side

Removemain bearing bymeans of twoM8x1.25 screwswith fullythreadedlengthof40mmorapuller(PartN°.7271-1460-119).

Note: To avoid deformation it is not recomended to replace thebearingbushing,completeassembly'sofbushingandsupportare available in standard, 0.25mmand 0.50mmundersizeconfigurationsasspareparts.

Whenrefittingtightenthescrewsat30Nm.


CRANKSHAFT TIMING GEAR

Disassembly:Usetool1(PartN°.7560-4000-052)andpuller2(PartN°.7271-1460-119)toremovethegear.

Reassembly:Heatthegearuniformlyandkeepitatatemperatureof300°Cfor15–20minutes.

Caution – WarningDanger of burning: pay attention to the hot surfaces.

Insert the gear into its seat by inserting the activation key into thegear opening and push until it comes into contact with the drivingshaft.Letitslowlycooldown.


- 42 -

70

71 72

69

68


Crankshaft center main bearing support

Whenrefitting,bothcenteringnotchesAandBmustbelocatedonthesameside.



Crankshaft lubrication ducts

Danger - AttentionDuring repair operations, when using compressed air, wear eye protection.

Removeplugs,cleanductAwithapointedtoolandblowincompressedair.Screwplugsagainandcheckforsealing.

Crankshaft removal

Topullout thecrankshaft tap lightfyon the timingsideendusingacopper-headedhammer.Whenrefittingaligncentermainbearingsupportsothatthelocatingscrewholecoincideswiththecrankcasehole.

CRANKSHAFT

Center main bearing support, locating screw.

Straightenplate1andunscrewscrew2beforeremovingcrankshaft.

Whenassemblingtightenthescrewatatorqueof30Nm.


- 43 -

A 059.45÷139.45

B 615.54÷005.54

C 053.55÷133.55

D 059.45÷139.45

75

76

73

74

4

How to measure main bearing inside diameter

Useaninsidemicrometergauge.


Dimensions (mm)Ref.

Main journal and crank pin diameter

Checking main journals and crank pins

Useanoutsidemicrometergauge.

Crankshaft journal radius

TheradiusRconnectingjournalstoshouldersis2.8÷3.2mm.

ImportantWhen grinding external main journals restore the R value to original specification.


- 44 -

A-E 980.0÷0500

0

0. 81.0

B-F 870.0÷230. 51.0

C-G 401.0÷450. 91.0

D-H 980.0÷050. 81.0

0

00

00

78

A 020,941÷000,941

B 020,741÷000,741

C 020,67÷000,67

79

80

E 020.55÷000.55

F 875.54÷845.54

G 534.55÷404.55

H 020.55÷000.55

77

I 020.941÷000.941

L 020.06÷000.06

M 810.741÷000.741

N 390.95÷470.95

O 010.67÷099.57

P 020.06÷000.06

Q 50.42÷59.32

R 02.13÷01.13


Limit value (mm)Clearance (mm)Ref.

Clearance between main journals/crank pins and connecting rod bearings

Main bearíng supports -Dimensions

1Flywheelside2Central3Gearside

Dimensions (mm)Ref.

Dimensions(mm)Ref.

Main bearing housings

Main bearing and connecting rod big end bearing inside diameter

Dimensions (mm)Ref.

Theabovedimensionsrefertodriveninortightenedbearings.

Note: Bothmainbearingsandconnectingrodbigendbearingsareavailablewithinsidediametersizemeasuring0.25and0.50mmlessthanthestandardversion.


- 45 -

82

84

83

81

A-I -0,020÷0,020 0,03B-M -0,018÷0,020 0,03C-O -0,010÷0,030 0,04

A 41,940÷41,9600,040÷0,085 0,160

C 42,000÷42,025B 27,940÷27,960

0,040÷0,085 0,150D 28,000÷28,025


CAMSHAFT

How to measure camshaft journals and housings

Useaninsidemicrometergaugeforhousingsandanoutsidemicrometergaugeforjournals.

Clearance (mm)

Limit value(mm)

Dimensions(mm)

Ref.

Dimensions of camshaft journals and housings

Crankshaft end play

When refitting crankshaft check end play bymeans of a thicknessgauge;thisvalueshouldbe0.08÷0.38mmandcanbesetbychangingthethicknessofgasketAwhichislocatedontheflywheel-sidemainbearings.Gasketswiththicknessof0.30and0.50mmcanbesupplied.

ImportantReplace the main bearings 1 and 3 (Fig. 79) if the axial clearance value still turns out to be too high even with a seal having a smaller thickness (fig. 79).

Ref. Clearance (mm) Limit value (mm)

Table “Clearance between main bearings and main bearing housings”


- 46 -

88

89

87

85 86


Valve timing without considering timing marks

Locatepiston1(onflywheelside)atthetopdeadcentre.PositiontwosmallcylindersAofthesameheightontothetappets.Rotatecamshaftstoppingwhencylinder1tappetsareinoverlapposition(intakeopen,exhaustclosed).BymeansofrulerBcheckthattappetsareatthesameheight.Engagecamshaftgearwithcrankshaftgear.

CAMSHAFT TIMING

Fitcamshaftgearbymakingtimingmark1coincidewithtiming-mark2onthecrankshafttiminggear.

Tightencamshaftbollat60Nm.

Camshaft end play

Endplayshouldbe0.10÷0.25mm;checkbymeansofadialgaugepushingorpullingcamshaftasrequired.

How to measure intake/exhaust cam height

A1 =1stcylinderintakecamS1=1stcylinderexhaustcamA2=2ndcylinderintakecamS2=2ndcylinderexhaustcam

ExhaustandintakecamsfeaturethesameheightH.

H=33.625÷33.650mm

ReplacecamshaftifHis0.1mmbelowthegivenvalue.


- 47 -

91

92

90


Valve timing - Angles

The angle values are determined by turning the driving shaftclockwise

S =PistonattopdeadcentreI =Pistonatbottomdeadcentreα =Intakevalveopenβ =Intakevalveclosedγ =Exhaustvalveopenδ =Exhaustvalveclosed

Timing angles for checking puposes(valve clearance = 0,65÷0,70 mm)

α =1°beforeSβ =21°afterIγ =23°beforeIδ =1°afterS

HYDRAULIC PUMP

Hydraulic pump p.t.o

Ahydraulicpumpofgroup1(1P)or2(2P)canbeinstalledonthegearside,3rdp.t.o.

Valve timing check

Checkvalvetimingatthecrankshaft.The values shownare checkedat the flywheel circumference (withflywheelof291mm.diametereachdegreecorrespondsto2.5mm).Setvalveclearanceat0.65÷0.70mm(aftercheckingrestorethevalueat0.15÷0.20mm).Setdialgaugeonintakevalvetoazerovalue;byrotatingthedrivingshaftaccordingtoitsdirectionofrotationyoucanmeasureα(intakevalveopeningadvancereferredto topdeadcentreS)andß (intakevalveclosingdelayreferredtobottom(I)deadcentre).Followthesameprocedureforexhaustvalvescheckingγ(exhaustvalveopeningadvance)andδ(exhaustvalveclosingdelay).


- 48 -

94

95

93


Mechanical speed governor components

1 Gear 2Weight 3 Mobilebell 4 Stopring 5 Thrustwasher 6 Yoke7 Lever 8 Driverod9 Governorspring10 Rackcontrollever

Weightsaremovedtotheperipherybythecentrifugalforceandthusaxiallyshiftamobilebellconnectedtotheinjectionpumprackcontrolleverbyalinkage.Aspringplacedundertensionbytheacceleratorcontroloffsettheweightcentrifugalforce.Balancebetweenthetwoforceskeepsspeedatanalmostconstantlevelinspiteofloadvariations.

Seepage62fortiming.

MECHANICAL SPEED GOVERNOR

Weight-typegovernorhousedinsidethecamshaftdrivegear.

Hydraulic pump components (1 P)

1Sealring2Centeringring3Coupling4Halfcoupling 5Flange6Gear 7Bracket8Thrustwasher 9Stopring10Cover

Themaximumtotaltorqueisthus30Nmcorrespondingto12.5HPat3000r.p.m.Reductionratio1:1.


- 49 -

96

97

98

4

1

2

3

6

7

6

1

2

3

4

5

99

16

53

4

7 2


Governor springs with single-spring system

1Extrafuelspring2lnjectionpumpcontrollever3Governorspring4Throttlelever

ELECTRONIC SPEED GOVERNOR(optional)

1 lnjectionpumpcontrollever2 Electromagnet3 Eccentricscrew4Conicalplug5Conicalplug6Actuator7 Eccentricscrew

Assemble the entire plate by centring it on the reference pins andmakesurethattheinjectionpumprackrodpinisinsidelever“1”.Fixtheplatebyusingthespecificscrewsforitsmodel.

Governor springs with rocker arm system

Thesystemfeaturestwospringsanchoredtoarockerarmandallowsforminimalr.p.m.changesatlowspeedlevels.

Thedeviceisoperatedautomatically:whentheengineisstoppedspring6actsoninjectionpumpcontrolyoke7providingmaximumfueldelivery,untiltheenginestartsandthegovernorcontrolstheiniectionpumprack.

Components:

1Rockerarmforspringanchoring2Governorsprings3Plate4Link5Throttlelever6Supplementarystart-upfuelspring


- 50 -

100

16

5

3

4

7

2

101


Adjustment of the stroke end (STOP):

1- Removetheconicalplug"5".2 - Through the eccentric "7" position and check by sight that the

leverinstoppositionisattheextremeleft.3 - From this position, always acting on the eccentric screw "7",

movethecontrollever1,0÷1,5mmtoright.4 - Lockthelocknutofthescrew"7".5 - Reassambletheconicalplug"5".

Adjustment of extra fuel delivery:

1- Removetheconicalplug"4".2 - Power theelectromagnet"2"witha12Vvoltageandmakesure

thattheplungerhasmoved.Inthiscaseyouwillhearthetypicalactivatedmagnetsound.

3 - Feedactuator"6"withatensionof12V(putbetweentheactuatorandthe12Va10Amp.fuse):theactuatortensionwillcausethepumpdeliverycontrollevertomovetotheright.

4 - Bytheeccentricscrew"3"placeandcheckbysightthattheleverinMaxpositionisattheextremeright;fromthisposition,alwaysactingonthescrew"3",movethedeliverycontrolleverby1,0÷1,5mmtotheleft.

5 - Lockthelocknutofscrew"3".6 - Removefeedingfromactuator"6"eelectromagnet"2".7 - Reassambletheconicalplug"4".

Speed governor wiring diagram

BlackRed

shielding

shielding

Black

RedViolet

Violet

WhiteBlack

Magneticsensor

24Velectriccontrolunit

Startingmotor

Red

Red


- 51 -

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- 52 -

102

1

2

3

4

6

5

7

9

10

11

12

13

14

15

8

5

Components:

1) Oilpreassuregauge2) Breather3) Connectingrodbigendbearing4) Crankshaftmainbearingongearside5) Cartridgefilter6) Oílpressurereliefvalve7) Oilpump8) Internalfilter

LUBRICATION SYSTEM

LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM

Danger – Attention - The engine can be damaged if allowed to operate with

insufficient oil. It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed.

- Use suitable oil in order to protect the engine. Nothing more than lubrication oil can influence the

performances and life of an engine.- Use of an inferior quality oil or failure to regularly change

the oil will increase the risk of piston seizure, will cause the piston rings to 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.

- The oil viscosity must suit the ambient temperature in which the engine operates.

Danger – Attention- Old engine oil can cause skin cancer if repeatedly left in

contact with the skin and for long periods of time. Wear protective gloves to avoid touching used oil.- If contact with the oil is unavoidable, you are advised to

wash your hands with soap and water as soon as possible. Dispose of old oil in the correct way as it is highly polluting.

9)Oilfillplug10) Rockerarmshafts11)Pushrodprotectiontube12)Hydraulicpumpgear13)Camshaftjoumalonfiywheelside14) Oìldipstick15)Oildrainplug

Standard lubrication system circuit


- 53 -

104 105

103

1

2

3

4

6

5

7

9

10

11

12

13

14

15

8

16

5

OIL PUMP

Checkthatthegearteethareintactandthatclearancebetweengearedgeandpumpbodydoesnotexceed0.15mm.Furthermorecheckthatthecontrolshaftisfreetorotatewithendfloatnotexceeding0.15mm.Oilpumpdeliveryat3000r.p.m.is9liters/min.

Lubrication system

Components:

1) Oilpressuregauge2) Breather3) Connectingrodbigendbearing4) Crankshaftmainbearingongearside5) Cartridgefilter6) Oílpressurereliefvalve7) Oilpump8) Internalfilter

9)Oilfillplug10) Rockerarmshafts11)Pushrodprotectiontube12)Hydraulicpumpgear13)Camshaftjoumalonfiywheelside14) Oìldipstick15)Oildrainplug16)Oilradiator

Lubrication system with oil radiator circuit


- 54 -

1 2

3 4 5

107

106

108

109

6

5 Lubrication System

OIL PRESSURE RELIEF VALVE

Details:

1Plunger2Washer3Valvebody4Spring5Ringsnap6 M9x1threadingforpuller

Operationstartpressure.............................5bar.

OIL FILTER CARTRIDGE (EXTERNAL)

Components:1 Gasket2 Plate3Gommino4 Spring5Filterelement6Bypassvalve7Spring Forcharacteristicsseepage17.

Disassembly:

Beforeremovingtheoilpressureregulatingvalve,removetheoilfilterbyusinganappropriatewrench.

RemovetheregulatingvalveusingahammerpullerequippedwithaM9x1threadedterminal.

Reassembly:

Makesurethat thevalveseat is freeofscratchesandscoreswhichcouldreducethepressureseal.

Insert the entire oil pressure valve into its housing by keeping it inline.Make sure that the valve is completely assembled to the engineguardbymeansofapad.


- 55 -

111

112

113

110

1

2

44

45

3

67

8

5

Oilpressure curve with engine at idle speed

Thecurveisobtainedattheoilfilterleverwithconstantenginespeedof1200r.p.m.inno-loadconditionsandataroomtemperatureof+25°C.Pressureisgiveninbarandtemperatureincentigrades.

If theoilpressurevalueisbelowtheindicatedone,pleasecheckallcomponentsindicatedonpage52÷53.

Oil pressure curve with engine at full speed

Thecurveisobtainedattheoilfilterlevelwithengineworkingat3000r.p.m.andmax.powerat+25°Croomtemperature.Pressureisgiveninbarandtemperatureincentigrades.

If theoilpressurevalueisbelowtheindicatedone,pleasecheckallcomponentsindicatedonpage52÷53.

OIL PRESSURE CHECK

Oncetheengineisfittedfillwithoilandfuel;connecta10barpressuregaugetothefitting.Starttheengineandcheckpressureasafunctionoftheoiltemperature.

OIL RADIATOR(on request)

Components:

1Radiator2Returnpipe3Oilfilter4Coppergasket5Deliveryhose6Union7Oildetectionflange8O-ring

Lubrication system


- 56 -

114

115

2

4

5

6

7

8

3

116

1

1

4

6

8

7

9

5

3

2

117

1

2

46

8

7

9

5

3

10

10

6FUEL FEEDING / INJECTION CIRCUIT

Fuel feeding / injection circuit with fuel filter inside the fuel tank

Components:

1Fueltank2Fuelfilter3Fuelfeedingtube4Fuelliftpump5lnjectionpump6High-pressurepipe7Injector8Injectorexhaustpipe

Fuel feeding / injection circuit with external fuel filter

Components:

1Fueltank2Fuelfeedingtube3Fuelfilter4Fuelliftpump5 lnjectionpump6High-pressurepipe7 Injector8 Injectorexhaustpipe

Fuel feeding / injection circuit with external fuel filter and double solenoid valve

Components:

1 Fueltank 2 Solenoidvalve 3 Fuelfilter 4 Fuelliftpump 5 Solenoidvalve 6 lnjectionpump 7 High-pressurepipe 8 Injector 9 Injectorexhaustpipe10 Non-returnvalve

Fuel feeding / injection circuit with fuel filter inside the fuel tank and double solenoid valve

Components:

1 Fueltank 2 Fuelfilter 3 Solenoidvalve 4 Fuelliftpump 5 Solenoidvalve 6 lnjectionpump 7 High-pressurepipe 8 Injector 9 Injectorexhaustpipe10 Non-returnvalve

FUEL SYSTEM


- 57 -

119

121

120

1

2

3

4

5

6

7

8

9

10

118

6Fuel system

FUEL FILTER

Fuel filter (inside fuel tank)

Components: 1Spring 2Disc 3Ring 4Cartridge 5Gasket 6Gasket 7Cap 8Ring 9Screw

Forcharacteristicsseepage17.

FUEL LIFT PUMP

Thefuelliftpumpisofthediaphgragmtypeoperatedbyacamshafteccentricthroughadriverod.Itfeaturesanexternalleverformanualoperation.

Fuel filter, external

1 Airreliefvalve2Support3Cartridge4Gasket5Filteringelement Forcharacteristicsseepage17.

Formaintenanceseepage22.

Fuel feeding / injection circuit with external fuel filter and QSD (Quick Stop System)

Components:

1Fueltank 2Fuelfeedingtube 3Fuelfilter 4Fuelliftpumpintaketube 5Fuelliftpumpdeliverytube 6Fuelliftpump 7lnjectionpump 8 High-pressurepipe 9 Injector10 Injectorexhaustpipe


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124

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6Fuel feeding pump components

Components:

1Driverod:-length:32,55÷32,65mm -measuredprotrusionA:1,47÷2,07mm2Gasket3Camshafteccentric4Manualpriminglever

Characteristics:whenthecontroleccentricrotatesat1000r.p.m.minimumdeliveryis73l/hwhileself-regulationpressureis0.5÷0.7bar.

Injection pump for Standard and 97/68 CE engines

Components:

1 Pumpbody 9 Gasket2 Holder-deliveryvalve 10 Rack 3 O-ring 11 Meteringsleeve 4 Filter 12 Tappetspring 5 Shim 13 Upperretainer 6 Valvespring 14 Lowerretainer7 Deliveryvalve 15 Tappet 8 Plungerandbarrelassembly 16 Tappetroller

INJECTION PUMP

The injection systemconsists of a single-body pumpwith plungersfeaturingconstantstrokeandfeedingonecylindereach.The pump,mounted on the crankcase is directly operated by thecamshaft.Speedgovernor,extrafuelandstopdeviceareseparatefromthepump(seepages48,49,50and78).

Fuel system

Piston fuel lift pump (on request)

Characteristics:whenthecontroleccentricrotatesat1000r.p.m.minimumdeliveryis65l/hwhileself-regulationpressureis1.5÷2.5bar.

ImportantThe drive rod and its protrusion do not change in relation to the diaphragm pump.


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128

6Fuel system

Injection pump for EPA engines

Components:

1 Holder-deliveryvalve 2 Lockingnutclamp 3 Screw 4 Valve-Spring 5 ORing 6 Coppergasket7 Plungerandbarrelassembly 8 Pinspring9 Rack10 Seatspring11 Springtappet12 Seatphasing13 Ringsnap14 Tappetassemblyroller15 Pintappetdriver16 Pumphousing17 Meteringsleeve18 Pinbarrellocating19 Coppergasket20 Gasketfibreseal21 Threadedcap22 Deliveryvalveassembly

How to check plunger and barrel for internal leakage

Thisoperationisonlyindicativesincepressurechangesdependingonthepumpingspeed.Connectthedeliveryunionwitha600barpressuregaugewithsafetyvalve.Adjustrackrodathalf-stroke.Turnflywheelaccordingtoitsdirectionofrotationsothattheplungerputsthecircuitunderpressure.Replaceplungerifthedisplayedpressureisbelow300bar.Repeatthesameoperationfortheotherplunger.

Plunger and Barrel Assembly

1Barrel2Fuelfeedingport3Controlhelix4Plunger5Retardationnotch

Plungerdiameteris7.5mm.

ImportantEveryplungermatcheswithitsownbarrel.Forthisreasontheyarenotinterchangeable.


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130

6

9 LD 625-2 - 626-2 - 625/626 CE

9 LD 625-2 EPA

Fuel system

Controlrodmax.force

Rodstrokefrommaxdeliv.point

R.P.M. Delivery Max.plungerdifference

Newton mm mm3/stroke mm3/stroke

0,50

10 1500 34÷37 3

13 500 7÷11 3

0 150 70÷78 --------

10 500 22÷26 3

Controlrodmax.force

Rodstrokefrommaxdeliv.point

R.P.M. Delivery Max.plungerdifference

Newton mm mm3/stroke mm3/stroke

0,50

9.5 1500 34÷37 3

11.5 500 3÷7 3

0 150 60÷68 --------

9.5 500 13÷18 3

Test data for injection pump delivery

Check onlymaximum plunger difference by positioning rack rodaccordingtotheindicateddeliveryvalue.


How to check injection pump delivery valve sealing

Components: 1Valves2Seat

Adjustpumprackathalf-stroke.Turnflywheelaccordingtoitsdirectionofrotationsothattheplungerputsthecircuitunderpressure.Duringthisoperationthedisplayedpressurewillgraduallyreachapeakfollowedbyasuddendropwhichcorrespondstovalveclosing.Pressuredropshouldbe30÷50bar.Replacethevalveifpressuredropisbelowthisvalue.Repeatthesameoperationfortheotherplunger.

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133 134

2

1

6Fuel system

How to reassemble injection pump components

After replacing theworn-out components, reassemble the pumpasfollows:

- IntroducesectorgearsintothepumpbodybymakingreferencepointsCmatchwiththeBpointsontherack.

- FixbarrelswiththeeccentricscrewsFonthepumpbody.

- Fitvalveswithseats,springs,fillersanddeliveryunionstighteningthemat35÷40Nm.

- FitplungersbymakingreferencepointsEmatchwiththesectorgearDpoints.

- Fixretainersandsprings;locktappetwithspecialstop.

- Checkthatbothplungershavethesamedeliverybyperformingthenecessarymeasurementsatthetestbed;ifdeliveryisnotthesamesetscrewF.


Checkthatrackrodslidessmoothly:ifnot,theenginemayfailtostartorhunt.

How to mount injection pump on the engine

During reassembly,makesure theadjustment rodpin1 is correctlyinsertedintotheoppositeseatintheadjustmentlever.

See“Injectionadvanceadjustment”onpage63for thechoiceoftheseals2.


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1

2

3

137

138

139

6 Fuel system

Injection pump/mechanical speed governor timing

Loosenscrew1Moveinjectionpumplever2tomaximumdelivery(totheright).Check that drive rod3 closes the speedgovernor; keeping lever2pressedtotherightthedriverodshouldhavenoclearance.Tightenscrew1.

(STATIC) INJECTION TIMING

Injection static advance adjustment

1 Removerockerarmcoversandhigh-pressurepipes.

2 Selectthecylinderonwhichtheinjectionstaticadvancecheckwillbecarriedout.

3 Assemblethevalveloweringtool(1460.285)byfasteningittothefixingholesoftherockerarmcoverscrews.

4 Before tightening the tool fixing screws,make sure that the dialindicatortraceriscorrectlyplacedontheintakevalvecollar.

5 Place the auxiliary tank at a higher height than the one of theinjectionpump(~30-40cm).

6 Connectthetanktotheinjectionpumpfuelsupplyhole.

7 Slowly rotate the crankshaft clockwise keeping lever 1 loweredand the valve positioned on the piston crown, until the dialindicator2showsthemaximummeasurement.

8 Set the maximum measurement dial indicator to zero which isequivalenttothecompressiontopdeadcentre.

9 Assemble theadvance tester4 (serial number1460.024)on theinjectionpumpdeliveryunionofthecylindercorrespondingtotheoneonwhichthevalveloweringtoolhasbeenpreviouslyinstalled.

10Rotatethecrankshaftclockwisebyapproximately45°.

11Rotatethecrankshaftalternatelyuntilthefuelleaksoutfromtester4withacertainpressure.

12Position the stop lever3 half a stroke so that the plunger delaymarkisexcludedandkeeptheleverinthisposition.


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4

140

141

*

*

*

*

6

2/526DL90003 °1±°62

49.4°4243.5°5267.5°6212.6°722/626DL9

2/526DL9APE 0003 °1±°71

69.1°5122.2°6115.2°7118.2°81

2/526DL9RNEC 0003 °1±°81

15.2°7118.2°8121.3°91

2/626DL9RNEC 0082 °1±°71

22.2°6115.2°7118.2°81

Fuel system

Enginetype

Piston lowering value (mm)

Advance de-greesR.p.m.

Injection advance adjustment

Ifthevaluesindicatedinthetabledonotcorrespondtothedetectedones,followtheoperationsaswrittenbelow:

1) Delayed Injection Advance: remove the shims under the pumpuntil the detected value corresponds to the one indicated in theTable“Conversionforestablishingadvance”

2) Advanced Injection Advance: add shims under the pump untilthedetectedvaluecorresponds to theone indicated in theTable“Conversionforestablishingadvance”.

Note: By removingoraddinga0.1mmshimunder thepump, it ispossibletoadvanceordelaytheinjectionbyabout1°.

Table “Conversion for establishing advance”

* Checkvalues.

13Turn theflywheel slowlyandclockwise.Stop turningassoonasyounoticethatthefuelismovinginsidetester4.

14Movelever1againsoasto lowerthevalveandbringitagain incontactwiththepiston.

15Measure the piston lowering value and bring it again in contactwiththepiston.

16Convert the registered value from millimetres to degrees (seeTable"Conversionforestablishingadvance").


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142

6 Fuel system

Size S Nozzle, only for standard engines

Features:Holenumberanddiameter...................4x0.28mm.Jetangles.............................................160°.Needlevalveelevation.........................0.20÷0.22mm

Cleannozzletipwithabrassbrush.Checkthatholesarenotobstructedusingamandrelwithsteelwìrewith0.28mmdiam.

Whenrefittingtightenringnutat60Nm.

INJECTOR

Size S Injector, only for standard engines

Components: 1 Intakefitting 2 Nozzleholder 3 Shim 4 Spring 5 Pressurerod 6 Intermediateflange 7 Nozzle 8 Needlevalve 9 Fixingflange10 Taperpin11 Gasket12 Systemduct13 Sump


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145

146

6Fuel system

Size P injector, for 97/68 CE and EPA engines

Components:

1Injectorhousing2 Intakefitting3 Shim4 Spring5 Pressurerod6 Taperpin7 Nozzle8 Cup9 Needlevalve10 Sump11 Systemduct12 Overflowpipe

Injector setting

Connecttheinjectortoadieselinjectorcalibrationpump.Check needle valve sealing by slowlymoving hand pump untilapproximately180barandmaintainthispressurefor10seconds.Chekthatsettingpressureis210÷220barforstandardengines(245÷230barforEPAeCEengines);maketherequiredadjustments,ifany,bymodifyingtheadjustingshimheight.

Whenreplacing thespring,settingshouldbeperformedata10bargreaterpressure(255÷265bar)toallowforbeddingduringoperation.Replacenozzleincaseofdripping.

Size P nozzle, for 97/68 CE and EPA engines

Features:Holenumberanddiameter............. 5x0.23mm.Jetangles....................................... 150°.Needlevalveelevation................... 0.200÷0.205mm

Cleannozzletipwithabrassbrush.Checkthatholesarenotobstructedusingamandrelwithsteelwìrewith0.23mmdiam.

Whenrefittingtightenringnutat42÷48Nm.


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147

7Electric starting layout with internal alternator

ELECTRIC SYSTEM

Electrical starting layout with external alternator

Components:

1Alternator2Startingmotor3 Voltageregulator4Battery5Pressureswitch6Oilpressurewarninglight7Keyswitch8Batterycharginglight

Note: Battery,which is not suppliedbyLombardini, should feature 12Vvoltageandcapacitynotbelow70Ah.

Components:1Alternator2Startingmotor3Battery4Keyswitch5Pressureswitch6Oilpressurewarninglight7Batterycharginglight

Note: Battery,which isnotsuppliedbyLombardini, should feature 12Vvoltageandcapacitynotbelow70Ah.


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149

150

151

7ALTERNATOR

Alternator - 12 V, 18A

Featuresafixedarmaturewindingmountedontheairshroudbracket.Therotatingpermanentmagnetinductorislocatedinthefanspindle.Onlythetwoyellowcablesareatoutput.

Dimensions (mm):A =158.80÷159.20B=27.50÷27.90

Note: Clearancebetweenarmaturewìndingandinductor(airgap)mustb0.48÷0.60mm.

Alternator battery charger curve (12 V, 18 A)

Thiscurveisobtainedat+25°Cwith12.5Vbatteryvoltage.

Alternator - 24 V, 6 A

Featuresafixedarmaturewindingmountedontheairshroudbracket.Therotatingpermanentmagnetinductorislocatedinthefanspindle.Therearethetwoyellowcablesandoneredcableatoutput.

Dimensions (mm):A =158.80÷159.20B=27.50÷27.90

Note: Clearance between armaturewinding and inductor (air gap)shouldbe0.48÷0.60mm.

Electric System


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155

152

153

154

Amp.

7Alternator battery charger curve - 24 V, 6 A

Thecurvewasobtainedatroomtemperatureof+20°Cwith25Vbatteryvoltage.

Magnetization checking tool (Part No. 7000-9727-001)

Components: 1Casing2Slider3Casingreferenceline4Sliderreferenceline

Restthetoolendhorizontallyontothemagneticpoles.Holdslidersothatitsreferencelinecoincideswiththecasingreferenceline.Releaseslider:ifnoattractionoccurstherotorisdemagnetized,inthiscasereplacealternator.

Alternator - 12 V, 14 A

Featuresafixedarmaturewindingmountedontheairshroudbracket.Therotatingpermanentmagnetinductorislocatedinthefanspindle.Therearethetwoyellowcablesandoneredcableatoutput.

Dimensions (mm):A =158.80÷159.20B=27.50÷27.90

Note: Clearance between armaturewinding and inductor (air gap)shouldbe0.48÷0.60mm.

Alternator battery charger curve standard - 12 V, 14 A

Thecurvewasobtainedat room temperatureof+25°Cwith12,5Vbatteryvoltage.

Electric System


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156

157

1

158

7Electric System

Checking for cable continuity

Checkthatstatorwindingshavenounsolderedconnections,burntareasorgroundedwìres.Usinganohmmetercheckforcontinuitybetweentheredcableandthetwoyellowones.Furthermore,checkthattheyareinsulatedfromtheground.

Alternator, external - 12 V, 33 A

Thealternatorisoftheclaw-polerotortypewithbuilt-involtageregulator.Therotatingmotionisconveyedbytheenginethrougha"V"beltandsheave.

Features:Ratedvoltage......................12VMax.current.........................33A(at7000alternatorr.p.m./min.).RHdirectionofrotation.

Tightenthenut1 atatorqueof70Nm.

Alternator battery charger curve - external, 12 V, 33 A

Thecurvewasobtainedatroomtemperatureof+25°C.Batteryterminalvoltageis12.5V.Ther.p.m.shownonthetablereferstotheengine.


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159

160

~ 6.35 0.80R 9.50 1.12+ 9.50 1.12LE 4.75 0.50oo 6.35 0.80

7

How to check voltage regulator for proper operation

- Checkthatconnectionscorrespondtothelayout.- Disconnecttheterminalfromthebatterypositivepole.- Connectad.c.voltmeterbetweenthetwobatterypoles.- FitanammeterbetweenthepositivepoleandtheB+ofthevoltageregulator(correspondingtoref.1inthepicture).

- Startacoupleoftimesuntilbatteryvoltagedropsbelow13V.- Whenbatteryvoltagereaches14.5Vtheammetercurrentsuddenlydropsdowntoalmostzero.

- Replaceregulatorifrechargecurrentiszerowithvoltagebelow14V.

Caution - Warning- When the engine is running do not disconnect battery cables or

remove the key from the control panel. - Keep regulator away from heat sources since temperatures above

75°C might damage it. - No electric welding on engine or application.

Electric System

VOLTAGE REGULATOR

TypeLOMBARDINI,suppliedbySAPRISAandDUCATI:Voltage12V,max.current26A.

Toavoidwrongconnections3differentsizesaresupplied.

ConnectionsDimensions (mm)

Width Thickness


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162

164

7Electric System

Voltage regulator - 12 V, 30 A

Thevoltageregulatorisofthebridgetype.

Seepage70fortagdimensions.

Voltage regulator - 12V, 26A, with “W” terminal

“W”poletab:Width=4,75mm;Thickness=0,5mm.


Voltage regulator - 12V, 30A, with “W” terminal

“W”poletab:Width=4,75mm;Thickness=0,5mm.



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166

P CV

N

J(A)

A

B

C

7

Characteristic curves for starting motor type Bosch - 12 V, 1.7 kW

Curvesareobtainedatroomtemperatureof+20°Cwith66Ahbattery.

V=MotorterminalvoltageinVoltP=PowerinkWC=TorqueinN/mN=Motorspeedinr.p.m6.J (A)=AbsorbedcurrentinAmpere.

STARTING MOTOR

Important- Made by MARELLI and BOSCH.- Apply to their distributors for any type of repair.

Bosch starting motor type GIF - 12 V, 1.7 kW

RHdirectionofrotation.A=29.5÷31.5mmB=RinggearplaneC=Flangeplane

Caution – WarningFlywheel should not project from ring gear plane B.

Electric System


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167

A

B

C

7Electric System

Starting motor type Bosch DW (R) 12 V, 1.7 kW

RHdirectionofrotation.

A=29.5÷31.5mmB=RinggearplaneC=Flangeplane

Caution – WarningFlywheel should not project from ring gear plane B.

Characteristic curves of the 24 V 1.6 kW starting motor

Thecurveshavebeenmeasuredata20°Ctemperaturewithan88Ahbattery.

V = VoltagetothemotorterminalsinVoltP = PowerinkWC = TorqueinN/m N = MotorspeedinrpmJ (A) =AbsorbedcurrentinAmperes.


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169

V21 V42

V21 V82

A14 A31

1

2 3

V21 V42

V21 V42

A04 A02

A36.0 A03.0

8

67

4

9

10

3

2

5

1

7 Electric System

Pre-heating glow plug

Components: 1Sheath 2Regulationfilament 3Heatingfilament

Whenremountingtightenatatorqueof20Nm.

Note: Theglowplugisnotdamagedinanywayduetotheprolongedactivationtime.

Nominalvoltage

Current

Glow plug Type

DIRECT STOP ELECTROMAGNETS

Reverse electromagnet – FIRE version

Features:

Components:1Nut2Studbolt3Flatwasher4Screw5Spacer6Sphericaljoint7Electromagnet8Stopcontrollever9Axialjoint10Stopcontrolelectromagnetsupport

Adjustment:- Carryouttheadjustmentsbyscrewingandunscrewingthejoints.- Adjust thedevicesoastomaketheelectromagnetget totheendof the stroke before the STOP lever reaches its limit stop afterperformingtheoperationstroke.

- Whentheelectromagnetisexcited,putthestopleveratabout1.0–1.5mmfromitslimitstop.

- Onceadjustmentphaseiscompleted,tightennut1.

ImportantThe control cover should not present the return spring of the stop lever.Remove the stop lever return spring without replacing the control cover if the device is applied to engines that were originally not equipped with it.

Operatingtension

Powercoilabsorption

Electromagnet type

Holdcoilabsorption


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170

1

2

7Direct stop electromagnet

Features:Operatingtension............................................ 12V.Powercoilabsorption...................................... 41A.Holdcoilabsorption......................................... 0.5A.

Setting:- Screw drive rod1 to the end of the thread on the electromagnetpiston.

- Excite the electromagnet and leave the stop lever in normaloperationposition.

- Bringdriverod1incontactwiththestopleverandtightenlocknut2.

Electric System


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172

173

8SPEED ADJUSTMENTS

WARNING- Adjustments should be carried out by Lombardini authorised

personnel only.- Any tampering with the adjustment immediately makes the

warranty null and void.

Idling speed setting in no-load conditions

Afterfillingwithoilandfuel,starttheengineandletitwarmupfor10minutes.Adjust idlingspeedat1000÷1100r.p.m.by turningsetscrew 1; thentightenlocknut.

INJECTION PUMP DELIVERY SETTING

ImportantThis adjustment must be performed with the engine connected to the

dynamometric brake. Without this the regulation is approximate.

lnjection pump delivery limiting and extra fuel device

LimitingdeviceClimitstheinjectionpumpmaximumdelivery.It also acts as a torque setting device since springN opposes theresistenceofspringMinsidethecylinderthroughleverL.The torque setting device allows leverL tomove over strokeHcorrespondingto0.15÷0.25mm.Thisconsequentlyincreasesinjectionpumpdeliverywithtorquereachingitspeakvalue.

Note: Ingeneratorsetsandpowerwelders,thetorquesettingdeviceactsasadeliverylimiteronly.

ItthereforedoesnotfeaturespringMorstrokeH.

Full speed setting in no-load conditions (standard)

After setting idle speed turn screw2 and set full speed in no-loadconditionsat3200r.p.m.;thentightenlocknut.

Note: Whentheenginereachesthepre-setpowerfullspeedstabilizesat3000r.p.m.

SETTINGS

Not valid onEPAengines, onwhich it is not possible tomodify theadjustmentofthemaximum.


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174

8Settings

Injection pump delivery setting with dynamometric brake

1)Runtheengineandbringittotheoperatingtemperature.2)ReleasetheflowlimiterscrewCcompletely(seepage175).3)Bringtheenginetomaximumrotationspeed.4)Activate the dynamometric brake to bring the engine to the

maximumspeed.5)Checkthatfuelconsumptionisinlinewiththevaluesgiveninthe

table“Specificfuelconsumption”. If it is not in line with the indicated values, reduce the

dynamometricbrakeload.6)After a few operation minutes and when the engine has

stabilized, slowly fasten screwC until the rotation speed startsdecreasing.

7)LockscrewCusingalocknut.8)Carryoutthefuelconsumptioncheckagain.9)Releasethedynamometricbrakeanddetecttherotationspeedof

the“stabilized”engine(maximumidlespeed).10)Bringtheenginetominimumidlespeed.Carryoutenginesetting

whentheengineis"stabilized".11)Switchofftheengineandletitcooldown.12)Checkthevalve/rockerarmclearance(see"Settingvalve/rocker

armclearance").

lnjection pump delivery setting without dynamometric brake

LoosendeliverylimitingdeviceCby5turns.Bringenginetofullspeedinno-loadconditionsi.e.3200r.p.m..Tightenlimitingdeviceuntiltheengineshowsadropinr.p.m..UnscrewlimitingdeviceCby1and½turns.Tightenlocknut.

Note: lftheengine,underfullload,generatestoomuchsmoketightenC;ifnosmokeisobservedattheexhaustandtheenginecannotreachitsfullpowerunscrewC.


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0003 05.52BN)21.91( 36÷06 002÷091

)272÷852(

0081 05.81BN)6.31( 59÷09 181÷171

)642÷332(

0081 05.61AN)31.21( 011÷401 371÷361

)532÷322(

0051 08.41BN)88.01( 611÷011 581÷571

)252÷932(

0051 03.31AN)87.9( 231÷521 871÷961

)342÷032(

0003 75.52BN)08.81( 5.16÷5.06 491÷091

462÷952

0003 05.52BN)08.81( 06÷95 091

)852(

(18,80)

8

9LD 625-2

9LD 625-2

9LD 625-2

9LD 625-2

9LD 625-2

9LD 625-2 EPA

9LD 625-2CE

Setting the stop limit stop

1)Removethethrottlelevercover.1)Completelyturnlever Ccounter-clockwiseandkeepitinthisposition. RetainerFshouldnotbeincontactwithleverC.2)UnscrewnutGandbringretainerFincontactwithleverC3)PushretainerFsothatleverCismovedbackwardsclockwiseby

1.0mm.4)LockretainerFbyscrewingnutG

Note: Inthiscondition,thelimitstopsoftheinjectionpumpadjustmentrodwillnotbedamagedbytheviolentimpactscausedbythepossibleassemblyofelectrostop.

Settings

Engine R.p.m.Power

HP(kW)

Specific fuel consump-tion *

Time (sec) per 100 cm3

g/HP h(g/kW h)

Theindicatedspecificfuelconsumptionreferstotheperiodfollowingapproximately30workinghours.

Required settings (as most commonly applies)


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8Settings


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9

- When the engines are not for more than 6 months, they have to be protected performing the operations described in the following pages.

- Iftheengineisnottobeusedforextensiveperiods,checkthestorageareaconditionsandthetypeofpackagingandmakesurethatthesearesuitableforcorrectstorage.

Ifnecessary,covertheenginewithaproperprotectivesheet.- Avoidstoringtheengineindirectcontactwiththeground,inenvironmentsthatarehumidandexposedtobadweather,near

highvoltageelectriclines,etc.

ImportantIf, after the first 6 months, the engine is still not used, it is necessary to carry out a further measure to extend the protection period (see “Protective treatment”).

1 - PourintheenginehousingAGIPRUSTIACprotectiveoiluptothemaximumlevel.2 - Fillupwithfuelcontaining10%AGIPRUSTIANT.3 - Starttheengineandkeepitidleatminimumspeedforsomeminutes.4 - Bringtheengineto¾ofthemaximumspeedfor5÷10minutes.5 - Turnofftheengine.6 - Emptyoutcompletelythefueltank.7 - SpraySAE10Wontheexhaustandintakemanifolds.8 - Sealtheexhaustandintakeductstopreventforeignbodiesfromentering.9 - Thoroughlycleanallexternalpartsoftheengineusingsuitableproducts.10 - Treatnon-paintedpartswithprotectiveproducts(AGIPRUSTIANT).11 - Loosenthealternator/fanbelt(ifpresent).12 - Covertheenginewithaproperprotectivesheet.

Caution - Warning

In countries in which AGIP products are not available, find an equivalent product (with specifications: MIL-L-21260C).

Important

Maximum every 24 months of inactivity, the engine must be started up by repeating all "Engine Storage" operations.

ENGINE STORAGE

PROTECTIvE TREATMENT

STORAGE


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9

PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIvE TREATMENT

Afterthestorageperiodandbeforestartinguptheengineandpreparingitforoperation,youneedtoperformcertainoperationstoensuremaximalefficiencyconditions.

1 - Removetheprotectivesheet.2 - Removeanysealingdevicesfromtheexhaustandintakeducts.3 - Useaclothsoakedindegreasingproducttoremovetheprotectivetreatmentfromtheexternalparts.5 - Injectlubricatingoil(nomorethan2cm3)intotheintakeducts.6 - Adjustthealternator/fanbelttension(ifpresent).7 - Turntheenginemanuallytocheckthecorrectmovementandsmoothnessofthemechanicalparts.8 - Refillthetankwithfreshfuel.9 - Makesurethattheoilisuptothemaximumlevel.10 - Starttheengineandaftersomeminutesbringitto¾ofthemaximumspeedfor5-10minutes.11 - Turnofftheengine.12 - Removetheoildrainplug(see“Oilreplacement”)anddischargetheAGIPRUSTIANTprotectiveoilwhiletheengineishot.13 - Pournewoil(see"Tableoflubricants")uptothemaximumlevel.14 - Replacethefilters(air,oil,fuel)withoriginalspareparts.

Caution - Warning

Over time, a number of engine components and lubricants lose their properties, so it is important considering whether they need replacing, also based on age (see Replacement table).

Important

Maximum every 24 months of inactivity, the engine must be started up by repeating all "Engine Storage" operations.

Storage


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-404020252525610102010525

25

106035101010451604025151010102540252520103025128÷10151045401225102053030302520252525

-8x1.018x1.58x1.258x1.258x1.258x1.256x1.06x1.06x1.08x1.256x1.05x0.88x1.25

8x1.25-

6x1.010x1.510x1.56x1.06x1.06x1.010x1.514x1.514x1.58x1.258x1.258x1.258x1.258x1.258x1.2510x1.58x1.258x1.258x1.256x1.08x1.2512x1.510x1.58x1.2510x1.56x1.010x1.514x1.510x1.012x1.58x1.08x1.255x0.88x1.258x1.2510x1.58x1.258x1.258x1.258x1.258x1.25

Loctite270

Loctite495Loctite270


Loctite270Loctite270Loctite270

10 TORQUE SPECIFICATIONS AND USE OF SEALANT

Table of tightening torques for the main components

Vibration-dampingtanksupportConnectingrodInjectionpumpdeliveryvalveunionRockerarmcoverCentermainbearingsupportIntakemanifoldExhaustmanifoldAirshroudAcceleratorcoverGovernorcontrolcoverAirconveyorshroudAlternatorcableclampHighpressurefuellineclampAircleaner

HydraulicpumpflangeAirconveyorshroudgasketHeadinjectorCamshaftgearOilpumpgearAirconveyorsheetInternaloilfilterpiercedplateBreathersheetStartingmotorBlowerhubNipplradiatorRockerarmshaftInjectionpumpcontrolleverpivotSpeedgovernorexternalcontrolleverpivotExternalstopcontrolleverpivotGovernorspringlowerleverpivotGearcoverplateEnginemountingfootFuelfeedingpumpInjectionpumpOilpumpNozzleholderOilpanOilpressureswitchStartermotorfixingstudFuelliftpumpfixingstudCylinderheadfixingstudCoolingfanguardStartingpulleyFuelfilterunionFuelliftpumpunionHighpressurefuellineunionFuelbleedinglineunionVoltageregulatorR.p.m.counterdrivinggearMainbearingsupport,gearcasesideMainbearingsupport,flywheelsideCentermainbearingsupportAirconveyorsupportHydraulicpumpgearsupportInjectionpumpcontrolleversupportGovernorleversupport(camshaftseal)Governorforksupport

POSITIONDiam. and pitch

( mm )Torque( Nm ) Sealant


- 83 -

8x1.255x0.88x1.25

14x1.510x1.56x1.016x1.520x1.5

30715

405510160300

Loctite242


10

FueltankbracketAlternatorstatorCrankaselubrificationplug

OildrainplugCylinderheadBlowerCoolingfanhubfixingscrewFlywheel

Torque specifications and use of sealant

POSITION Diam. and pitch( mm )

Torque( Nm ) Sealant


- 84 -

M3M4M5M6M8M10M12M14M16M18M20M22M24M27M30

R>400N/mm2 R>500N/mm2 R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2

Nm0,71,53513254368105145205275355525725

Nm0,61,42,84,71223406398135193260333500680

Nm0,91,83,86,316315484131181256344444656906

Nm12,24,57,51937651011582183084135337881088

Nm1,42,961025498613521029041055071010501450

4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9

Nm0,51,12,33,89,418325179109154206266394544

Nm1,94,18,5143569120190295405580780100015002000

Nm2,34,910174183145230355485690930120018002400

M8x1M10x1M10x1,25M12x1,25M12x1,5M14x1,5M16x1,5M18x1,5M18x2M20x1,5M20x2M22x1,5M24x2M27x2M30x2

R>400N/mm2 R>500N/mm2 R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2

Nm10212036385684122117173164229293431600

Nm142826484575113163157230218305390575800

Nm132624454270105153147213204287367533750

Nm1735335956941412031962882733814887191000

Nm20423971681131692442353453274585858631200

Nm275652959015022532531346043661078011501600

Nm387973135125210315460440640615860110016002250

Nm4595881601502503805505307707401050130019502700

4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9

10

Table of tightening torques for standard screws (coarse thread)

Resistance class (R)

Quality/Dimensions

Diameter

Table of tightening torques for standard screws (fine thread)

Quality/Dimensions

Resistance class (R)

Diameter

Torque specifications and use of sealant


- 85 -

1460-285

1460-024

1460-119

1460-047

3

1

2

7560-4000-052

11SPECIAL TOOLS

SPECIAL TOOLS DESCIPTION Part N°.

Special tools and equipment for maintenance

Valve lowering tool for static injection timingcheck1Spacers,h=40mm2 Dialgaugeindicator3Dialgaugeextension

Statictimingtool

ToolforvalvestemO-ringassembly

Flywheelpuller

Timingcontrolgearextractorfork


- 86 -

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........................................................................................................................................................................9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03

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cod. ED0053022860

9 LD Engine Series

workshop manual · 2014-10-01 · - attach the engine to a suitable lifting device (lifting beam)....

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