Lombardini 3LD 450 Workshop Manual Download Page 1

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WORKSHOP MANUAL

Engine Series 3 - 4 LD

Summary of Contents for 3LD 450

Page 1: ...WORKSHOP MANUAL Engine Series 3 4 LD ...

Page 2: ... and without obligation LOMBARDINI srl reserves the right to make at any time changes in the engines for technical or commercial reasons These changes do not require LOMBARDINI srl to intervene on the marketed production up to that time and not to consider this manual as inappropriate Any additional section that LOMBARDINI srl will deem necessary to supply some time after the main text shall be ke...

Page 3: ...NGINE TYPE AND SERIAL NUMBER Version K on the engine name plate Tel No appears on service booklet or on the website www lombardinigroup it Pls contact Service Centers for special applications GENERAL SERVICE MANUAL NOTES 1 Use only genuine repair parts Failure to use genuine parts could result in sub standard performance and low longevity 2 All data presented are in metric format dimensions are pr...

Page 4: ...nd their symptoms 13 Technical data 11 3 DISASSEMBLY REASSEMBLY 16 29 Camshaft 27 Camshaft axial clearance 25 Camshaft intake and exhaust cam height 28 Camshaft intake and exhaust cam timing 27 Camshaft pin and housing dimensions mm 28 Clearance volume 23 Connecting rod equipped with bearings and piston pin 24 Connecting rod big end bearings 24 Cylinder and piston 22 Decompression by request 18 Di...

Page 5: ...12 V 14 A electrical ignition diagram with voltage regulator battery recharge lamp and manostat 36 12 5 V 14 A alternator battery recharge curve 36 12 5 V 14 A alternator 36 Bosch DW L 12 V 1 1 KW type starting motor 37 Bosch JF L 12V 2 5 kW type starting motor 38 Characteristic curves for Bosch DW L 12V 1 1 kW type starting motor 38 Characteristic curves for Bosch JF L 12V 2 5 kW type starting mo...

Page 6: ...environments containing flammable materials explosive atmospheres or easily combustible powders unless adequate and specific precautions have been taken and are clearly stated and certified for the machine To prevent the risk of fire keep the machine at a distance of at least one metre from buildings or other machines Children and animals must be kept at a sufficient distance from the machine to p...

Page 7: ...the machine e g Startpilot systems which utilise ether etc Before carrying out any work on the engine turn it off and allow it to cool down Do not perform any operation while the engine is running Check that the discharged oil the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment Close the fuel tank filler cap carefully after each fílli...

Page 8: ...oducts Use the oils and greases recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a dut...

Page 9: ... 9 Workshop Manual_3 4 LD_cod ED0053025560_4 ed_ rev 03 ...

Page 10: ... 10 2 Workshop Manual__3 4 LD_cod ED0053025560_4 ed_ rev 03 MANUFACTURER AND MOTOR IDENTIFICATION DATA TECHNICAL INFORMATION ...

Page 11: ...ume at 3000 rpm Cooling air volume at 3000 rpm Max axial load permissible for drive shaft in two directions instantaneous Max inclination extended to 1 h permanent It stands for power It stands for NB power It stands to NB power at 2600 rpm According to the application D at 2600 rpm Note For LDA 450 LDA 510 LDA 96 LDA 97 LDA 820 out of production engines the repair specifi cations are equal to tho...

Page 12: ... heavy duty services at constant rpm and load The above mentioned power levels refer to the engine equipped with air filter standard silencer suction fan which previously underwent a breaking in period at 20 C ambient conditions at 1 bar The maximum power is guaranteed with a 5 tolerance These powers are reduced of abt 1 every 100 m height and of 2 for every 5 C exceeding 25 C C NB Specific fuel c...

Page 13: ...kage from the exhaust TROUBLE Black smoke White smoke Cylinder head gasket M A I N T E NANCE Clogged pipings Clogged fuel filter Presence of air in the fuel circuit Clogged tank breather Faulty fuel pump Blocked injector Blocked injection pump valve Wrong injector setting Plunger excessive leakage Stuck injection pump delivery control Wrong injection pump delivery setting High oil level Blocked pr...

Page 14: ...uctions INTERVALS HOURS OPERATION DETAIL 10 50 125 250 500 1000 2500 5000 AIR FILTER OIL BATH CLEANING HEAD AND CYLINDER FINS FUEL TANK INJECTORS AIR FILTER OIL CHECK LEVEL SUMP OIL BATTERY LIQUID FUEL HOSE COUPLING FASTENING VALVE AND ROCKER ARM CLEARANCE INJECTOR SETTING AIR FILTER CHANGE SUMP OIL FILTER CARTRIDGE FUEL FILTER CARTRIDGE OVERHAUL PARTIAL GENERAL First replacement In particular run...

Page 15: ...able to one with a preceding letter or number An SF oil for instance is more performing than a SE oil but less performing than a SG one LUBRICANT SAE Classification In the SAE classification oils differ on the basis of their viscosity and no other qualitative characteristic is taken into account The first number refers to the viscosity when the engine is cold symbol W winter while the second consi...

Page 16: ...ling ring 2 Filtering mass made 5 Filterning mass of polyurethan 3 Internal sealing ring 6 Bowl Silencer standard Danger Attention Allow the exaust manifold to cool before demounting it in order to preventscorchingand burns Make sure that it is free from any carbon and oily residues if contaminated replace it While reassembling it replace the gaskets and tighten the brass nuts at 25 Nm RECOMMENDAT...

Page 17: ... for 3LD 450 3LD 450 S 3LD510 3LD 510 s and at 350 Nm for 4LD 640 4LD 705 4LD 820 Note The flywheels of the left hand engines 3LD 451 S 3LD 510 S have a blading turned in the opposite direction and the nut 1 shall be anticlockwise unscrewed Vent plug Components 1 Vent plug and oil refiling 2 O ring 3 Diaphragm Starting pulley In order to carry out any easier staring it is necessary to place the dr...

Page 18: ...aft The engine rocker arm cover can be equipped with a decompression device which compresses the exhaust valve at the TDC top dead centre lowering it of abt 1mm during the starting phase The lowering is adjusted by the gaskest thickness 2 Make sure that the lever turns for abt half a stroke before it actuates the valve Warning The use of decompression to stop the engine may cause serious damages R...

Page 19: ...on of the nozzle ends A with respect to the head surface shall be 2 5 3 mm for 3LD 450 3LD 451 S 3 3 5 mm for 3LD 510 3LD 510 S 3 5 4 mm for 4LD 640 4LD 705 4LD 820 Adjust by means of a copper gasket B having a thickness of 0 5 mm 1 mm 1 5mm Head Do not disassemble while it is hot as to avoid any possible distortion If the head surface is distorted smooth it by removing up to 0 3 mm thickness Alwa...

Page 20: ...necessary to increase the housing C of 0 5 mm for the assembly Valve guides insertion Heat the head at 160 180 Force the guides according to A and B distance with respect to the head surface 3LD 450 3LD 451 S 3LD 510 3LD 510 S A 30 80 31 2 B 18 8 19 2 4LD 640 4LD 705 4LD 820 A 35 8 36 2 B 17 8 18 2 Note if the guides are supplied with the housing for the lock ring C insert the ring then drive the ...

Page 21: ...12 D 31 10 31 12 4LD 640 4LD 705 4LD 820 mm A 42 99 43 01 C 36 99 37 01 B 43 12 43 14 D 37 10 37 12 Drive the seats in the housings and mill at 45 Valve seat grinding After milling grind with fine emery paste in engine oil bath The S sealing surface shall not exceed 2 mm Embed valves D after grinding for 3LD 450 3LD 451 S 3LD 510 3LD 510 S 0 55 1 05 mm for 4LD 640 4LD 705 4LD 820 0 45 0 95 mm ...

Page 22: ... pin picture 25 Remove the piston rings and clean the slots Replace the piston as well as the segments in case the dia wear exceeds 0 05 mm as regards to the minimum value prescribed Dimensions mm Note Even if 3LD 450 3LD 450 S and 3LD510 3LD510 S pistons have the same bore they differ in other dimensions thus they are not interchangeable ENGINES Distance among segment ends mm Insert the piston ri...

Page 23: ...ubricate the following parts with oil before mounting the piston pin the piston the cylinder and the big end bearing Couple the piston with the connecting rod thus the combustion chamber centre B is perpendicularly under end A of the nozzle housed inside the head Lubricate the piston pin and insert it in the piston lightly pressing with your thumb Make sure that the two stop rings are well housed ...

Page 24: ...d to 0 25 and 0 50 mm Connecting rod big end bearings While reassembling the A and B centering marks should not be on the same side Tighten the screws at 30 Nm for 3LD 450 3LD 451 S 3LD 510 3LD 510 S and at 45 Nm for 4LD 640 4LD 705 4LD 820 Main bearing on flywheel side Extract the bearing using three screws as per picture 38 While reassembling replace gasket 1 Check that the oil seal ring is inta...

Page 25: ... 640 4LD 705 4LD 820 picture 41 4 Port 5 Gasket 6 Ball bearing Fix the port at its base at 40 Nm Camshaft axial clearance Carry out this check before assembling the head Fix the side distributor port or bell 1 at 25 Nm Remove the intake and exhaust tappets and with an implement operate on the camshaft forward and backward in an axial direction The axial clearance A shall be A 0 20 0 60 mm 3LD 450 ...

Page 26: ...s Caution Warning Always wear protective goggles if compressed air is used Remove the caps clean the ducts A and B with a point and blow them with compressed air Replace the caps by caulking them on their seat then check their seal Drive shaft connecting radius R 3 mm R1 3 5 mm Note When the main journal and the crank are ground it is essential to reset R and R1 values in order to avoid any possib...

Page 27: ...070 A B C D see picture 45 E A 0 065 0 080 worn limit 0 16 F B 0 051 0 10 worn limit 0 18 G C 0 45 0 080 worn limit 0 16 CAMSHAFT Components 1 Base side pin 2 Intake cam 3 Injection cam 4 Exhaust cam 5 Gear 6 Side distributor port pin Note The two engine series 3LD 450 3LD 510 and 4LD 640 4LD 820 have the same camshaft it differs in 3LD 451 S and 3LD 510 S left handed engines Camshaft intake and e...

Page 28: ...thus the intake cam B and the exhaust cam C are well balanced while the intake opens the exhaust closes Insert the respective tappets D and E Carry out the check the intake D and exhaust E tappets laid on their cams shall be at the same level F Distribution timing assemble the camshaft gear by coinciding reference 1 with reference 2 of the gear camshaft key Camshaft intake and exhaust cam height T...

Page 29: ...spring with two plates 4 energized by the accelerator control 5 opposes the action of the governor cetrifugal force The balance between the two forces keeps the rpm rate constant with the change of load Timing of the speed governor Adjust the injection pump control lever 1 thus when the governor is closed it is placed at distance A as to the external surface of the base Loosen the screw 2 Close th...

Page 30: ...an 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...

Page 31: ... Screw 3 Spring Tighten the support at 25 Nm For 4LD 640 4LD 705 4LD 820 see picture 64 1 Support 5 Spring 2 Gasket 6 Flange 3 Valve support 7 Plate 4 Ball 8 Screw Tighten the support at 40 Nm Oil filter cartridge Componens 1 Gasket 5 Bowl 2 Assembly 6 By pass valve 3 Antidrainage rubber cap 7 Spring 4 Filter element Features Maximum operating pressure 7 bars Maximum operating temperature 25 150 C...

Page 32: ... curve with the engine at its maximum speed It is shown on the filter and obtained with the engine at 3000 rpm at N power the pressure is expressed in bars and the temperature in degrees Celsius The curve represents the pressure minimum value while its maximum value is 5 bars The minimum oil pressure 1200 rpm with the oil temperature at 100 C shall not be lower than 0 8 bars Note When the engine h...

Page 33: ...carried out with the eccentric 4 at rest The projection A of rod 3 is 0 8 1 2 mm it shall be adjusted with the following supplied gaskets having a thickness of 0 50 0 80 and 1 0 mm Rod length 65 4 mm for 3LD 450 3LD 450 S 3LD 510 3LD 510 S and 75 2 mm for 4LD 640 4LD 705 4LD 820 Fuel filter inside the tank standard Details 1 Spring 6 Gasket 2 Disk 7 Cover 3 Ring 8 Ring 4 Cartridge 9 Bolt 5 Gasket ...

Page 34: ...e the engine revs out Assemble the collar 20 the tappet 13 with rollers 14 15 and pin 16 While pressing on the tappet insert the pin 19 and the ring 17 Advanced injection static Disconnect the diesel oil thrust pipe fitting being careful not to loosen also the pump delivery fitting 1 then screw the tester for the advanced injection check 2 Fill the tank checking that the fuel level is at least 10 ...

Page 35: ...Injector Components 1 Ring nut 2 Nozzle 3 Needle 4 Fitting 5 Nozzle bearing 6 Pressure rod 7 Spring 8 Spring seat 9 Union 10 Ring nut Setting Connect the injector to a manual pump and check that the setting pressure is 190 200 bars If necessary adjust actuating the union 9 While replacing the spring the setting shall be carried out at a pressure higher than 10 bars 200 210 bars in order to counter...

Page 36: ...tteries which are not supplied by Lombardini shall have a 12 V voltage and the following capacity 3LD 450 3lD 451 S 3LD 510 3LD 510 S 45 Ah 4LD 640 55 Ah 4LD 705 66 Ah 4LD 820 70 Ah 12 5 V 14 A alternator battery recharge curve It is carried out at 25 C ambient temperature 12 5 V battery voltage 12 5 V 14 A alternator It is equipped with a fixed rotor assembled on the main journal while the pivoti...

Page 37: ...s until the battery voltage goes down to 13 V When the battery voltage reaches 14 5 V the ammeter current will drop to a value near zero If the voltage is lower than 14 V and the recharge current is zero replace the regulator Note The voltage regulator does not work when not earthed and the battery is completely discharged Warning when the engine runs do not remove the battery cables and do not ta...

Page 38: ...ic circuit Characteristic curves for Bosch DW L 12V 1 1 kW type starting motor Characteristic curves for Bosch JF L 12V 2 5 kW type starting motor Bosch JF L 12V 2 5 kW type starting motor For 4LD 640 4LD 705 4LD 820 Anticlockwise rotation seen from the pinion side A 23 25 mm ...

Page 39: ... the screw 2 stays in the centre of the slot Tighten the screws 1 and 2 Carry out the exhaust smoke check as it follows Abruptly start the accelerator at idle In case of a quick pickup with light exhaust smoke to the Bosch scale index 3 this means that the limiting device is correctly adjusted In case of a slow pickup without smoke move the limiting device towards the left pumping duration increas...

Page 40: ...al to change the balance conditions measured on the brake operating either on the load and on the regulator When the engine is steady carry out the consumption check again 5 Move the limiting device 3 towards the right as per picture 88 until the engine rpm number descreases Lock the limiting device by means of the two screws 6 Completely release the brake and check the rpm at which the engine set...

Page 41: ...e not available find an equivalent product with specifications MIL L 21260C Maximum every 24 months of inactivity the engine must be started up by repeating all Engine Storage operations PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT After the storage period and before starting up the engine and preparing it for operation you need to perform certain operations to ensure maximal effi...

Page 42: ...ributor side port Oil pressure switch Starting pulley Main bearing on flywheel side Sump oil drain bolt Cylinder head Flywheel 3LD 450 3LD 510 3LD 450 S 3LD 510 S MAIN DRIVING TORQUES MAIN DRIVING TORQUES 4LD 640 4LD 705 4LD 820 40 30 250 25 80 20 10 30 25 25 20 15 60 40 40 25 25 35 35 25 35 50 170 POSITION Torque Nm Dia Pitch mm REFERENCE Picture NO 18x1 5 8x1 25 14x1 5 8x1 25 16x1 5 8x1 25 6x1 8...

Page 43: ...m Nm M 8x1 10 14 13 17 20 27 38 45 M 10x1 21 28 26 35 42 56 79 95 M 10x1 25 20 26 24 33 39 52 73 88 M 12x1 25 36 48 45 59 71 95 135 160 M 12x1 5 38 45 42 56 68 90 125 150 M 14x1 5 56 75 70 94 113 150 210 250 M 16x1 5 84 113 105 141 169 225 315 380 M 18x1 5 122 163 153 203 244 325 460 550 M 18x2 117 157 147 196 235 313 440 530 M 20x1 5 173 230 213 288 345 460 640 770 M 20x2 164 218 204 273 327 436 ...

Page 44: ...conveyor Stud bolt for clamping on engine flange bell Rocker arm fulcrum pin for injection pump control Bracket clamping screw on side plates Stud bolt for clamping at feeding pump POSITION USE OF DOPE FOR 3LD 450 3LD 510 3LD 451 S 3LD 510 S POSITION Bearing on port or bell Regulating pin threading Stud bolt for clamping on engine head Stud bolt for clamping on main bearing on flywheel side Stud b...

Page 45: ... 45 Workshop Manual_3 4 LD_cod ED0053025560_4 ed_ rev 03 ...

Page 46: ... 46 Workshop Manual__3 4 LD_cod ED0053025560_4 ed_ rev 03 ...

Page 47: ... 47 Workshop Manual_3 4 LD_cod ED0053025560_4 ed_ rev 03 ...

Page 48: ...bardini behält sich alle Rechte vor diese Angabe jederzeit zu verändern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación 42100 Reggio Emilia Italia ITALY Via Cav del Lavoro Adelmo Lombardini 2 Cas Post 1074 Tel 39 0522 3891 Telex 530003 Motlom I Telegr Lombarmotor R E A 227083 Reg Impr RE 10875 Cod fiscale e Partita IVA 01829970357 CEE Code IT 0182997...

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