Lombardini LDA 422 Workshop Manual Download Page 83 | Manualshive

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83

REG. CODE

1-5302-596

MODEL N°

50881

DATE OF ISSUE

15-05-2003

REVISION

00

DATE

15-05-2003

ENDORSED

COMPILER TECO/ATI

XI

M 10x1

M 14x1,5

M 22x1,5

M 6
M 6

M 14x1,5

M 10x1,25

M 8
M 6
M 6
M 6
M 6
M 8
M 8
M 6

M 10

M 12x1,5

M 6
M 8
M 6

M 22x1,5

M 6

M 10x1.25

M 6

M 14x1,5

M 8

M 10x1,25

M 8

M 24

M 8

M 12x1,25

M 8
M 6
M 8
M 6
M 6
M 6
M 6

M 26x1,5
M 12x1,5

M 5
M 7
M 5

M 10

70

180÷200
120÷140

8

10

120÷140

65÷70
20÷22

8
8
8
8

20÷22
20÷22

8

40÷44

22

20÷22
25÷30

8

45÷50

8

40 Nm + 180°

8

15

20÷22
70÷75
25÷28
60÷80

30
15

20÷22

8

19÷21

8
8
8
8
6

18÷22

4

12

4

40

MAIN TORQUE SPECIFICATIONS

POSITION

Torque

( Nm )

Diam. and pitch

( mm )

Connecting rod cap fixing nut
Flywheel fixing screws
Clutch – flywheel fixing screws
Fan – alternator rotor fixing screws
Clutch disk pusher fixing screw
Primary ring gear of gear box fixing screw
Differential ring gear fixing screws
Half crankcases assembly screws
Clutch housing fixing screws
Clutch cover fixing screws
Axle shaft hood flange fixing screws
Shift-select lever case fixing screws
Shift-select lever case fixing screws
Fan volute fixing screws
Air shroud cover fixing screws
Belt tensioner fixing nut
Oil pressure switch
Starter motor fixing screws
Cylinder head – exaust system fixing screws
Guard tile fixing screws
Oil termal switch
Air shroud fixing screws
Cylinder head fixing nuts
Timing belt cover fixing screws
Cylinder head fixing stud bolt
Cam shaft carrier fixing screws
Oil pump fixing screws
Timing belt gear fixing screw
Injection timing fixing screws
Injector
Injection pump fixing screws
Spark plug
Feed pump fixing nuts
Tappet cover fixing screws
Cylinder head exhaust manifold fixing nuts
Dipstick tube fixing screw
Clamp for starter motor fixing screws
Starter motor to clamp fixing nuts
Oil duct plugs
Injector – injection pump connecting pipe
Stator to volute fixing screws
Piston cooling valve
Plug wire fixing nut

Setting up with belt driven alternator

Bracket to crankcase fixing screws

MAIN TORQUE SPECIFICATIONS

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85
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Summary of Contents for LDA 422

Page 1: ...1 LDA 422 REG CODE 1 5302 596 MODEL N 50881 DATE OF ISSUE 15 05 2003 REVISION 00 DATE 15 05 2003 ENDORSED COMPILER TECO ATI WORKSHOP MANUAL LDA 422 engines code 1 5302 596 1st Edition ...

Page 2: ......

Page 3: ... engines have been adequately trained and outfitted to safely and professionally carry out the necessary tasks 2 the persons who service Lombardini engines possess the necessary skills and special Lombardini tools to safely and professionally carry out the necessary tasks 3 the persons who service Lombardini engines have read the specific information concerning the above mentioned Service operatio...

Page 4: ...et support Camshaft extraction Camshaft oil seal and timing pulley Camshaft support Check of tappets clearance Clearance A on assy mm Clutch Clutch assembly Clutch side housing half Clutch side housing half Disassembling of gearbox shaft roller case and multiple gear ball bearing Connecting rod Connecting rod small end bush Cooling fan flywheel Coupling pinion Crankcase half flywheel side Cranksha...

Page 5: ...n pump Injection pump Injection pump MICO type F 002 F 10 006 Injection pump and check static injection advance Injection pump control cam INJECTOR Injector MICO F 002 C 6 Z 396 Injector setting Injector fireproof bulkhead LUBRICATION SYSTEM DESCRIPTION Magneto positioning on the governor Main features of electrical starter Mass play axial play and adjusting spacers Measure execution for determina...

Page 6: ...es Shim thickness for tappet gap adjustment Small end bush wrist pin Speed gear control box Tappet Tappet disassembling Then check injection advance tinning as follows Timing gear and speed gear control box Timing pulley Timing pulley and camshaft sealing ring Valve guide valve stim Valve seat Valves inside spring Valves outside spring Valves caps Valves grinding X TOOLS XI MAIN TORQUE SPECIFICATI...

Page 7: ...s who may be in the vicinity of the machine The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and the deriving dangers This condition is also essential when it comes to routine and above all extraordinary maintenance operations which in the latter case must only be carried out by persons specifically trained by Lombardini and who wo...

Page 8: ...e engine is running The coolant fluid circuit is under pressure Never carry out any inspections until the engine has cooled and even in this case only open the radiator plug or expansion chamber with the utmost caution wearing protective garments and goggles If there is an electric fan do not approach the engine whilst it is still hot as the fan could also start operating when the engine is at a s...

Page 9: ...system fins Inadequate engine oil level Check and if necessary replace Purge by operating the fuel pump lever Replace Detect the problem and if necessary overhaul or replace Check and if necessary replace Check and if necessary replace Check and if necessary replace Clean and if necessary replace Replace Check and time correctly Verify fuel filter check injection and fuel pumps efficiency Check th...

Page 10: ...ke Weak return spring Worn or burnt driven disk gasket SPEED GEAR SPONTANEOUS GEAR DISENGAGEMENT Worn or damaged gearbox Incorrectly adjusted control rod Wrongly assembled or worn gearbox or coupling spider gears VIBRATIONS TRANSMITTED FROM ENGINE TO FRAME The silent blocks anchoring the engine to the frame are not locked correctly or are damaged Heat the engine for few minutes at low speed Check ...

Page 11: ... machine and or system LDA 422 ENGINE MAINTENANCE INTERVAL KM OPERATION CLEANING CHECK REPLACEMENT Dry type air filter Injector Cooling system fan guards fins Valve clearance Water in the fuel filter Integrity of propeller shaft boot Low pressure fuel lines Clutch pedal stroke Bolts and nuts correct fastening Glow plug performance Injection Advance Injector calibration Engine oil Oil filter Fuel f...

Page 12: ...596 MODEL N 50881 DATE OF ISSUE 15 05 2003 REVISION 00 DATE 15 05 2003 ENDORSED COMPILERTECO ATI III MODEL NUMBER AND IDENTIFICATION Displacement cc r p m Lombardini Diesel Air cooled Customer s code Engine serial number ...

Page 13: ...0 R P M 1 Fuel consumption Oil quantity without oil filter Oil quantity with oil filter Dry weight TECHNICAL DATA LDA 422 ENGINE MAIN SPECIFICATIONS 4 stroke single cylinder engine Indirect injection Diesel cycle type Forced air cooling system Differential gear and gearbox assembly on rear axle OHC axle driven by toothed belt Lubrication is made through a lobe pump controlled by driving shaft chai...

Page 14: ... Components 1 Air cleaner paper filtering cartridge 9 Fuel return pipe from injector 2 Induction duct 10 Return pipe to tank of exceeding fuel 3 Induction valve 11 Preheating plug 4 Fuel tank 12 Piston 5 Fuel feed pump 13 Cylinder 6 Fuel filter 14 Camshaft 7 Injection pump 15 Delivery adjusting rod 8 Injector 16 Fuel delivery regulator unit ...

Page 15: ...15 REG CODE 1 5302 596 MODEL N 50881 DATE OF ISSUE 15 05 2003 REVISION 00 DATE 15 05 2003 ENDORSED COMPILER TECO ATI VI LUBRICATION SYSTEM ...

Page 16: ...DATE 15 05 2003 ENDORSED COMPILERTECO ATI VI LUBRICATION SYSTEM CYLINDER VALVE FOR PISTON COOLING CRANKSHAFT CYLINDER HEAD OIL SUMP CONROD CAMSHAFT GOVERNOR OIL PRESSURE VALVE OIL FILTER OIL PUMP OIL PICK UP LDA 422 OIL CIRCUIT DIAGRAM CYLINDER HEAD OIL VALVE CAMSHAFT SUPPORT ...

Page 17: ... REG CODE 1 5302 596 MODEL N 50881 DATE OF ISSUE 15 05 2003 REVISION 00 DATE 15 05 2003 ENDORSED COMPILER TECO ATI VII TIMING DIAGRAM Timing diagram Data concern 1 mm cold play between tappets and valves ...

Page 18: ...DESCRIPTION The engine cooling is carryed out by means of air blown by the centrifugal fan attached on the flywheel on the cylinder head unit The heat is removed from the cylinder and cylinder head through the appropriate finning of themself Moreover particularly in the cylinder head area close to the exaust valve seat and to the pre combustion chamber the heat is removed by the lubrication oil as...

Page 19: ...re parts for a correct repair First drain the engine oil through the drain hole then remove the negative cable from the battery the electric cables from the alternator flywheel and from the starting motor the fuel pipes the controls of accelerator braking lights speed gear clutch etc remove the inlet boot and the aprons Oil filter and cooling covers and starting motor Install the engine gear box a...

Page 20: ...r Fig 9 housing to fix the flywheel remove the flywheel retaining screw using a 22 mm socket wrench and extract the cone and remove the flywheel Fig 11 using extractor 981075 420 equipped with component 984651 457 NOTE After extracting the cone if flywheel removal should prove difficult use extractor 981075 418 Fig 14 Belt cover and fan scroll After removing the belt cover Fig 15 unscrew the 6 scr...

Page 21: ...he belt tensioner and clamp it up high as shown remove the timing belt Fig 21 22 and the oil dipstick Fig 23 by removing the 3 coupling screws Loosen the timing pulley fastening bolt so that it can turn freely on the shaft Drive shaft clamping Disassemble the clutch then fit clamping hub 5900 217 together with component 8430 124 on the drive shaft and refer to the key for the clutch assembly Fig 2...

Page 22: ...n the belt Then tighten the belt tensioner nut with a 40 40 4 Nm torque Fig 29 Tighten the camshaft pulley to 70 Nm then fit again the safety washer on the bolt Fig 30 31 Now remove both pins to allow the shafts to turn plug the hole on the camshaft support with the washer and the plug Fig 32 33 Use the flywheel to rotate the engine for 2 3 revs thus bedding the belt Remove the clamping hub of the...

Page 23: ...let it slide downwards and tighten it again to the rated torque then re check the tension When removing the timing belt you must replace it even though its scheduled life spar is not over Injector fireproof bulkhead Remove the tappets cover Fig 38 Wher disassembling the injection tube keep the injection pump fitting clamped using a 19 mm wrench Fig 39 Assemble 981075 413 extractor in place of the ...

Page 24: ...trol rod and extract the pump Remove the injection tappets with the related collar housed inside it Fig 45 46 Governor assembly Unscrew the 5 bolts Fig 47 and remove the governor assembly Fig 48 Injection advance variator Unscrew the fixing bolt using a 14 mm wrench use extractor 981075 421 and turn the screw to remove the weights while keeping the central hexagon clamped Fig 51 puller 981075 421 ...

Page 25: ...xtraction Turn the shaft and position the cam lobe to coincide with the opening provided for it Fig 57 Repeat the procedure on the second cam lobe to extract the shaft completely Fig 58 Timing pulley and camshaft sealing ring Straighten the retaining washer unscrew the bolt and remove the timing pulley Fig 54 Remove the sealing oil ring use a screw driver Fig 55 the snap ring use pliers for intern...

Page 26: ...upport and the fuel supply pump control rod By using the appropriate wrench unscrew the coupling screws to the head and remove the camshaft support Tappet disassembling Mark the tappets and the adjustment shims making sure that they are reassembled in the same position The collar surface on which the shim identification code is indicated shall be assembled facing the tappets socket DISASSEMBLY REA...

Page 27: ...0 DATE 15 05 2003 ENDORSED COMPILER TECO ATI 67 68 69 IX Cylinder head Unscrew the 4 retaining nuts Fig 67 extract the cylinder head assembly Fig 68 and remove the gasket Fig 69 When reassembling always replace the cylinder head gasket with a new one DISASSEMBLY REASSEMBLY ...

Page 28: ...ol 981075 412 to clamp the ring gear and unscrew the bolt Fig 79 N B When reassembling the bolt shall be locked by using the same tool Clutch Disassemble the cover Figg 70 71 and place the stop key 985110 039 Using pliers extract the snap ring then remove the clutch pressure plate Unscrew the nut Figg 73 74 use extractor 981075 419 and extract the clutch by turning the central screw Fig 76 puller ...

Page 29: ...aft gear Fig 84 85 Using tool 981075 425 together with component 984651 457 extract the cone Fig 81 and remove the ring gear Fig 82 Oil pump gear and oil pump Hold the oil pump control gear using a screwdriver and unscrew the lock bolt Fig 86 then remove the chain Fig 87 Unscrew the two bolts which secure the oil pump Fig 88 and extract the oil pump noticing the correct sequence for reassembly see...

Page 30: ...o the cylinder head 5 to camshaft support 9 and to the journal bearings 10 the oil is filtered through a total flow filter cartridge 11 In case of obstruction of the filter an internal by pass valve 12 opens up Nearby on the clutch side crankshaft support a nozzle with a closing valve is fixed These nozzle valve is preset and has the function of cooling the piston through its oil jet and to lubric...

Page 31: ... from their seat by means of a screwdriver Fig 95 96 then extract the wrist pin Fig 97 Oil pressure regulating valve Remove the snap ring extract the spring and the by pass valve Check for possible dirt build up in the ducts and for good spring condition Timing gear and speed gear control box Remove the timing gear Fig 98 Unscrew the 5 fastening bolts and remove the speed gear control box Fig 99 D...

Page 32: ...figure and separate the two housing halves by hitting with a mallet Crankshaft Reverse shaft Gearbox shaft Multiple gear Differential gear assembly Remove reverse gear 1 Fig 102 gearbox shaft 2 multiple gear 3 crankshaft 4 andremovedifferentialgearassembly 5 usingextractor981075 411 which is provided Fig 107 108 When reassembling the shoulder washerswhicharelocatedbetween drive shaft and flywheel ...

Page 33: ...the multiple gear A and with an external Ø of 36 mm for roller case of the gear shaft B external diameter mm 36 external diameter mm 24 Clutch side housing half Disassembling of gearbox shaft roller case and multiple gear ball bearing Assemble puller 981075 415 onto the gearbox shaft roller case and work on the central nut until the extraction is completed Fig 112 Remove the snap ring D work on th...

Page 34: ...h is connected with the speed control lever 14 The lever 15 which is connected to the engine stop control 16 acts on the lever 4 and then on the injection pump control rod 7 On the governor box a magnet 18 is fixed its function is to keep the lever 4 in the position of supplementary flow at the engine start position The lever 6 pushcs on the regulation screw 19 that puts in a correct position the ...

Page 35: ...E 15 05 2003 REVISION 00 DATE 15 05 2003 ENDORSED COMPILER TECO ATI IX FIG 1 FIG 2 DISASSEMBLY REASSEMBLY The governor main functions are the following Engine low idling speed adjustment Engine maximum RPM limitation Delivery increase during start up ...

Page 36: ...0 Maximum RPM governor spring 11 Delivery control screw 12 Adjustment spring container 13 Adjustment lever 14 Magnet Remove the snap ring extract pin 7 disassemble the adjustment lever rod control lever 4 spacers F and shim washers G which are located between the two levers when assembling follow the correct sequence Remove the cover by way of the 6 retaining screws Remove retainer A cap B and idl...

Page 37: ... holding the lever in extra fuel position Fig 122 If the spring holder shaft for maximum RPM governing has to be replaced use a pin driver punch as shown in Fig 126 When reassembling follow a reverse sequence than the above described one Delivery regulator reassembly When reassembling is completed check the axial endfloat of Z shaft using the special no studbolts tool 981075 417 which comprises a ...

Page 38: ...ion The magnet with the help of the supplementary spring keep in the maximum fuel flow position the control rod until the engine has not reached about 2000 rpm When the engine exceed 2000 rpm the flyweight centrifugal force exceed the spring and magnet force so open the flyweight that shift by means of the slider i the control rod lever and then the pump connecting rod i to lower fuel flow positio...

Page 39: ...that means that the movements of the accelerator lever produce proportional mouvements of the pump connection rod At intermediate engine speed the governor generate a load that compress partially the flow adjusting spring moving the rod control lever producing consequently change of the pump flow against change of rpm ENGINE AT FULL LOAD Moving completely the accelerator lever until the position o...

Page 40: ... exceede the reaction of the maximum speed regulating spring the expanding flyweights move the regulating lever and the pump connecting rod towards a position of lower fuel flow If the engine continues to accelerate the flyweights continue to move until the pump connecting rod reaches the position of zero flow The governor begins to operate at about 3800 rpm and the zero fuel flow occures at about...

Page 41: ... should exceed the dimension C on the piston to be fitted marked on the piston itself by the value indicated for each part clearance on assy Piston rings Part name Diameter mm Piston ring upper Piston ring lower 83 Scraper ring assy Superiore Upper Inferiore Lower Raschiaolio Scraper N B Piston rings must be fitted with inscription Top facing piston crown and the inside spring of scraper ring must...

Page 42: ...on slot 3 020 3 040 Scraper ring 2 990 2 975 0 030 0 065 Piston Piston pin Piston A Ø 25 0 001 0 006 Piston pin B Ø 24 991 0 002 Assembling gap C Ø 0 001 0 010 Small end bush wrist pin Small end A Ø 25 006 25 009 Wrist pin B Ø 24 991 0 002 Clearance C on assy 0 013 0 020 DISASSEMBLY REASSEMBLY Connecting rod small end bush Con rod S E Bush A Ø 28 0 80 0 118 Con rod SM end B Ø 28 0 0 021 Interferen...

Page 43: ... 033 Valve stim exh and ind B 7 974 7 992 Crankshaft big end Part name Dimension mm Big end A 51 333 0 0 013 Con rod bearing half C 1 535 1 526 Crankshaft B 48 288 0 02 0 Clearance C on assy 0 023 0 059 N B Dimension of valve guide inside dia is understood to be after assembly and after machining DISASSEMBLY REASSEMBLY Denomination Valve seat chanfer angle Valve head chanfer angle Valve head diame...

Page 44: ...90 3 95 4 00 4 05 4 10 4 15 4 20 4 25 4 30 4 35 4 40 4 45 4 50 4 55 4 60 Tolerance 0 015 Tappet Tappet dia A 35 000 35 025 Tappet seat dia B 34 975 34 995 Clearance on assy C 0 005 0 050 Valves inside spring Free length L mm 41 8 Load at 31 mm heightkg 14 9 0 5 Load at 31 mm heightkg 27 4 1 2 Valves outside spring Free length L mm 53 9 Load at 36 mm heightkg 38 9 1 5 Load at 26 5 mm height kg 59 5...

Page 45: ...ter for gear needle bearing clutch side Ø 46 983 46 958 REVERSE GEAR Shaft seat Ø 18 016 18 034 Gap 0 016 0 052 Reverse gear shaft Ø 18 000 17 982 Interference Reverse gear Ø 17 944 17 962 0 056 0 020 DIFFERENTIAL HOUSING Denomination Dimensions Matching Differential box Ø 75 970 75 924 gap Differential seat Ø 76 000 76 046 0 122 0 030 CRANKSHAFT CRANKCASE BEARING HOUSING Denomination Dimensions M...

Page 46: ...the pump on the bench Adjusting lever in reference to central position r p m Delivery mm3 cycle Rack rod stroke form max delivery position 1500 23 3 0 5 9 1900 20 8 1 8 3 2250 29 1 9 5 Adjusting lever in max delivery position r p m Delivery mm3 cycle 150 45 3 5 Injection pump Caption 1 High pressure injector pump delivery pipe 2 Nut for connection to the delivery pipe 3 Spring 4 Filler 5 Valve 5 P...

Page 47: ...justments if any by changing the shim over the spring Eleven different shims are available as spares with size from 1 to 2 mm When replacing the spring setting should be performed at a 10 bar greater pressure 160 bar to allow for bedding during operation Check needle valve sealing by slowly moving the hand pump until approximately 120 bar for 10 seconds Injector sealing Seal Keep inside injector a...

Page 48: ...e spring 4 External valve spring 5 Valve guide sealing rings 6 Valve spring lower collars 7 Precombustion chamber 8 Exhaust valve 9 Intake valve Dismantling values Compress valves springs by using a valve lifting clamp as shown in fig 157 the tool was not included in the special tool set as it is commercially available take away cotters halves and release the fixture until spring and valves are re...

Page 49: ...ve a uniform surface so as to assure a perfect valve seal Otherwise carry out valves seat grinding This operation must be performed as follows with the best attention smear valves with fine emery introduce the valve in its guide and fix wrench O to the stem end Alternately maneuver the wrench by changing from time to time position Absolutely avoid that emery is introduced into valves guides When t...

Page 50: ...ced every time it is extracted Before assembling the new precombustion chamber the depth of the seat inside the head shall be measured Fig 160 161 the resulting measurement will determine the most appropriate precombustion chamber of the four of different height that are available In order to identify them each precombustion chamber is marked with a paint brush stroke in different colors according...

Page 51: ... the two rotors If the desired values are not found replace the faulty parts Oil pump Pump lobe type Pump control through a chain gear dragged by the drive shaft Pressure adjusting valves on pump body Rotor seat dia A 40 601 40 626 Rotor outside dia B 40 551 40 576 Clear bet seat and rotor C 0 025 0 075 Rotor height D 21 96 21 98 Rotor seat depth E 22 00 22 02 Side clear between rotors and pump bo...

Page 52: ...g 5 Crankshaft 6 Connecting rod cap fastening nuts 7 Connecting rod cap 8 Oil pump gear Connecting rod Remove the two retaining nuts and the connecting rod When reassembling place the connecting rod onto the crankshaft keeping the cap and connecting rod marks oriented in the same way as before the disassembling see Fig 173 Then tighten the two bolts gradually to a 70 Nm torque N B Replacement of c...

Page 53: ...provided as spare part in eight different sizes of thickness 1 750 1 830 1 910 1 990 2 070 2 150 2 230 2 310 Caption 1 Gearbox shaft with differential gear control coil 2 Speed coupling spider 3 Spacer 4 4th speed gear 5 3rd speed gear 6 2nd speed gear 7 1st speed gear 8 Reverse gear 9 Clearance ring 10 Stop ring 11 Speed control stem Gearbox shaft Remove the snap ring Q the shoulder washer P and ...

Page 54: ...screwing the gearbox coupling screws disengage the gear speed control stem from the selector switch sliding block and disassemble the gearbox Caption 1 Lever pin with P I 2 O ring 3 Sliding block 4 Selector switch 5 Elastic pin 6 Lock ring 7 Ball 8 Spring 9 Spring housing 10 Reverse sensor 11 Return spring 12 O ring 13 Safety pin 14 Lock ring 15 Pin 16 Pin 17 Lever ...

Page 55: ...r washer H and crown wheel Extract pin and remove side pinions and the other crown wheel Replace the damaged parts and reassemble by following the reverse procedure of removal Torque the 6 bolts E according to values of locking torque 55 60 Nm Differential gear box Caption 1 Differential gear ring 2 Screws 3 Differential gear pin 4 Differential gear box 5 Differential gear side pinions 6 Clearance...

Page 56: ...nd solder by the countersunk part of the hole plated cables be careful to tin penetrate into holes Fit a new plate with both brushes on which the two new brushes l should be fitted Charge the spring H and reassemble the previously removed parts Armature After removing cap cover and brushes holder plate L remove stator N bolt O retaining coupling fork and extract armature P Coupling pinion By means...

Page 57: ...ckets are specific for the test with 66 Ah battery 1 No load test maximum input of no loaded starter 7 5 A by feeding voltage of 11 5 12 V r p m 8 000 2 Under load test brake the starter so that the input reaches 390 A by feeding voltage of 7 5 9 V the torque should be 1 Kgm and the revolving speed 1200 1500 r p m 3 Start test by jammed starter and feeding voltage 5 6 V the input should result 600...

Page 58: ... with 4 tracks for the lubrication facing crankshaft and the appendix placed in its housing as pointed out by arrow in fig 182 punzone 986290 108 DISASSEMBLY REASSEMBLY Gear cluster ball bearing and drive shaft d c roller bearing Fit by using if necessary an outside dia 50 mm 1 96 punch ball bearing D and with pliers introduce circlip E Let crankcase cool and by using the specific punch 986290 105...

Page 59: ...al gear Insert the differential gear Fig 196 assembly the multiple gear Fig 197 the gearbox shaft Fig 198 the reverse gear Fig 199 the drive shaft Fig 200 the oil filter G the pipe N and the sealing ring I Fig 201 202 as indicated in the figure Clean the union surfaces of housing halves Fig 203 204 smear with sealant Loctite 518 Fig 205 and couple the housing halves by setting the screws to the sp...

Page 60: ...inal tightening the two fastening bolts A of the pump case to the housing half check that the pump turns freely by rotating the shaft manually 4 or 5 times The two bolts A are tightened to an 8 Nm torque Reassemble the chain after attaching it by using the oil pump control gear The bolt fastening the gear to the oil pump shaft shall be tightened to a 10 12 Nm torque Oil pump pressure check The oil...

Page 61: ...utch housing pan by using the appropriate tool 986290 110 Smear the coupling surface with sealant Loctite 510 assemble the clutch housing pan by the 10 bolts and the single nut by tightening them to a 8 Nm torque Engine gear Assemble the gear L the clearance shim M and the snap ring N by using the pliers for internal snap rings Use the tool 986782 034 provided with a dial indicator on the housing ...

Page 62: ... REASSEMBLY Clutch assembly To replace the duct disk no particular tools are required simply remove the 6 bolts B and remove the duct disk When reassembling before locking bolts B assemble the clutch assembly on the drive shaft to help centering the duct disk then place washer C secure nut D 120 140 Nm and the 6 bolts B 10 Nm by fastening the clutch assembly using the appropriate stop key 985110 0...

Page 63: ...rol box union surface engage sliding bloc of 3rd and 4th gears lever then the one of reverse bottom and 2nd gears Lock the box by means of the 5 securing bolts and check the regular speed gear operation Piston and cylinder Fit piston with combustion chamber A facing upwards lubricate and turn piston rings so that ring gops result between themselves displaced by about 120 Position gasket B on crank...

Page 64: ...haft or crank case half if one of the mentioned conditions is absent the new gasket must be equal external identification to the previously fitted one Measure execution for determination of cylinder head gasket thickness Use the dial indicator on the tool 981075 417 and set it to zero on the surface plate Assemble the tool on the cylinder by using the 2 head clamping stud bolts set the piston to t...

Page 65: ...4 Complete the torquing with a second rotation of 90 1 4 turn Cylinder cylinder head securing studs to avoid progressive permanent elongation from repeated torquing operations it is necessary to replace the studs every three dismantling and reassembly operations of the cylinder head If in doubt replace them every time Camshaft and tappet support Assemble the camshaft support on the head by tighten...

Page 66: ...20 If the right axial endfloat is not obtained replace the shoulder washer with one of a higher or lower size as required until the specified endfloat is obtained to this end 6 washers having different thickness are provided Camshaft oil seal and timing pulley Insert by using the proper punch 986290 110 oil seal DISASSEMBLY REASSEMBLY Shoulder Thickness mm washers Camshaft Camshaft pivots diameter...

Page 67: ...iming pulley Fit the camshaft clamping pin assemble the timing pulley then tighten the bolt as torque specified refit again the retorning washer DISASSEMBLY REASSEMBLY WARNING Assembly of toothed belt and timing The assembly timing and tension adjustment of the timing drive toothed belt have already been described from page 21 to page 23 ...

Page 68: ...the side opposed to the one shown in the figure keep the timing gear locked and clamp the weight holder hub along with the related bolt by tightening it to a 25 28 Nm torque Important When the unit is installed check that weights carry out their complete stroke without sticking DISASSEMBLY REASSEMBLY Injection advance variator Caption 1 Injection advance variator fastening screw 2 Washer 3 Calibra...

Page 69: ... both with the fulcrum on two pins of the centrifugal weights C of a counterflange F integral with the injection cam and free to rotate on the camshaft on which two slots are made where the pins D connected to the centrifugal weights slide Appropriate springs B are applied between the centrifugal weights C and the flange A With the engine stopped and at low idling speed the spring load is higher t...

Page 70: ...to position cuts A on the upper part to make easier caps removal 2 Insert tool 981075 424 between suction valve cap and camshaft and push so as to compress the tappet Insert part 2 to hold the tappet and extract part 1 3 Undermine the cap by using a shin point remove it and replace with another one with a suitable dimension As spares 28 caps from 3 25 mm up to 4 60 mm are pointed out on this page ...

Page 71: ...se conditions do not occur act on adjusting screw Z until such zero setting is realized Lock by holding the screw Z steady lock nut V and check by placing more times lever B to max position that the dial gauge result is set to zero Warning The mentioned checking operations must be carried out without injection pump control tappet DISASSEMBLY REASSEMBLY tool 981075 423 ring 984070 499 INJECTION EQU...

Page 72: ... cover compression stroke 3 Operate hand pump and bleed the circuit by means of plug on hole D previously fitted Then exert pressure on the gas oil so as it comes out from injection union F 4 Fit a transparent pipe H on union F Operate again the pump and at the some time rotate the engine towards T D C up the point where the climbing of gas oil in the transparent hose doesn t cease Timing is corre...

Page 73: ...ee from scoring signs 2 Install the sensor V of tester paying attention not to turn it after fastening Connect the tester supply cable as shown in fig 311 3 Start and heat the engine With the engine idling at 1200 rpm use the button on the stroboscopic gun to make path S on the clutch flywheel coincide with path T of TDC on the clutch cover Check that the advance read on the tester display is 13 I...

Page 74: ...13 T S P M S 314 DISASSEMBLY REASSEMBLY 4 If the conditions described at point 3 are not satisfied and the injection timing is advanced or delayed replace or increase the gaskets under the injection pump following the instructions given in Injection pump and checking the static injection advance relevant to the engine static timing ...

Page 75: ...e head place the copper seal B on the injector screw the injector into its seat and tighten it to a 70 Nm torque as specified Then fit the rubber cap with the elastic self tightening clamp on the injector waste union Note The copper seal and the fireproof bulkhead must be replaced every time the injector is disassembled FLAME BREAKER BUSH PIECE NAME SPARK ARRESTOR OUTSIDE DIAMETER SPARK ARRESTOR H...

Page 76: ...iate union screw or the injection pump inspection plug fit the fuel supply pump control rod then reassemble the pump fixing it with the appropriate nuts to a 20 Nm torque as specified Reassemble the injection pump injector high pressure union pipe by tightening it to an 18 20 Nm torque Assemble the tappets cover by anchoring them with the 4 screws tightened to 8 Nm Feeding pump Minimum flow at 200...

Page 77: ...RSED COMPILER TECO ATI 302 303 304 305 306 307 301 308 309 IX DISASSEMBLY REASSEMBLY Reassembling Oil level rod Starting motor Flywheel Fan scroll together with the stator Belt cover Exhaust manifold Cooling covers Fan scroll cover Muffler etc Complete the engine with the above mentioned details ...

Page 78: ... max r p m must be carried out with a warm engine as follows act after unlocking the lock nut on screw F of accelerator lever position so as min r p m result 1200 and lock again lock nut loosen the lock nut of screw G gradually accelerate the engine until 4150 r p m are reached and by means of a screw limit accelerator lever stroke in this position and lock the lock nut DISASSEMBLY REASSEMBLY ...

Page 79: ...60 169 981075 412 1460 168 981075 413 1460 172 981075 414 1460 166 981075 415 1460 165 981075 416 TOOLS DESCRIPTION DRAWING LOMBARDINI PART CODE LOMBARDINI DRAWING CODE Timing reference tool A G and Pin for camshaft timing Pin for camshaft timing Differential box extraction tool Primary gear blocking tool Flame protection cover extraction tool Flywheel blocking tool Bearing extractot diam 35 mm He...

Page 80: ...1460 181 981075 419 1460 180 1460 179 984651 457 981075 420 984651 457 1460 177 981075 422 1460 184 981075 423 984070 499 TOOLS Head seal identification tool Flywheel extraction tool Anticipation extraction tool Clutch extraction tool Flywheel cone extraction tool Engine support tool 422 Maximum load control tool DESCRIPTION DRAWING LOMBARDINI PART CODE LOMBARDINI DRAWING CODE ...

Page 81: ...75 425 984651 457 1460 173 985110 039 1460 187 986290 104 1460 159 985820 212 1460 176 985430 007 1460 174 986290 105 TOOLS Bearing extractor Double fork to check the P NP differential shaft Valve plates replacement tools Bearing extractor Clutch stop hook Punch to install roller box on the primary shaft of the cover flywheel side Piston insertion spring Buffer handle Punch for roller box for elbo...

Page 82: ...6800 254 986800 255 1460 157 986290 110 1460 160 986290 109 1460 164 986782 034 TOOLS Differential bearing punch Punch for roller box diam35 Punch to calk the crosspiece Punch to install sealing rings Punch to install sealing ring on the valve trach Comparator support to check the play of the engine gear Punch for roller box for elbow shaft on flywheel side DESCRIPTION DRAWING LOMBARDINI PART CODE...

Page 83: ...ch housing fixing screws Clutch cover fixing screws Axle shaft hood flange fixing screws Shift select lever case fixing screws Shift select lever case fixing screws Fan volute fixing screws Air shroud cover fixing screws Belt tensioner fixing nut Oil pressure switch Starter motor fixing screws Cylinder head exaust system fixing screws Guard tile fixing screws Oil termal switch Air shroud fixing sc...

Page 84: ... 8 2 02 27 8 2 84 33 3 40 8x1 25 29 6 3 02 41 6 4 25 50 5 10 9x1 25 38 3 88 53 4 5 45 64 2 6 55 10x1 50 52 5 5 36 73 8 7 54 88 7 9 05 12x1 75 89 9 09 125 12 80 150 15 30 14x2 00 135 13 80 190 19 40 228 23 30 16x2 00 205 21 00 289 29 50 347 35 40 18x2 50 257 26 30 362 37 00 435 44 40 20x2 50 358 36 60 504 51 50 605 61 80 22x2 50 435 44 40 611 62 40 734 74 90 24x3 00 557 56 90 784 80 00 940 96 00 TO...

Page 85: ...85 REG CODE 1 5302 596 MODEL N 50881 DATE OF ISSUE 15 05 2003 REVISION 00 DATE 15 05 2003 ENDORSED COMPILER TECO ATI NOTE ...

Page 86: ... Angabe jederzeit verändern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación 86 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 01829970357 E MAIL atl lombardini it Internet ht...

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