Lombardini LDW 422 SERIES Workshop Manual Download Page 11

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18-10-2004

REG. CODE

1-5302-662

MODEL N°

51092

DATE OF ISSUE

REVISION

ENDORSED

COMPILER TECO/ATI

DATE

TROUBLE SHOOTING

WHITE EXHAUST SMOKE

Cold engine

Faulty injector

High oil level

BLACK EXHAUST SMOKE

Air filter clogged

Incorrect injection pump delivery

Faulty injector

NOISY ENGINE

Wrong injection advance

Faulty injector

Tappets with excessive clearance

Excessive wear of the engine internal parts

LOW OIL PRESSURE

Insufficient oil level

Worn oil pump

Worn or damaged crankshaft or small end bearings

CLUTCH : SLIPPING

Insufficient idle stroke

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 and, if necessary, replace

Restore the level

Replace

Check and restore

Clean and, if necessary, replace

Check the static and dynamic advance and restore

Clean and, if necessary, replace

Adjust

Overhaul

Restore the level

Overhaul

Adjust the stroke

Replace

Replace the disk

Check and, if necessary, replace

Adjust

Overhaul

Lock or replace

FAULT FINDING

REMEDIES

Summary of Contents for LDW 422 SERIES

Page 1: ...LDW 422 18 10 2004 00 18 10 2004 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION DATE ENDORSED COMPILER TECO ATI 1st Edition WORKSHOP MANUAL LDW 422 engines 4 Speed EURO 2 Version code 1 5302 662 ...

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: ...ON 18 VIII FUEL SYSTEM 22 24 FUEL SUPPLY CIRCUIT WITH QUICK STOP DEVICE QSD 22 Fuel circuit air bleeding 24 QSD behaviour with excited electromagnet 22 QSD behaviour with de excited electromagnet 23 QSD WIRING DIAGRAM 24 Running engine excited electromagnet 23 Running engine excited electromagnet 22 IX TIMING DIAGRAM 25 X PREHEATING SYSTEM 26 27 Distraction time diagram 27 Preheating system 26 Pre...

Page 5: ...Disassembly 31 Cooling liquid circulating pump Assembly 96 CRANCKCASE BEARINGS CLUTCH SIDE MULTIPLE GEAR BALL BEARING 67 CRANCKCASE BEARINGS CRANKSHAFT CRANKCASE BEARING HOUSING 67 CRANCKCASE BEARINGS DIFFERENTIAL HOUSING 67 CRANCKCASE BEARINGS NEEDLE BEARING HOUSING 67 CRANCKCASE BEARINGS REVERSE GEAR 67 Crankcase half flywheel side 84 Crankshaft Reverse shaft Gearbox shaft Multiple gear Differen...

Page 6: ...m Disassembly 45 Injection pump control cam Assembling 97 Injector MICO F 002 C 6 Z 396 69 Injector setting 69 Injector fireproof bulkhead Disassembly 41 Injector injection pump connecting pipe Assembly 105 Main features of electrical starter 82 Measurement to determine the thickness of the head gasket 90 Min and max r p m regulation 115 Minimum oil pressure switch Assembly 106 Muffler Assembly 10...

Page 7: ...ssembly 105 Timing belt cover air shroud and stator support 32 Timing gear and speed gear control box Disassembly 51 Timing pulley and camshaft oil seal ring Disassembly 45 Timing system 37 Toothed camshaft timing pulley Assembly 93 Toothed crankshaft timing pulley Assembly 93 Toothed timing belt Disassembly 39 Toothed timing belt Reassembly 39 Toothed timing belt tensioner Assembly 96 Valves grin...

Page 8: ... 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 wor...

Page 9: ...he 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 ...

Page 10: ...of the cooling fan are broken Low 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 Chec...

Page 11: ...e 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 a...

Page 12: ...rol and possible adjustment Bolts and nuts correct fastening Dinamic Injection Advance Engine oil Oil filter COMPONENT after the first 1000 Km LDW 422 ENGINE ORDINARY MAINTENANCE INTERVAL KM OPERATION CLEANING CHECK REPLACEMENT Dry type air filter Injector Checking engine oil level Checking cooling liquid level Valve clearance Water in the fuel filter Integrity of propeller shaft boot Low pressure...

Page 13: ... could be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed Use a suitable oil in order to protect the engine The lubrication oil influences the performances and life of the engine in an incredible way Use of an inferior quality oil or failure to regularly change the oil will increase the risk of...

Page 14: ... 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION DATE ENDORSED COMPILERTECO ATI IV MODEL NUMBER AND IDENTIFICATION Displacement cc r p m Lombardini Diesel Water cooled Customer s code Engine serial number ...

Page 15: ...que at 3200 R P M 1 Fuel consumption Oil quantity without oil filter Oil quantity with oil filter Dry weight TECHNICAL DATA LDW 422 ENGINE MAIN SPECIFICATIONS 4 stroke single cylinder engine Indirect injection Diesel cycle type Liquid cooling system with axial fan Differential gear and gearbox assembly on rear axle OHC axle driven by toothed belt Lubrication is made through a lobe pump controlled ...

Page 16: ...16 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION DATE ENDORSED COMPILERTECO ATI VI LUBRICATION SYSTEM ...

Page 17: ...ATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE VI CYLINDER VALVE FOR PISTON COOLING CRANKSHAFT OIL SUMP CONROD CAMSHAFT GOVERNOR OIL PRESSURE VALVE OIL FILTER OIL PUMP OIL PICK UP LDW 422 OIL CIRCUIT DIAGRAM CYLINDER HEAD CAMSHAFT SUPPORT LUBRICATION SYSTEM ...

Page 18: ...ng liquid level 8 Thermostat 2 Overflow pipe 9 Liquid circulating pump 3 Plug with calibrated pressurizing valve 10 Engine outlet radiator inlet hose 4 Compensation tank 11 Radiator outlet engine inlet hose 5 Breathing pipe 12 Radiator 6 Pipe for the connection to the expansion vessel 13 Cooling fan 7 Liquid temperature monitoring thermostat FORCEDLIQUIDCOOLINGSYSTEMWITHAXIALFAN ...

Page 19: ...ion of 50 H2O and 50 glycol solution It s mandatory the use for the cooling system of the correct percentage of mixture water and glycole The lack to the above prescription will result in warranty avoidance PLUG SETTING WATER SOLUTION WITH 30 50 GLYCOL 0 50 bar 98 C 102 105 C 0 70 bar 102 C 107 110 C 0 90 bar 105 C 110 112 C 1 00 bar 106 C 112 114 C Thermostatic valve features Opening starting poi...

Page 20: ...ssible liquid leakages thus indicating an incipient failure of the pump seal Particularly during the engine run in period small leakages of fluid are to considered normal Make sure the pump shaft does not show any axial clearance and can turn freely without undue localised friction Check that the impeller is free from dents cracks or worse some blade is broken or missing at all If anyone of these ...

Page 21: ...plashes and overflows Be careful not to knock over the container Check of the coolant temperature switch Dip the threaded part of the sensor in a metal container filled with engine lube oil monitor the oil temperature using a precision thermometer with max reading of 150 C Heat up the oil until it reaches the required temperature of 110 3 C Since the switch is the ON OFF type the check is made thr...

Page 22: ... Q and K The device operation is based mainly on a special electronically controlled slide valve integrated in the fuel filter During the stop phase of the engine fuel is sucked from the injection pump thanks to the suction vacuum of the fuel pump This ensures reliable and rapid engine stops and subsequent start ups Running engine excited electromagnet CAPTION 1 Fuel tank 5 Special union for QSD v...

Page 23: ...II FUEL SYSTEM FROMINJECTIONPUMP TOFUELPUMPSUCTION FROM FUEL PUMP DELIVERY TOFUELTANK Running engine excited electromagnet CAPTION 1 Fuel tank 5 Special union for QSD valve closed 2 Fuel filter with QSD 6 Injector 3 Fuel supply pump 7 Fuel return pipe to tank 4 Injection pump QSD behaviour with de excited electromagnet ...

Page 24: ...ENDORSED COMPILERTECO ATI VIII A FUEL SYSTEM QSDWIRINGDIAGRAM Should you empty the fuel circuit completely bleed it carefully by using the indicated screw A This operation is to be carried out once the fuel refilling is over and with the engine running at idle speed Fuel circuit air bleeding ...

Page 25: ...5 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE IX TIMING DIAGRAM Timing diagram Data concern 1 mm cold play between tappets and valves ...

Page 26: ...t turns off the glow plug maintains the temperature for about 4 seconds distraction time even if no start command has been given Once the engine is running the gear case receives a signal and maintains the glow plug temperature for further 5 seconds preheating time Whereas the preheating phase is necessary to start the engine and varies according to the ambient temperature the post heating phase i...

Page 27: ...he engine Distraction time diagram C Switch keyturnedfromONtoOFFpositionbeforethesetpreheating time is over Preheating time beyond zone B the preheating indicator lamp is off the glow plug is on but only for a few seconds D Tolerance the preheating indicator lamp and the glow plug are off Post heating time diagram E Post heating time the indicator lamp is off the glow plug is heated the engine is ...

Page 28: ...28 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION DATE ENDORSED COMPILERTECO ATI NOTE ...

Page 29: ...l cables of the alternator flywheel and of the starting motor the fuel pipes the controls of accelerator braking lights speed gear and clutch have all been disconnected Remove the engine only after draining the oil from the engine cover Old oil is highly polluting and must be disposed of in the correct way Do not litter support 986171 193 Muffler disassembly To disassemble the muffler it is necess...

Page 30: ...loosen the 3 lower screws see picture 5 Loosen the 4 M6x20 fastening socket head screws to disassemble the cooling fan see picture 8 Be sure the fan blades are intact should one be damaged the fan must be replaced Flywheel side air shroud Disassembly To remove the flywheel side air shroud loosen the 5 M 6x20 fig 9 socket head screws Starting motor Disassembly Unscrew the 3 M 8x40 fastening hex bol...

Page 31: ... the liquid cooling fan support of the radiator from the flywheel puller 981075 420 puller 981075 418 Flywheel disassembly Place tool 981075 414 onto the starting motor housing see picture 15 to lock the flywheel remove the flywheel retaining screw using the 22 mm socket wrench see picture 16 and extract the cone see pictures 18 19 using puller 981075 420 equipped with component 984651 457 and rem...

Page 32: ... to remove the clamp from the alternator cable Fig 25 Internal alternator Components 1 Stator 2 Rotor 3 Flywheel 4 Toothed crown In this installation the rotor section is composed of permanent magnets generating a rotating magnetic field The number of rotor pole pairs is equal to the number of rotor windings and is evenly distributed on its 360 circle Current is taken to stator windings and adjust...

Page 33: ...L N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE XI 28 29 DISASSEMBLY REASSEMBLY Internal alternator features 3 phase magnet flywheel Max rpm 5000 rpm Rotor poles 12 Stator poles 18 Operating temperature 10 C 110 C Battery recharge curve ...

Page 34: ...04 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION DATE ENDORSED COMPILERTECO ATI XI Alternator voltage regulator connecting cable Tree phase alternator and voltage regulator wiring diagram DISASSEMBLY REASSEMBLY ...

Page 35: ...35 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE XI DISASSEMBLY REASSEMBLY ...

Page 36: ...5 hex bolts to disassemble the entire clutch cover fig 30 31 Extract the snap ring using pliers then remove the thrust plate fig 32 33 Place the stop device 985110 039 see picture 34 and unscrew the fastening nut see picture 35 Place the puller 981075 419 and loosen the middle screw to remove the clutch pack see picture 37 38 Caption 1 Collar retaining ring 2 Thrust cap 3 Nut 4 Cup spring 5 Clutch...

Page 37: ...ary Camshaft timing Remove the screw plug from the camshaft support see picture 41 Turn the timing gear until hole 3 on the camshaft is aligned with the hole on the support from which screw plug 1 has been removed see picture 43 Then fit timing gear 2 see picture 43 serial number 8430 123 see picture 44 and screw it down till it is tight on the camshaft boss surface Thanks to this operation the ca...

Page 38: ...ng Place tool 5900 217 see picture 46 on the crankshaft replacing the previously disassembled clutch pack by using the key By means of the same fastening nut used for the clutch tighten the tool to 120 140 Nm Then fit timing pin 8430 124 see picture 46 and screw it on the clamping hub so that it corresponds to the hole on the clutch housing pan see picture 48 The crankshaft is now locked in timing...

Page 39: ...the tightener upwards until it lays against the cover and lock it in this position by retightening the nut This operation allows to release the tension on the toothed timing belt thus enabling its removal fig 52 Toothed timing belt Reassembly Loosen the fastening nut of the toothed timing pulley controlling the camshaft so that it can rotate freely on the shaft fig 53 Insert the new toothed belt o...

Page 40: ...y using a copper seal and the special plug fig 62 Use the flywheel to make the crankshaft rotate two or three times in order to settle the timing belt By using a special tool check that the toothed timing belt tensioning is correct fig 63 In our example the tool used is supplied by DENSO To read the correct tensioning value place the tool sensor onto the belt tooth fig 64 The correct tensioning va...

Page 41: ...or fig 68 Loosen and remove the injector from the head by using a ring spanner Check that the copper seal is present fig 70 To remove the fireproof bulkhead from the head the special tool serial number 981075 413 is to be used fig 71 Screw this tool in the head in the injector place then operate the registers on top of the tool itself to let the mandrel expand so as to hook the fireproof bulkhead ...

Page 42: ...then glows starting from the tip and growing towards the thread If you see the glow plug getting red and then glowing not from the tip but from the middle of the glow tube just replace it The whole procedure must be carried out in few seconds not to damage the glow plug WARNING this check shall be considered dangerous because the glow plug in a few seconds reaches a very high temperature over 1 00...

Page 43: ...n pump by paying particular attention to the seals inserted between the pump and the cover surfaces These seals allow modifying the engine static advance By increasing their thickness the pump moves away from the injection cam delay By decreasing the thickness the injection pump moves closer to the cam advance fig 82 Remove the injection tappet with the relevant collar housed inside it fig 83 84 T...

Page 44: ...this reason when disassembling we advice you to cover the Oldham union with grease so that it can act as an adhesive fig 91 Injection advance variator Disassembly Unscrew the fastening bolt of the injection advance variator by using a 14 mm wrench fig 92 use puller 981075 421 and rotate screw B to remove weights fig 93 94 While doing this keep the hexagonal support A locked Thermostat Disassembly ...

Page 45: ...ssembly After unscrewing the flanged fastening nut remove the safety washer the belt tightener and the tensioner spring Fig 97 As for the belt tightener pin if it is not worn out or broken there is no need to disassemble it Timing pulley and camshaft oil seal ring Disassembly Open the safety lock unscrew the bolt and remove the timing pulley Fig 98 Remove the oil seal ring by using a screwdriver F...

Page 46: ...ig 102 Repeat the procedure on the second cam to extract the shaft completely Fig 103 Tappets Disassembly To remove the tappet shims rotate the tappets until it is possible to insert a screwdriver into one of the special cuts to detach the shim from the tappet itself The surface of the adjusting collar on which the shim identification number is marked should be facing the tappet socket If you are ...

Page 47: ... cam driven rod controlling the pump fig 110 Always check and replace the two seal rings if necessary fig 109 Camshaft support Disassembly Use a proper wrench to unscrew the four M6x20 cheese screws for the anchoring to the head fig 111 and then remove the camshaft support fig 112 Cylinder head Disassembly Unscrew the 4 fastening nuts Fig 113 extract the cylinder head assembly Fig 114 and remove g...

Page 48: ...u to replace the two seal rings fig 118 Should the water pump not work properly it cannot be repaired but only replaced Oil pressure switch Disassembly Oil dipstick case Disassembly Unscrew the two HH M6x20 hex screws and disassemble the oil dipstick case Check and replace if necessary the seal ring to be found between the case clamping flange and the cover fig 119 120 Technical specifications Typ...

Page 49: ... and unscrew the fastening bolt Fig 125 As you disassemble the clutch housing pan fig 123 make sure not to damage the oil seal ring by scraping it against the crankshaft gear N B When reassembling the bolt shall be tightened using the same tool Using tool 981075 425 together with component 984651 457 fig 126 extract the cone fig 127 and remove the ring gear fig 128 Driving shaft gear After removin...

Page 50: ... screwdriver in order to unscrew the retaining bolt Fig 132 and then remove the chain Fig 133 Unscrew the two bolts securing the oil pump Fig 134 and extract it minding the correct sequence for reassembly see fig 135 Replace the gasket whenever you disassemble the oil pump Fig 136 Oil pressure regulating valve Disassembly Remove the snap ring extract the spring and the by pass valve Check for poss...

Page 51: ...der Piston Wrist pin Disassembly After extracting the cylinder Fig 139 remove the retaining snap rings from their seat by using a screwdriver Fig 140 141 then extract the wrist pin Fig 142 and disassemble the piston Timing gear and speed gear control box Disassembly Remove the timing gear Fig 143 Unscrew the 5 fastening bolts and remove the speed gear control box Fig 144 ...

Page 52: ...rate the two housing halves by hitting with a mallet Crankshaft Reverse shaft Gearbox shaft Multiple gear Differential gear assembly Remove reverse gear 1 Fig 147 gearbox shaft 2 Fig 148 multiple gear 3 Fig 149 crankshaft 4 Fig 150 and remove differential gear assembly 5 using extractor 981075 411 Fig 151 which is provided Figg 152 153 When reassembling the shoulder washerswhicharelocatedbetween d...

Page 53: ...for the roller case of the multiple gear A and with an external Ø of 36 mm for roller case of the gear shaft B Fig 155 external diameter mm 36 external diameter mm 24 Clutch side housing half Gearbox shaft roller case and multiple gear ball bearing Disassembling Assemble puller 981075 415 Fig 156 onto the gearbox shaft roller case and work on the central nut until the extraction is completed Fig 1...

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Page 55: ...55 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE XI NOTE DISASSEMBLY REASSEMBLY ...

Page 56: ...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 57: ...ODEL N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE XI 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 58: ... screw 12 Adjustment spring container 13 Adjustment lever 14 Magnet Delivery regulator Disassembly Remove the cover by way of the 6 retaining screws Fig 160 Remove retainer A Fig 161 cap B and idling spring C Fig 162 Set adjustment lever 13 Fig 162 towards the outside extract supplementary spring D extract retainer E and remove pump control rod 6 Fig 163 Remove the snap ring fig 164 extract pin 7 ...

Page 59: ...float is different from schedule replace clearance shim V To this end 3 washers having different thickness values from mm 1 2 1 3 1 4 are provided tool 981075 417 Remove the snap ring from its slot using the pliers which are provided Fig 169 then extract the shaft and the weights holder shaft Fig 170 Now unscrew the two retaining nuts A see Figg fig 171 172 then remove the metal plate and disassem...

Page 60: ...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 61: ...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 62: ... 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 63: ... 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 64: ...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 65: ... 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 66: ... 35 3 40 3 45 3 50 3 55 3 60 3 65 3 70 3 75 3 80 3 85 3 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 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 2 5 DISASSEMBLY REASSEMBLY ...

Page 67: ...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 68: ...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 69: ...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 70: ... spring 4 Valve guide sealing rings 5 Valve spring lower collars 6 Precombustion chamber 7 Exhaust valve 8 Intake valve Dismantling values Compress valves springs fig 192 by using a valve lifting clamp as shown in fig 191 the tool was not included in the special tool set as it is commercially available take away cotters fig 193 halves and release the fixture until spring and valves are removed all...

Page 71: ...s 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 the operation has been carried out carefully wash and blow cylinder head and valves For the checking of the perfect seal of valves pour some g...

Page 72: ... 198 199 200 201 202 203 DISASSEMBLY REASSEMBLY Reassembly of valves Prior to valve reassembling which is done in reverse sequence as to disassembling always replace the two sealing rings fig 195 on the valve guides using punch 986290 109 fig 197 198 Important Before reassembling valves lubricate guides and stems punch 986290 109 ...

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Page 74: ...y time it is extracted Before assembling the new precombustion chamber the depth of the seat inside the head shall be measured Fig 205 206 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 to its ...

Page 75: ...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 40 576 40 588 Rotor outside dia B 40 513 40 551 Clear bet seat and rotor C 0 025 0 075 Rotor height D 5 985 6 00 Rotor seat depth E 11 025 11 050 Side clear between rotors and pump bo...

Page 76: ...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 218 Then tighten the two bolts gradually to a 70 Nm torque N B Replacement of c...

Page 77: ...ar 9 Clearance ring 10 Stop ring 11 Speed control stem 12 Spider clamping ring nut Gearbox shaft 4th speed gear Gearbox shaft Remove the snap ring Q the shoulder washer P and the gears Unscrew the stem R set the coupling spiders one at a time to coincide with the slot for the sliding groove and extract them from the shaft Reassembling the gearbox shaft tightening the speed coupling spider Insert t...

Page 78: ... replace the shoulder washer with one of higher or lower size as needed Once the check is completed reassemble the snap ring IMPORTANT the shoulder washer S is 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 tools 1460 206 Reassembling the gearbox shaft tightening the spider clamping ring nut Apply Loctite 270 fig 221a on the thread of t...

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Page 80: ...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 81: ...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 82: ... 2 Kgm REVOLUTION MIN 8 000 g 1 MIN 1 500 g 1 Connection with engine Starting motor 4 pole permanent magnet type starting motor It is controlled by a remote control allowing pinion clutch and power supply enabling The starting motor is battery powered and controlled by a key switch It is connected to the engine by means of the pinion and of the ring gear on the flywheel Solenoid starter characteri...

Page 83: ...83 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE XI DISASSEMBLY REASSEMBLY Characteristic curve of the 12 V 1 6 kW starting motor ...

Page 84: ...C with 4 tracks for the lubrication facing crankshaft and the appendix placed in its housing as pointed out by arrow in fig 182 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 position d c roll...

Page 85: ...al gear Insert the differential gear Fig 241 assembly the multiple gear Fig 242 the gearbox shaft Fig 243 the reverse gear Fig 244 the drive shaft Fig 245 the oil filter G the pipe N and the sealing ring I Fig 246 247 as indicated in the figure Clean the union surfaces of housing halves Fig 248 249 smear with sealant Loctite 518 Fig 250 and couple the housing halves by setting the screws to the sp...

Page 86: ...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 87: ...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 88: ... 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 89: ...r control 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 DISASSEMBLY REASSEMBLY tool 985820 212 Piston and cylinder Assemble piston with the combustion chamber A facing upwards fig 280 lubricate and rotate the sealing rings so that the cuts have a ...

Page 90: ...equal external identification fig 288 to the previously fitted one Tool 981075 417 DISASSEMBLY REASSEMBLY 0 45 0 60 1 50 1 notch 0 60 0 75 1 65 2 notches 22 5 23 5 0 75 0 90 1 80 3 notches Measurement to determine the thickness of the head gasket Use the dial indicator on the tool 981075 417 fig 284 and set it to zero on a surface plate Assemble the tool on the cylinder by using the 2 head and cyl...

Page 91: ...uing 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 fig 292 by tightening the bol...

Page 92: ...g 298 If the right axial endfloat is not obtained replace the shoulder washer A 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 fig 299 Camshaft oil seal and timing pulley Insert by using the proper punch 986290 110 fig 300 oil seal fig 301 DISASSEMBLY REASSEMBLY Shoulder Thickness mm washers Cams...

Page 93: ... a 70 75 Nm torque as specified fig 304 fit again the brake washer fig 305 Toothed crankshaft timing pulley Assembly Taking care that the key remains in its housing reassemble the toothed pulley on the crankshaft fig 306 Oil dipstick case Assembly After inserting the sealing ring in the special housing reassemble the oil dipstick case and fix it by tightening the bolts at 8 Nm fig 307 Oil level ch...

Page 94: ...94 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION DATE ENDORSED COMPILERTECO ATI XI NOTE DISASSEMBLY REASSEMBLY ...

Page 95: ...95 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE XI NOTE DISASSEMBLY REASSEMBLY ...

Page 96: ...age 33 Cooling liquid circulating pump Assembly At every disassembly replace the sealing rings A and B fig 308 Insert the cooling liquid circulating pump in its housing in the cylinder fig 309 310 and fix it by tightening the screws at 15 Nm fig 311 Toothed timing belt tensioner Assembly Insert the calibrated spring for the toothed timing belt tensioning inside the tensioner the spring can be asse...

Page 97: ...ection pump control cam on the timing shaft fig 313 then insert the shoulder washer and assemble the snap ring by means of pliers for internal snap rings fig 314 Centrifugal weights assembly Assembling Insert the centrifugal weights assembly taking care to insert the pins of the weights L inside the slots M FIG 315 Working on the side opposed to the one shown in the figure keep the timing gear loc...

Page 98: ...ncreases in accordance with the engine RPM attains 24 at 3500 R P M then renains constant The advance variation is obtained through the injection advance regulator see fig 321 It consists of the flange A fig 321 splined to the camshaft and the carrier both with the fulcrum on two pins of the centrifugal weights C fig 322 of a counterflange F fig 321 integral with the injection cam and free to rota...

Page 99: ...323 XI DISASSEMBLY REASSEMBLY When the RPM increases the centrifugal weights force becomes higher than the spring load the weights move and through the pins D fig 323 engaged into the slots rotating the injection cam At 3500 R P M the weights are completely open see fig 323 and the injection advance is 24 before P M S ...

Page 100: ...r 2 Insert the tool 981075 424 fig 326 between the intake tappet collar and the camshaft fig 327 and push to compress totally the tappet Insert the component 985620 320 fig 328 to keep the tappet lowered and extract the component 981075 424 fig 328 3 Disconnect the collar using a steel tip extract it and replace it with one of a suitable size fig 329 330 28 collars from 3 25 mm to 4 60 mm are avai...

Page 101: ...reproof bulkhead must be replaced every time the injector is disassembled A B fig 331 FLAMEBREAKERBUSH PIECENAME SPARK ARRESTOR OUTSIDEDIAMETER SPARK ARRESTOR HOUSING NOMINAL DIMENSION ASSEMBLING GAP Thermostat Assembly Place the thermostat in its housing in the thermostat head making sure that the bleeding hole is assembled facing upwards fig 335 Check and replace the seal if necessary Tighten th...

Page 102: ...tappet with the relevant collar inside its housing on the camshaft support fig 337 Insert the injection pump placing the gaskets which thanks to their thickness determine the static advance fig 337 The injection pump can be inserted on the support only in one direction which is determined by the dowel 1 fig 338 Looking through the special inspection hole check the correct insertion of the pin whic...

Page 103: ...hese 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 tool 981075 423 ring 984070 499 DISASSEMBLY REASSEMBLY INJECTION E...

Page 104: ...d protrusion from the spacer surface measurement A must be from 2 to 2 5 mm To make the protrusion fall into the specification A 2 rods are available with different leghth 1 mm 65 700 0 050 2 mm 66 100 0 050 After checking with a dial indicator the protrusion of both rods install the one which is in the specified tolerance measurement A Check the rod protrusion from the spacer surface when the cam...

Page 105: ...e injector and on the opposite end to the two way banjo Fasten the banjo to the union on the injection pump by using a M 8 union bolt tightened at 20 25 Nm fig 353 Injector injection pump connecting pipe Assembly Assemble the injector injection pump pipe and tighten it at a 18 20 Nm torque fig 354 Air shroud and stator support Timing belt cover Assembly Reassemble the air shroud and stator support...

Page 106: ...oling fan support onto the flywheel and fasten it by tightening the five screws at 12 15 Nm fig 356 Starting motor Assembly Assemble the starting motor by tightening the three M 8x40 screws at 29 Nm and the two M 6x22 anchoring bracket ones at 12 15 Nm fig 357 Air shroud cooling fan Radiator shroud Assembly Fasten the cooling fan shroud to the cover by using the five M 6x20 screws Assemble the coo...

Page 107: ...lter Assembly Lubricate and oil the seal between the oil filter and the support surface on the half casing using engine oil fig 361 362 Then screw and tighten the cartridge manually fig 363 Muffler Assembly Insert the exhaust manifold by placing the seal between head and manifold Tighten the fastening nuts at 19 21 Nm Tighten the muffler anchoring bracket nuts at 30 Nm ...

Page 108: ...e speed governor support and remove the Oldham union fig 369 Unscrew the injection advance variator fixing screw fig 371 and remove the injection advance variator weights with the proper puller fig 372 puller 981075 421 Disassemble the injection pump fig 374 and replace it with dial indicator together with dial indicator holder previously reset fig 375 by means of proper template 4200 051 to 53 2 ...

Page 109: ...hims according to the measured error For example if the distance between guard base plane and injection cam base is less than 0 2 mm add two 0 1 mm shims If the distance is higher than 0 2 mm remove two 0 1 mm shims Calculate and position the right number of shims between guard and tool base planes and fix the tool by means of proper knobs fig 380 Reassemble the injection advance weights on the in...

Page 110: ... and timed injection advance variator injection cam camshaft and injection tappet fig 387 Now tighten the advance variator fixing screw to 25 28 Nm by means of the torque wrench fig 388 Disassemble the equipment reassemble the Oldham union and coat all contact surfaces with loctite 510 Then reassemble the speed governor support to the camshaft support Position the injection pump by inserting the m...

Page 111: ...111 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE XI NOTE DISASSEMBLY REASSEMBLY ...

Page 112: ...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 correct if in such a point reference mark the clutch is aligned to A I S mark static injection advance 11 before T D C If the engine results ...

Page 113: ...free 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 369 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...

Page 114: ...397 T S P M S 398 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 115: ...he operations of min and 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 ...

Page 116: ...116 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION DATE ENDORSED COMPILERTECO ATI NOTE ...

Page 117: ...460 169 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 H...

Page 118: ...60 181 981075 419 1460 180 1460 179 984651 457 981075 420 984651 457 1460 177 981075 422 1460 184 981075 423 984070 499 LDA LDW 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 119: ...075 425 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 elb...

Page 120: ...164 986782 034 1460 206 1460 206 4200 051 4200 051 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 LOMBARDINI DRAWING CODE Gear...

Page 121: ...TE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE 1460 192 1460 192 XII 1460 193 1460 193 TOOLS TOOLS DESCRIPTION DRAWING LOMBARDINI PART CODE LOMBARDINI DRAWING CODE Calibrated tool for injection cam positioning Positioning tool for injection cam advance variator ...

Page 122: ... screws Shift select lever case fixing screws Shift select lever case fixing screws Belt tensioner fixing nut Oil pressure switch Starter motor fixing screws Muffler fastening nuts Speed governor protection fastening screws Air shroud fixing screws Cylinder head fixing nuts Timing belt cover fixing screws Cylinder head fixing stud bolt Cam shaft carrier fixing screws Timing toothed pulley fastenin...

Page 123: ...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 MAI...

Page 124: ...124 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION DATE ENDORSED COMPILERTECO ATI NOTE ...

Page 125: ...125 18 10 2004 18 10 2004 00 REG CODE 1 5302 662 MODEL N 51092 DATE OF ISSUE REVISION ENDORSED COMPILER TECO ATI DATE NOTE ...

Page 126: ...Angabe jederzeit verändern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación 126 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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Lombardini LDW 422 SERIES, Workshop Manual

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