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Lombardini LGA 280 OHC, Workshop Manual

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Lombardini LGA 280 OHC Workshop Manual Download Page 4

REG. CODE

1-5302-528

MODEL N°

50805

DATE OF ISSUE

31.07.2001

REVISION    

00

DATE

31.07.2001

ENDORSED

COMPILER TECO/ATL

4

INDEX

I

TROUBLE SHOOTING

II

WARNING SIGNS - SAFETY INSTRUCTIONS

III

ENGINE IDENTIFICATION

IV

TECHNICAL FEATURES

V

CHARACTERISTICS

VI

OVERALL DIMENSION

VII

MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

VIII

DISASSSEMBLY/REASSEMBLY

General information for correct repairs
Engine disassembly
Engine preparation
Flywheel extraction
Head disassembly
Disassembly of camshaft-tappets valves
Timing pulley removal
Timing cover removal
Crankshaft extraction
Cylinder head
Camshaft
Valves - guides - seats - valve spring - tappets
Valves and valve-guides dimensions after assembly in the head
Valves and valve-guides gap
Valve guide
Oil seal ring on valve guide
Valve seats
Valve springs
Tappets
Breather valve
Cylinder
Connecting rod
Piston and rings
Crankshaft
Main journals and crank pin diameter (mm)
Governor and balancing shaft gear command
Balancing shaft
Speed governor
Bearings
Crankcase and timing cover
Recoil starter
Rope and return spring replacement
Oil watch device (optional)
Crancshaft and oil seal rings
Piston and connecting rods
Speed governor
Timing cover

This manual gives the main instructions on how to repair LOMBARDINI LGA 280-340 OHC
gasoline-fuelled engines, updated as of 31.07.2001.

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Summary of Contents for LGA 280 OHC

Page 1: ...ANUAL LGA 280 340 OHC Series engines code 1 5302 528 SERVICE LGA 280 OHC LGA 340 OHC COMPILER TECO ATI REG CODE 1 5302 528 MODEL N 50805 DATE OF ISSUE 31 07 2001 REVISION 00 ENDORSED DATE 31 07 2001 1st Edition 1 ...

Page 2: ...d professionally perform the subject operation 2 The person or persons performing service work on Lombardini series engines possesses adequate hand and Lombardini special tools to safely and professionally perform the subject service operation 3 The person or persons performing service work on Lombardini series engines has read the pertinent information regarding the subject service operations and...

Page 3: ... for different expenses damages and direct indirect losses deriving from the engine use or from both the total or partial impossibility of use is excluded The repair or replacemnt of any component will not extend or renew the warranty period Direct labor required to make repairs or to replace components found to be defective in materials or workmanship will be completed at no cost to the end user ...

Page 4: ... Valves and valve guides dimensions after assembly in the head Valves and valve guides gap Valve guide Oil seal ring on valve guide Valve seats Valve springs Tappets Breather valve Cylinder Connecting rod Piston and rings Crankshaft Main journals and crank pin diameter mm Governor and balancing shaft gear command Balancing shaft Speed governor Bearings Crankcase and timing cover Recoil starter Rop...

Page 5: ...RAZIONI Engine assembling Governor lever adjustment Engine test Starting with the recoil starter Electric starting Carburetor and R P M adjustment XII STORAGE Storage Temporary inactivity Preparation for starting XIII INSTALLATION INCLINATION AND OPERATING LIMITS Axial load radial load and maximum overhang Installation Inclination and operating limits XIV TORQUE SETTING Main torque specifications ...

Page 6: ...REG CODE 1 5302 528 MODEL N 50805 DATE OF ISSUE 31 07 2001 REVISION 00 DATE 31 07 2001 ENDORSED COMPILER TECO ATL 6 NOTE ...

Page 7: ...ed Dirty carburetor Carburetor needle valve blocked Speed governor rod blocked Grounded spark plug Broken spark plug lead Defective coil Clogged air filter Low oil level oil watch alerted Air filter chocked Blocked valves Worn piston rings Excessive valve play Defective oil seals Worn valve guides Worn governor spring Piston seizure Loose head locking nuts Low idling rate Driving belt broken POSSI...

Page 8: ...above all special maintenance work For special maintenance contact personnel trained specifically by Lombardini This work should be carried out in accordance with existing literature Lombardini declines all responsibility for accidents or for failure to comply with the requirements of law if changes are made to the engine s functional parameters or to the fuel flow rate adjustments and speed of ro...

Page 9: ...may come on even when the engine is not running Clean the cooling system with the engine turned off While cleaning the oil bath air filter check that the oil is disposed of in such a way as not to harm the environment Any filtering sponges in the oil bath air filter should not be soaked with oil The cyclone pre filter cup must not be filled with oil Since the oil must be emptied out while the engi...

Page 10: ...528 MODEL N 50805 DATE OF ISSUE 31 07 2001 REVISION 00 DATE 31 07 2001 ENDORSED COMPILER TECO ATL 10 III ENGINE IDENTIFICATION LOMBARDINI ENGINE TYPE SWEPT VOLUME CUSTOMER CODE ENGINE IDENTIFICATION NUMBER Í Í Í Í Î Ï ...

Page 11: ...city Dry weight Spark plug Ignition system Cooling system Type of engine TECHNICAL FEATURES LGA 280 340 OHC ENGINE TYPE N mm mm cc RPM kW HP kW HP kW HP Nm Kgm g kW h g HP h l l Kg LGA 280 LGA 340 1 74 64 275 8 5 1 3000 3800 6 0 8 1 6 6 9 0 5 6 7 6 6 3 8 5 5 2 7 1 5 9 8 0 19 1 94 329 242 6 1 2 30 112 2100 067 Electronic Forced air 4 stroke integral camshaft 1 82 64 338 8 5 1 3000 3800 7 4 10 8 1 1...

Page 12: ...O 3046 1 ICXN CONTINUOUS RATING WITH OVERLOAD CAPABILITY continuous heavy duty with constant speed and constant load MN Torque curve at N powe r MB in NB curve MA in NA curve C Curve of specific fuel consumption measured at power N The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tol...

Page 13: ...E 1 5302 528 MODEL N 50805 DATE OF ISSUE 31 07 2001 REVISION 00 ENDORSED DATE 31 07 2001 13 VI OVERALL DIMENSIONS OPTIONAL P T O AND FLANGES POWER TAKEOFFS AND SPECIAL FLANGING OVERALL DIMENSIONS Note The values are given in mm ...

Page 14: ... not smoke or use naked flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the plug to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting FUEL When refuelling it is advisable to use a funnel to prevent fuel from spilling o...

Page 15: ...earings and all other moving parts Engine life will also be notably reduced Oil viscosity must suit the ambient temperature in which the engine operates Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time If contact with the oil is inevitable you are advised to thoroughly wash your hands with soap and water as soon as possible Appropriate protecti...

Page 16: ...REG CODE 1 5302 528 MODEL N 50805 DATE OF ISSUE 31 07 2001 REVISION 00 DATE 31 07 2001 ENDORSED COMPILER TECO ATL 16 NOTE ...

Page 17: ...d condition tank casing flywheeI coil carburetor air filter exhaust fan cowl cylinder head the use of a Short Blocks is advised composed of crankcase crankshaft connecting rod piston timing cover already enclosed and prepared to be completed by the outside parts Once assembly operations have been completed proceed with setting up ENGINE PREPARATION After having drained off the oil from the engine ...

Page 18: ...ge 42 position the central screw on the opposite side from that used to extract the flywheel tighten the two screws in the threaded holes on the timing cover fig 4a DRIVESHAFTEXTRACTION After the completion of operations loosen the connecting rod screws slide out the piston and extract the drive shaft Do not demount and remount when hot to avoid deformations CYLINDER HEAD Made in die cast aluminiu...

Page 19: ...pin from the cam was 0 65 0 75 mm Camshaft with protusion of the pin between 0 50 0 60 mm will be delivered as spare parts VALVES GUIDES SEATS VALVE SPRINGS TAPPETS After disassembly and cleaning with a metal brush check that the valves heads are not deformed burned or worn in the seats replace the valves if damaged If the general condition is good reset the face track P in the seat with a grindin...

Page 20: ...o gauge with pitch code 1460 103 on page 42 Internal valve guides diameter after assembly in the head min 7 015 mm max 7 025 mm valve guides gauge diameter 7 010 mm passes 7 097 mm does not pass lf the diameter of the guide exceeds the plug diameter replace the guide In order to extract the valve guide from the seat use puller code 1460 104 on page 42 after having removed the safety ring OILSEALRI...

Page 21: ...at and rotating the valve using slight pressure and an alternating movement until the surfaces are perfectly set fig 13 Wash the valve and seat thoroughly with oil or petrol to eliminate all traces of lapping paste or shavings To check the efficiency of the seal between the valve and seat once lapping is terminated proceed as follows 1 Fit the valve on the head with the spring and cotters 2 Pour a...

Page 22: ...CYLINDER Using a dial gauge check two internal diameters a b perpendicular each ather at three different heights fig 17 lf the taper c d and ovalization a b exceed the limit of 0 06 mm the cylinder has to be rebored The oversizes are shown on page 36 lf the cylinder is rebored observe a machining allowance of 0 020 0 lf the taper c d and ovalization a b do not exceed the 0 06 mm limit and the cyli...

Page 23: ... that the difference between the two ends of the pin does is not more than 0 05 mm if this value is exceeded the connecting rod will require squaring The squaring operation can be carried out using a small mechanical press a Position the connecting rod on two shims making sure that it is perfectly horizontal with the press surface b Using the press apply pressure in jolts on the rod on the opposit...

Page 24: ...limit compress ring 0 20 0 40 0 20 0 463 1 scraper ring 0 20 0 40 0 20 0 463 1 Engine type Nominal end Initial Max limit LGA 340 OHC gap mm end gap mm end gap mm min max min max limit compress ring 0 25 0 50 0 25 0 563 1 2 scraper ring 0 25 0 50 0 25 0 563 1 2 lf the gap exceeds the values shown above and the cylinder does not require reboring replace the rings with others of the same type Check t...

Page 25: ... according to the data shown in table on page 43 When grinding the allowance for the crank pin is 0 0000 0 011 mm The surface must be finished without scoring to a roughness of 0 4 µmn Ra NOTE 1 When grinding the crank pin restore the radius value to original specification 2 7 3 0 mm 2 The main journals must not be ground GOVERNORANDBALANCINGSHAFTGEARCOMMAND Checkthatthegovernorgearteetharenotworn...

Page 26: ...aft gear are in corrispondence with the ones of the crankshaft gear SPEEDGOVERNOR The speed governor is of centrifugal counterweight type fig 28 Check that the gear rotates freely on the pin and that movement is not obstructed Check that the counterweights expand freely and that the action provides continuity of movement to the cap through to total opening BEARINGS The crankshaft is supported on b...

Page 27: ...ring and insert the new spring taking care that the direction of rotation is correct the clockwise engine rotation position DX is stamped on the self winding disk the replacement spring is supplied closed with clips therefore insert the outside U1 shaped eyelet in the starter disk seat and position the spring removing the clips one at a time fig 32 5 assemble the disk complete with spring and rope...

Page 28: ...nside the crankcase causing breather problems Before mounting oil the pin the piston the cylinder and the big end bush PISTON AND CONNECTING RODS The piston and the connecting rod must be assembled in a particular manner For correct assembly operations proceed as follows the connecting rod must be fitted using the triangular reference marks on the big end facing the fitter in the same position the...

Page 29: ...tive bushing code 1460 106 on page 42 to the conical end of the crankshaft b fitthetimingcover rememberingtopositionthegasketbetweenthetwo surfaces fig 36 and torque the screws to a 23 5 Nm value N B care should be taken when mating the governor gear with the crankshaft gear Do not force the cover if the mating has not been carried out correctly as this action may result in serious damage to the g...

Page 30: ... camshaft pulley tighten the pulley retaining screw to a 11 8 Nm 1 2 Kgm torque value turn the cam shaft until the cam is facing upward clearance adjustment will be facilitated in this position Using a feeler gauge check that the clearance is between 0 10 0 15 mm for both valves when the engine is cold fig 39 Inordertoreplacetheshims usetoolcode1460 109onpage42 lowerthe tappetsandraisetheshims the...

Page 31: ...ter value is 7 1 N 5 to check the timing use the flywheel make a few complete turns and check that the reference marks stamped on the crankcase and cylinder head match those on the pulleys If not loosen the tightener and repeat the entire operation 6 iftimingiscorrect tightthetightenernutatatorqueof 23 5NM 2 4Kgm FLYWHEEL ASSEMBLY AND COIL GAP ADJUSTMENT Fitthealternatorontheenginecrankcase ifprov...

Page 32: ...t in the seat Replace if necessary Check the condition and free movement of the float Check that the throttle rod is free to rotate throughout its field of action and that there is not excessive clearance between the rod and theseatallowingairinfiltration Check that the choke plate is not worn and that it rotates freely LUBRICATION Lubrication of internal moving parts is by means of oil taken from...

Page 33: ...ype of kik back during starting making this operation simple and safe both for the operator and the mechanical parts SPARKPLUG Clean the electrodes with a metal brush and compressed air cheek that the gap between electrodes fig 46 is between 0 6 0 8 mm lftheisolatingmaterialissplinteredortheelectrodesareworn replacewith a spark plug with appropriate thermal rating as shown in the table SPARK PLUG ...

Page 34: ...r Check the efficiency of the alternator as follows disconnect the rectifier wires connect a 10 20 V a c Voltmeter or a tester between the wires start the engine and check that the voltage reading on the voltmeter or tester corresponds to the values in the following table RPM Volts 2000 13 5 14 5 2500 17 18 3000 20 5 22 3600 25 26 lf the voltage reading is less than these values the rotating induc...

Page 35: ...therestingposition ifIeftinthefirstposition therectifierwillbedamaged and the battery will be discharged The panel electric wiring diagram is shown in fig 47 LIGHTING SYSTEM WITH ALTERNATOR Systemchecks Apply a charge lamp with an absorption of 60 70 W start the engine and set at the maximum power speed 3800 r p m the voltage should beapproximately12Vatutilization Insert an amperometer 5 A bottom ...

Page 36: ...lerator lever c fitted on the controls plate The governor spring should always be fixed to the external hole on the acceleratorlever Fit the tie rod d between the governor lever and the carburetor throttle command rod fit the take up spring Adjustment should be carried out as follows 1 Move the accelerator to the max position with the carburetor throttle fullyopen fig 54 2 Rotate the governor rod ...

Page 37: ...T 1 Start the engine and leave running for a few minutes 2 Attach an r p m counter to the end of the crankshaft Using screw a in fig 58a adjust the minimum speed to the value of 1300 1350 r p m 3 Fully tighten the air adjustment screw b in fig 58b and then loosen slowlyuntilitisinthenormalfunctioningposition usuallyapproximately two turns Check that the minimum speed is maintained at the values no...

Page 38: ... tank by removing the feed pipe and empty the carburetor using the drain button positioned under the carburetor bowl clean the fins on the cylinder and head remove the spark plug and pour in a spoonful of engine oil allow the enginetoturnoverinordertodistributetheoilonthecylinder thenreplace the spark plug close the exhaust and intake holes of the air filter using adhesive tape cover the engine an...

Page 39: ...LOAD RADIALLOADANDMAXIMUMOVERHANG The axial thrust in both directions Fa fig 65 must not exceed 250 Kg The maximum radial load Fr fig 65 for belt transmission is 80 Kg with a maximum overhang S of the cylinder axis of 140 mm When increasing the overhang S reduce the load Fr so that at the bending moment Fr x S does not increase 63 INSTALLATION INCLINATION LIMITS OF OPERATION 64 65 ...

Page 40: ... M 10 M 6 M 18 x 1 5 M 6 M 6 M 8 M 8 M 6 M 6 38 b page 29 34 a page 28 42 page 31 42 page 31 39 page 30 41 b page 31 36 page 29 39 page 30 Cylinder head Connecting rod cap Flywheel Coil Camshaft pulley Belt stretcher Timing cover Fan cowl Breather cover MAIN TORQUE SETTINGS Note Comply with the following general regulations for the nuts and bolts not indicated in the table M6 10 Nm M8 25 Nm M10 45...

Page 41: ... 8x1 25 9x1 25 10x1 50 13x1 75 14x2 00 16x2 00 18x2 50 20x2 50 22x2 50 24x3 00 0 62 1 22 2 08 3 40 5 10 6 55 9 05 15 30 23 30 35 40 44 40 61 80 74 90 96 00 0 52 1 01 1 73 2 84 4 25 5 45 7 54 12 80 19 40 29 50 37 00 51 50 62 40 80 00 3 6 7 12 19 8 29 6 38 52 5 89 135 205 257 358 435 557 5 1 9 9 17 27 8 41 6 53 4 73 8 125 190 289 362 504 611 784 6 11 9 20 4 33 50 64 2 88 7 150 228 347 435 605 734 94...

Page 42: ...flywhell side Oil seal installation cone P T O side Belt stretcher tool Valve stem oil seal assembly tool Valve clearance shim disassembly tool Camshaft bearing assembly tool Head oil seal ring assembly tool Assembly tool for bearing oil seal rings and pulley Valve retainer assembly tool Crankshaft pulley disassembly tool T D C check tool 1460 103 1460 104 1460 119 1460 105 1460 106 1460 107 1460 ...

Page 43: ...EARANCES AND ADJUSTMENTS TABLE Valve guide and stem INTAKE EXHAUST Piston pin and small end hole of connecting rod Piston and pin Connecting rod bearing and crankshaft journal Valve clearance when cold Gap between ignition coil and flywheel Spark plug electrode gap Distance between ends of compression rings LGA 280 Distance between ends of scraper ring LGA 280 Distance between ends of compression ...

Page 44: ...diese Angabe jederzeit verändern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación REG CODE 1 5302 528 MODEL N 50805 DATE OF ISSUE 31 07 2001 REVISION 00 DATE 31 07 2001 VISTO COMPILER TECO ATI 44 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 ...

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