Lombardini LGW 523 Series Workshop Manual Download | Manualshive

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REG. CODE

1-5302-509

MODEL N°

50778

DATE OF ISSUE

10.06.99

REVISION

00

DATE

10.06.99

ENDORSED

COMPILER TECO/ATI

90

DRIVING TORQUES

XVI

POSITION

Torque

( Nm )

30 *

4
8

40
40
12

9

40
60
80
80
80
50

360***

5
4

80
25
25
40

6

10

8

10

Diam. X Pitch

( mm )

14 x 1.25

5 x 0.8

6 x 1

10 x 1.5
10 x 1.5

6 x 1
6 x 1
8 x 1

10 x 1.5

10 x 1.25
10 x 1.25
10 x 1.25
10 x 1.25

16 x 1.5 LH

6 x 1

5 x 0.8

10 x 1.25

12 x 1.5
20 x 1.5
12 x 1.5

5 x 0.8

6 x 1
6 x 1
6 x 1

Reference

( figure N° and page)

N° 153 - page 63

N° 3 - page 19

N° 128 - page 51

N° 43 - page 30

N° 19/20 - page 23

N° 37/40 - page 24

N° 83 - page 38

N° 94/95 - page 41

N° 11 - page 21
N° 22 - page 23
N° 126 - page 50

N° 14 - page 22
N° 128 - page 51

N° 3 - page 19

N° 112/113 - page 46

N° 152 - page 62

N° 65/66 - page 34

Spark plug
Intake manifold fixing nut (LGW 627)
Carburetor fixing nut
Rocker arm journal bearing fixing nut
Tightening pulley nut
Flange for rear tang retention ring
Rocker cap fixing
Cast iron connecting rod cap
Main journal cap
Flywheel fixing (self-locking nut)
Timing system pulley fixing
Fuel pump eccentric
Air pump coupling
Driving pulley fixing
Carburetor stud bolt
Intake manifold stud bolt (LGW 627)
3rd P.T.O. control pulley
Oil pressure switch
External oil filter union
Oil sump plug
Enabling lamination screw
Timing system shaft bearing locking screw
Intake manifold fixing screw (LGW 523)
Oil sump fixing screws

MAIN DRIVING TORQUES

*

Tightening without torque wrench: tighten the spark plug fully on to the head by hand.
Tighten to a 90° angle using the relative wrench. Tighten when the engine is cold.

***

Lubricate under the screw head and pulley centering with "Molyslip".

Note: Comply with the following general regulations when tightening screws and nuts not indicated in the table:

M 6

è

10 Nm - M 8

è

25 Nm - M 10

è

45 Nm material A 8.8

POSITION

DENOMINATION

( Diam. in mm )

SEALER

( Loctite type )

518
270
242

DAW CORNING 7091

495
270

648 BV

242 / E

270
242
242

DR 270

270
270
638

648 BV

242
242
270
270
242

Cylinder head water thermostat unit
Oil pump stud bolts
Carburetor fixing on intake manifold
Main bearing gaskets
External water pump gasket
Timing shaft bearing lamination
Engine block
Engine block
Fuel pump stud bolt
Carburetor stud bolt
Cylinder block stud bolt on exhaust side
Belt tightening pulley stud bolt
Oil filter cartridge union
External oil filter union
Plate centering pin (internal alternator)
Cylinder head
Cylinder head
Enabling lamination screw
Flange fixing screw on flywheel side (2 ext.alternator through holes)
Oil pump fixing screw
External alternator cable fixing screw

H

2

O thermostat unit

M 5 x 0.8

3 screws 6 x 16

Plug Ø 30

Plug M 12x1.5

M 5 x 0.8

M 6 x 1

M 20 x 1.5
M 20 x 1.5

Plug Ø 30

M 6 x 1

M 5 x 0.8

USE OF SEALING AGENT

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89
90
91
92
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Summary of Contents for LGW 523 Series

Page 1: ...ANUAL Series LGW 523 627 and LGW 627 GPL engines code 1 5302 509 SERVICE 1 LGW 523 LGW 627 1st Edition COMPILER TECO ATL REG CODE 1 5302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 ...

Page 2: ... 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 operations and that they have clearly understood the operation...

Page 3: ...elf or by means of authorized workshops All other total and partial liability and obligation for other direct or indirect expenses damages or losses deriving from use or the impossibility to use the engines shall however remain excluded Repairs or supply of substitutions shall in no way extend or renew the length of the warranty period Expenses sustained to remove the engine from the machine or hu...

Page 4: ... and alternator belt Cylinder head removal Cylinders Cylinders class Cylinders roughness Crank shaft float Crank shaft front and rear oil retention seals Crank shaft lubrication ducts Crank shaft main journal and crank inspection Demounting and remounting the pin stop rings Demounting the oil pump Diameters of main journal and big end journals Driving pulley Exhaust manifold Flywheel Head gasket H...

Page 5: ...gine LGW 627 Rocker shaft Rocker shaft demounting and refitting Supporting half rings Tank on request Third drive components for LGW 627 Timing belt and gears Timing belt guard Timing pulley Disassembly Reassembly Timing pulley Timing system tuning reference marks Transmission pulley Tuning angles to check the timing system valve clearance 2 mm for LGW 523 Tuning angles to check the timing system ...

Page 6: ... adjustment Idling speed Fuelling circuit Inspections and adjustments Mixture adjuster screw regulation idling rate Normal speed Partial air powered opening of the ignition throttle Pick up Pick up pump delivery Positive opening Preliminary conditions Speed adjuster screw regulation idling rate XII IGNITION 523 ignition process Introduction LGW 523 coil LGW 523 cut off LGW 523 ignition system LGW ...

Page 7: ...rnator and module serial N 122 2193 113 Wiring diagram of gasoline petrol fuelled engine LGW 523 withour idling back up device with internal alternator and module serial N 122 2193 108 Wiring diagram of gasoline petrol fuelled engine LGW 627 with external alternator and module serial N 122 2193 109 Wiring diagram of gasoline petrol fuelled engine LGW 627 with external alternator and module serial ...

Page 8: ...ISSUE 10 06 99 REVISION 00 DATE 10 06 99 ENDORSED COMPILER TECO ATI 8 TABLE OF CONTENTS XVI MAIN DRIVING TORQUES Driving torques for standard screws Main driving torques Use of sealing agents XVII SPECIFIC TOOLS Specific tools 90 91 90 90 92 92 ...

Page 9: ...lter clogged Electronic module defective Hall module sensor faulty Battery low Wiring uncertain or incorrect Defective ignition switch Defective starter motor Defective coil Spark plug grounded or defective Spark plug cable disconnected Cut Off defective or disconnected Air filter clogged Coolant fluid radiator clogged Coolant fluid level low or containing air Engine overloaded Speed governor leve...

Page 10: ...ho 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 work ...

Page 11: ...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 sta...

Page 12: ...ATE 10 06 99 ENDORSED COMPILER TECO ATI 12 III CODE AND IDENTIFICATION é ç Max speed setting r min Type of engine Serial N Performance approval N of version K modulus Exhaust approvals Note The Performance Approval and Exhaust Approvals are only stamped for Diesel engines ...

Page 13: ...ilter excluded Oil consumption measured at N power rating Oil consumption measured at NA power rating Recommended battery Dry weight IV TECHNICAL SPECIFICATIONS LGW 523 627 SPECIFICATIONS TYPE OF ENGINE N mm mm cc Nm l min g kW l l g kWh g kWh V ah Kg In N power SELF DRIVING POWER Discontinuous service at variable rate and load In NA power CONT OVERLOADABLE POWER Continuous heavy duty service at c...

Page 14: ...easured at power N The indicated power ratings refer to engines equipped with air filter standard silencer and fan with the running in period terminated and at environmental conditions of 20 C and 1 bar Maximum power is guaranteed with a 5 tolerance The power ratings drop by about 1 for every 100 m of altitude and by 2 for every 5 C above 25 C Note Consult LOMBARDINI for power torque curves and sp...

Page 15: ...COMPILER TECO ATL REG CODE 1 5302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 15 VI OVERALL DIMENSIONS Note The values are in mm LGW 627 LGW 523 ...

Page 16: ...to carry out the operations described in the table may lead to technical damage to the machine and or system MAINTENANCE RECOMMENDED OIL COOLANT FLUID FUELS AND LUBRICANTS LGW 523 ENGINE MAINTENANCE 10 50 80 100 175 250 350 500 1000 2000 5000 FREQUENCY HOURS PART OPERATION OIL COOLED AIR FILTER FUEL TANK AIR FILTER OIL LEVEL SUMP OIL BATTERY FLUID RADIATOR FINS ALTERNATOR BELT TENSION VALVE AND TA...

Page 17: ...INA CCMC G 3 G 5 CCMC PD 1 PD 2 CCMC D 2 D 4 CCMC D 3 D 5 MIL L 2104 D MIL L 2104 E MIL L 46152 C MIL L 46152 D E MB 226 1 MB 226 5 MB 227 1 MB 227 5 228 3 MB 228 1 VW 501 01 VW 500 00 VOLVO VDS MAN QC 13 017 VW 505 00 SH API The engine 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 U...

Page 18: ...rect way Do not litter COOLANT FLUID Remember to use anti freeze and protective fluids e g es AGIP ANTIFREEZE ESSO PERMANENT ANTIFREEZE etc mixed with decalcified water for preference The freezing point of the coolant fluid mixture depends on the concentration of the product in water at 15 30 at 20 C 35 at 25 C 40 at 30 C 45 at 35 C 50 Besides lowering the freezing point permanent liquid also rais...

Page 19: ...degrease the housing on the carburetor and apply Loctite 401 adhesive Consult page 16 for the maintenance replacement instructions Never clean the filtering element using solvents with a low flash point This could cause an explosion It is inadvisable to blow compressed air on to the paper filter element If necessary lightly and repeatedly tap the element on a hard surface to eliminate any excess d...

Page 20: ...burns Exhaust manifold When the exhaust manifold is demounted make sure that the interior is perfectly clean and free from cracks or fractures Replace the seals whenever the manifold is remounted Torque the fixing nuts to 25 Nm when the parts are remounted DISASSEMBLY REASSEMBLY VIII 6 5 4 When engines LGW 523 and LGW 627 are being installed remember that any variation to the intake system type of...

Page 21: ...arry out the operations outdoors or in a well ventilated place Keep your face well away from the filler cap or you could inhale harmful fumes Dispose of fuel in the correct way as it is highly polluting Do not litter Tank on request Demount the fuel filter and then unscrew the screws from the fixing clamps Completely empty the tank and check inside to make sure there are no impurities Make sure th...

Page 22: ...ter motor and mount tool 7107 1460 051 in its place see page 92 To remove the pulley slacken off the central screw 1 and proceed with the four side screws 2 The central screw 1 is unscrewed in a clockwise direction When remounting apply Moly slip anti seize to the screw thread and torque to 360 Nm Note When reference mark A coincides with B the piston of the cylinder on the flywheel side first cyl...

Page 23: ...Components 1 Nut 2 Washer 3 Belt guide pulley 4 Ball bearing 5 Shaft 6 Bearing plate 7 Timing belt tightening lever Torque nut 1 to 40 Nm when remounting Pulley on crank shaft Make sure that the key remains in its housing when remounting Note reference mark 1 on the timing pulley and reference mark 2 on the oil pump casing are used to tune the timing system When the two reference marks are aligned...

Page 24: ...e Tighten nut 1 by hand until the belt tightener rests on the surface of the engine block Belt remounting must begin with the camshaft pulley and then pass to that of the drive shaft not the driven shafts Tuning the timing system Belt tightening tool Fit tool 1 Serial N 7107 1460 049 see page 92 into lever 2 Tuning the timing system Tightening the timing belt and belt tightener torque Fit the torq...

Page 25: ...a a a a a Intake valve opening b b b b b Intake valve closing g g g g g Exhaust valve opening d d d d d Exhaust valve closing Operative timing system tuning angles valve clearance 0 26 mm for LGW 523 a a a a a 38 before S b b b b b 58 after I g g g g g 70 before I d d d d d 26 after S Tuning angles to check the timing system valve clearance 2 mm for LGW 523 a a a a a opens 2 after S b b b b b clos...

Page 26: ...r rod 8 Intermediate rod 9 Governor spring holes the various holes are used to modify the speed drop with the same spring 10 Accelerator support bracket When remounting make sure that all components are in a good condition and perfectly functional A badly operating speed governor can seriously damage the engine and any bystanders in the vicinity Remounting the LGW 627 speed governor Fit all parts ...

Page 27: ... block and set the piston of cylinder N 1 flywheel side to top dead center These conditions allow key A to pass through cavity B Oil pump Details and components 1 Outer casing of oil pump in aluminium 2 O Ring 3 Oil pump cover in steel 4 Gasket between oil pump and engine block 5 Centering pins 6 Bolt to fix oil pump to engine block 7 Bolts to fix oil pump to engine block 8 Countersunk screw to fi...

Page 28: ...e cylinder head 8 Oil return from bleed to sump see description in point 5 9 Seal between rocker cover and cylinder head The rocker cover seal ensures that the rocker pivot camshaft lubrication circuit is tight It is therefore advisable to replace it whenever it is demounted and to remount it with particular care Damage or breakage of the seal could lead to a pressure drop in the lubrication circu...

Page 29: ... to remount it with particular care Damage or breakage of the seal could lead to a pressure drop in the lubrication circuit Torque the fixing screws to 9 Nm when remounting the cover LGW 523 bleed The operating principle of the bleeding system for engine LGW 523 is similar to that of engine LGW 627 Vapour and oil are no longer recovered in the rocker cover but in the engine block cover 3 The oil v...

Page 30: ... to allow for lubrication and is closed at both ends by two plugs Rocker shaft demounting and refitting To take the shaft 1 from the support 2 remove pin 3 by drilling it with a 4 mm bit On remounting insert a new pin and recess it in relation to the surface of support A 0 to 1 mm Check the shaft diam B and rocker holes diam C for wear Remove the closing plugs 4 from the ends and thoroughly clean ...

Page 31: ...he aid of bushes Note The eccentric that controls the fuel pump 3 is not an intengral part of the camshaft but is faced on to it and fixed with a bolt Tighten the screw on the eccentric to an 80 Nm torque in case of replacement Camshaft inspection of pin diameters and housings Measure the diameters of the housings with a internal comparator and the camshaft journals with an externalmicrometer Cams...

Page 32: ...lead to deformations CYLINDER HEAD removal If deformation exceeding 0 10 mm is gauged on the cylinder head surface level off by grinding removing 0 20 mm at most Consult fig 82 when tightening the head Valves To remove the valves first take out the cotters Place a shim under the valve mushroom strongly press on the upper spring plate as shown in the figure Components 1 Valve stem 2 Oil retainer se...

Page 33: ...o 45 45 D 29 00 mm Intake valve B Material X 45 Cr Si 8 UNI 3992 1 Chromium plated section a a a a a1 60 30 to 60 45 C 33 00 mm Valve guides and housings The intake and exhaust guides are both made of grey iron of phosphorous pearlitic matrix and are dimensionally the same Dimensions mm A 36 4 to 36 6 B 11 045 to 11 054 C 11 000 to 11 018 D 5 80 to 6 20 E 9 75 to 9 85 Note Since they are pre finis...

Page 34: ...ead surface and the retention width of seat S Old engine 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 unavoidable you are advised to wash your hands with soap and water as soon as possible Dispose of old oil in the correct way as it is highly polluting Do not litter Oil sump removal Remove the fixing screws Insert bla...

Page 35: ...ng the pin stop rings Remove the circlip by inserting a pointed tool into slot A When remounting insert the circlips with their tips pointing downwards within the angles a a a a a 15 Piston class and logotype Depending on their diametral values the pistons are divided into classes A B C This reference is marked on the crown of the piston see fig 71 The logotype is marked inside the piston Dimensio...

Page 36: ...nce between tips A in the operating zone 1st piston ring A 0 20 to 0 40 wear limit 1 0 2nd piston ring A 0 20 to 0 40 wear limit 1 0 3rd piston ring A 0 20 to 0 45 wear limit 1 0 Piston rings play between slots mm A 0 030 to 0 050 B 0 020 to 0 040 C 0 010 to 0 030 Piston rings assembly order A 1st piston ring tapering and torsional interior B 2nd piston ring tapering interior C 3rd oil scraper pis...

Page 37: ...n connecting rod unit to the crank shaft consult fig 83 for the head connecting rod torque value Piston protrusion test Establish value A of each piston by checking in four different diagonally opposite points of the piston crown then make sure that the protrusion does not exceed the following values 0 95 to 1 27 Series LGW 523 627 has a head gasket with a single thickness measurement 1 65 mm This...

Page 38: ...to thoroughly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the first time Connecting rod Big end bearing After having uncoupled the connecting rod from the crank shaft in order to make the necessary inspections make sure when remounting that the two centering marks A and B are on the same side see fig 83 Tighten the big end cap bolts to a 40 Nm...

Page 39: ... to 40 Nm D 17 996 to 18 000 E 50 900 to 51 100 B D 0 015 to 0 039 B D wear limit 0 060 Note When the small end bearing is inserted make sure that the two lubrication holes coincide Lubricate before remounting Connecting rod alignment Use a gauge with surface plate or a comparator as shown in the figure Check the alignment of the axes using the piston pin deviation A 0 015 mm limit 0 030 mm Small ...

Page 40: ...istons measure the diameter of zone Z of each cylinder according to the axis perpendicular to the crank shaft Cylinders class The class references of the pistons A B C are on the piston crowns while those of the cylinders are on the cylinder block in the places indicated by the arrows see fig 91 Note For engine LGW 523 with aluminium cylinder block the cast iron cylinders can be normally ground to...

Page 41: ...ntion surface only project Proceed in the same way for the front main bearing cap To fit the supports into the cylinder block insert the two 0 1 mm thick laminations C and D between their surfaces tool serial N 7107 1460 053 Tighten the screws to a 60 Nm torque Note It is advisable to apply a few drops of silicone sealer on the shearing plane of gasket 2 Checking for play between bearings and main...

Page 42: ...ntion seals Front oil retention seals 1 in the oil pump cover and rear oil retention seals 2 in the flange on the flywheel side Replace the seals if they are deformed hardened or damaged To replace Thoroughly clean the housing Keep the seals immersed in engine oil for about half an hour Insert it in its housing with a plug exercising an even pressure all over its front surface The two surfaces A a...

Page 43: ...erweights are different Crank shaft main journal and crank inspection Use a micrometer for exteriors Diameters of main journal and big end journals Dimensions A 47 984 to 48 000 wear limit 47 900 B 39 984 to 40 000 wear limit 39 900 The diametrical values of the main journal and big end journals are the same for all the engines in the series LGW 523 LGW 627 Inner diameters of main and big end bear...

Page 44: ...n be supplied by the third drive is 7 kW corresponding to a 37 Nm torque at 3600 rpm Engine r min pump r min transmission ratio 1 0 5 Third drive components for LGW 627 1 Splined sleeve 2 Timing pinion 3 Retention ring 4 Flange for hydraulic pump 1 PD 5 Retention ring Note Sleeve 1 also includes the fuel pump control eccentric and should be fixed with the same bolt as the standard eccentric but wi...

Page 45: ...tion speed Use suitable oil in order to protect the engine Nothing more than lubrication oil can influence the performances and life of an engine Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston rings to jam and will lead to rapid wear on the cylinder liner the bearings and all other moving parts Engine life will a...

Page 46: ...a 40 Nm torque Oil pump Oil pump flow rate test at 1000 r min with oil at 80 C Engine Flow rate l min Pressure bar LGW 523 LGW 627 4 to 4 3 3 to 3 5 Flow rate test at 3600 r min with oil at 80 C Engine Flow rate l min Pressure bar LGW 523 LGW 627 19 3 4 to 4 5 Oil pump play between rotors Measure play A between the teeth as shown in the figure The max value is 0 171 mm wear limit play 0 250 mm Con...

Page 47: ...3 Rubber pad 7 Spring 4 Spring Specifications Maximum working pressure 7 bar Maximum bursting pressure 20 bar Filtering degree 15 m By pass valve setting 1 5 to 1 7 bar Total filtering area 730 cm Oil pressure check After remounting fill up with engine oil fuel and coolant fluid Remove the pressure switch fit on a union and connect a 10 bar pressure gauge Start the engine and watch the pressure va...

Page 48: ... 4 Cylinder block 5 Fluid temperature thermoswitch 119 The cooling circuit contains fluid under pressure Do not carry out any inspections until the engine has cooled and even then open the plug of the radiator or expansion chamber with caution Keep well away from a hot engine if an electric fan is installed since this could start up even when the engine is at a standstill Coolant fluid is pollutin...

Page 49: ...r a manual air pump Compress the air to a pressure of 1 bar for about two minutes Make sure that there are no leaks from the radiator The tank plug has a vacuum valve 1 and an overpressure valve 2 Overpressure valve opening pressure 0 7 bar Cooling fluid pump components 1 Impeller 2 Front seal 3 Pump casing 4 Drain hole 5 Bearing 6 Pulley 7 Shaft Thermostatic valve 1 Stainless steel or brass casin...

Page 50: ... type serial N 3730 106 You are advised to use genuine spare parts since their 350 cm filtering area volume and their filtering degree have been specially researched It is advisable to replace the fuel filter after every 350 hours service in normal operating conditions When replacing check the arrow that indicates the correct mounting direction see fig 125 Fuel pump Components 1 Fuel pump casing 2...

Page 51: ...00 r min until the thermostat opens do not allow the engine to heat at idling rate alone as measurement of the CO content would not be valid in these conditions Operate with the cold starting device deactivated Work on the speed adjuster screw 1 see fig 129 unable obtaining a stable rate of 900 r min Mixture adjuster screw regulation idling rate Work on the idling mixture adjuster screw 1 see fig ...

Page 52: ...eck nuts 1 after having calibrated Disconnect the vacuum gauge and plug the two holes to check the vacuum on the head with the relative screws as indicated in fig 130 Apply a weak thread locking product to make certain that these screws are perfectly tight High and idling speed adjustment Using a precision revolution counter check the high speed with no load and adjust it to the required value by ...

Page 53: ...dling mixture adj screw seal 14 Valve fixing screw 15 Float chamber 16 Fuel filter 17 Fuel pipe union pipette 18 Pipette fixing screw seal 19 Pipette fixing screw 20 Fuel shut off pin 21 Float pin 22 Float chamber seal 23 Float chamber fixing plug seal 24 Float chamber fixing plug 25 Rod 1 26 Rod 2 ADJUSTMENTS AND CALIBRATION DESCRIPTION Choke Float Level from float chamber surface Fast running je...

Page 54: ...justments This adjustment must only be carried out with the right equipment It can however be done without this material see next section Without analyzer Proceed in the following way after having brought the engine to a 1100 to 1200 r min idling rate 133 135 134 Remove the sealing plug from enrichment screw B fig 135 and using it find the top rate Increase the idling speed by 50 r min using screw...

Page 55: ... XI CALIBRATED PARTS ADJUSTMENTS DESCRIPTION Choke Centering device Main jet Brake air jet Diffuser tube Slow running jet Slow running air jet Pump jet at 20 Pump discharge Pump cam Ignition cam Relief capsule bush Pin valve Fuel return hole Non return hole Idling mixture adjuster hole Idling mixture bush Lead hole under throttle Slot compression holes 1st CONDITION 22 2 8 120 190 F 74 50 160 40 4...

Page 56: ...acuum reaches under the throttle the spring acts on the diaphragm and the valve opens a complementary circuit to the main jet At a high rate a power enricher 11 adds a a supplementary quantity of fuel to the engine by the action of vacuum at jet level Idling speed Fuel from the float chamber passes through jet 3 and reaches the sump of the diffuser tube A hole transfers the fuel to slow running je...

Page 57: ...open after each cycle Before beginning the return to idling stroke make sure that the pump jet has stopped delivering Wait a few seconds in the idling position to allow the pump to make a complete delivery After the pump has been operated about ten times delivery i e the quantity of fuel collected in the test tube must be between 8 and 12 cc Positive opening Fully pull out the starter lever and ke...

Page 58: ...lectronic module to handle the ignition phase compared to the original one which gave an increasing timing to to 3000 r min the modified module has a constant 11 timing up to 2000 r min in closed throttle conditions This allows an optimum adjustment of the air device when hot The actuator consists of a diaphragm which controlled by the vacuum allows the throttle valve to open and the idling speed ...

Page 59: ...ig 145 connected by means of two high voltage cables to the respective spark plugs Operating principle The ignition system installed on these engines allows the firing control point to be monitored using the number of engine revolutions and the reference given on a level with top dead center as parameters The data concerning the required spark lead curve are in mapped the memory of the microproces...

Page 60: ...olarities The central electrode of one will be positive and the other negative this latter is more liable to wear Phase sensor The phase sensor used to identify the correct phase angle is a sensor with Hall effect 1 It is activated by a magnet inside the sensor itself The influence of the magnet is eliminated when lamination 5 is held by sensor 1 thus determining an output signal The engine rotati...

Page 61: ...s are discovered LGW 523 coil The coil is powered by two wires The red one is constantly powered by the battery through 15 54 The brown or pale blue wire is controlled by the module To charge the coil the module is grounded by the second wire via an internal contact this allows current to circulate regulated by the module and no longer at 6 A and the magnetic circuit of the coil to charge The mome...

Page 62: ...gnition system fig 152 Foreword A phase sensor and two high voltage coils with one output are activated 1 Timing pulley of the camshaft with lamination in configuration 1 for engine LGW 627 at 90 to transmit to the sensor with Hall effect 2 Electronic module 3 Cover situated on the camshaft on the timing system side with the Hall effect sensor installed 4 Coils Apply a 6 Nm driving torque to remou...

Page 63: ...ug type Champion RC12YC Fit the spark plugs in place by fully screwing them on to the head by hand Final torquing must be carried out with the relative 90 angle wrench or to a 30 Nm driving torque Hex nut 1 to demount and remount the spark plug measures 16 mm If necessary clean the electrodes with a bronze bristle brush and blow with compressed air If the ceramic insulation is chipped or the elect...

Page 64: ... 50778 DATE OF ISSUE 10 06 99 REVISION 00 DATE 10 06 99 ENDORSED COMPILER TECO ATI 64 155 ELECTRICAL CIRCUIT XIII Wiring diagram of gasoline petrol fuelled engine LGW 627 with external alternator and module serial N 122 2193 109 ...

Page 65: ... 1 5302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 65 XIII ELECTRICAL CIRCUIT 156 Ignition module of gasoline petrol fuelled engine LGW 627 with spark lead variation device serial N 122 2193 109 ...

Page 66: ... 50778 DATE OF ISSUE 10 06 99 REVISION 00 DATE 10 06 99 ENDORSED COMPILER TECO ATI 66 157 ELECTRICAL CIRCUIT XIII Wiring diagram of gasoline petrol fuelled engine LGW 627 with external alternator and module serial N 122 2193 114 ...

Page 67: ... 1 5302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 67 158 Ignition module of gasoline petrol fuelled engine LGW 627 with spark lead variation device serial N 122 2193 114 XIII ELECTRICAL CIRCUIT ...

Page 68: ...ODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 DATE 10 06 99 ENDORSED COMPILER TECO ATI 68 159 ELECTRICAL CIRCUIT XIII Wiring diagram of LPG fuelled engine LGW 627 with external alternator and module serial N 122 2193 114 ...

Page 69: ...302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 69 160 Ignition module of gasoline petrol and LPG fuelled engine LGW 627 with spark lead variation device serial N 122 2193 114 XIII ELECTRICAL CIRCUIT ...

Page 70: ...ISSUE 10 06 99 REVISION 00 DATE 10 06 99 ENDORSED COMPILER TECO ATI 70 161 ELECTRICAL CIRCUIT XIII Wiring diagram of gasoline petrol fuelled engine LGW 523 without idling back up device with internal alternator and module serial N 122 2193 108 ...

Page 71: ...DE 1 5302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 71 162 Ignition module of gasoline petrol fuelled engine LGW 523 without idling back up device serial N 122 2193 108 XIII ELECTRICAL CIRCUIT ...

Page 72: ... OF ISSUE 10 06 99 REVISION 00 DATE 10 06 99 ENDORSED COMPILER TECO ATI 72 163 ELECTRICAL CIRCUIT XIII Wiring diagram of gasoline petrol fuelled engine LGW 523 with idling back up device internal alternator and module serial N 122 2193 113 ...

Page 73: ...ODE 1 5302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 73 164 Ignition module of gasoline petrol fuelled engine LGW 523 with idling back up device serial N 122 2193 113 XIII ELECTRICAL CIRCUIT ...

Page 74: ...tself Never work on the battery near naked flames lighted cigarettes or sparks risk of explosion or fire outbreaks The fluid in the battery is poisonous and corrosive Avoid contact with the skin and eyes The battery must be recharged in a well ventilated place well away from naked flames and possible sources of sparks Batteries contain substances that are very harmful to the environment If the bat...

Page 75: ...ten nut 1 to a 60 Nm torque Characteristic curve of alternator Marelli AA 125 R 14V 45A The curves were measured with an electronic voltage governor after a 25 C heat stabilizing process test voltage 13 5 V P1 Power in KW I Current in Amperes h h h h h Alternator efficiency Note The r min rates in the table multipled by 1000 are those of the alternator Engine r min alternator r min ratio with 88 m...

Page 76: ...4 Stator Battery recharging curve for 12V 20A alternator three output wires The test was conducted after a 20 C heat stabilizing process The current delivery with reference to the curve may be subjected to variations between 10 and 5 Battery recharging curve for 12V 30A alternator with two output wires The test was conducted after a 20 C heat stabilizing process The current delivery with reference...

Page 77: ...1 KW The curves were measured at a temperature of 20 C with a 66 Ah battery U Voltage to starter motor terminals in Volts n Starter motor speed in r min I Power draw in Amperes P Power in KW M Torque in Nm Sensor for coolant fluid temperature indicator Specifications Circuit unipolar Power source voltage rating 6 to 24 V Power draw 3W Circuit closing temperature 107 to 113 C Driving torque 25 Nm P...

Page 78: ...ion longer than 6 months Besides the previous operations it is advisable to Treat the lubrication system and moving parts with rust inhibitor oil corresponding to MIL L 21260 P10 grade 2 specifications SAE 30 E g ESSO RUST BAN 623 AGIP RUSTIA C SAE 30 Allow the engine to turn when full of rust inhibitor then drain off the excess Cover the external unpainted surfaces with rust inhibitor oil corresp...

Page 79: ...COMPILER TECO ATL REG CODE 1 5302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 79 Engine LGW 627 LPG fuelled XV LPG fuelled ENGINE LGW 627 ...

Page 80: ...same from all liability for operating faults and for any damage the engine might sustain Operation of the LPG conversion unit LPG flows from the tank and reaches the regulator atomizer through the high pressure pipe The gas flow is regulated by a solenoid valve that remains closed when the engine is at a standstill or when it is fuelled with gasoline petrol The gas changes from the liquid to gaseo...

Page 81: ...mp fuse D Ignition coil E Gas solenoid valve F Gasoline petrol solenoid valve G Regulator Connections 1 Brown wire antenna the high voltage wire of the ignition coil can be wound around this or it can be connected to the revolution counter wire 2 Red wire connect to an ignition key controlled positive making sure that 12V are supplied 3 Black wire earth connection 4 Blue wire connect to gas users ...

Page 82: ...on kit which allows the module to pilot the starter motor This relay is essential owing to the current value required by the starter motor 10 A with 30 A peaks values not tolerated by the module driver It is important for the module to handle the starter motor to prevent undesired explosions in the intake manifold The starter motor is activated when the ignition key is turned to the start position...

Page 83: ...of the first stage valve 2 Engine intake through gas outlet 7 creates a vacuum in the second stage chamber and produces an axial movement of membrane 8 The membrane is connected to lever 9 and controls the opening movement of valve 10 allowing gas to reach the second stage chamber through duct 11 and from thence to the engine through gas outlet 7 Appropriately calibrated spring 12 retains valve 10...

Page 84: ...he regulator to prevent impurities from penetrating the regulator body check to make sure that when the engine is running there are no leaks from the water pipes the water pipes are generally connected to the heating circuit of the passenger compartment make sure that the thermostat operates correctly checking that the regulator atomizer heats quickly Whenever the engine cooling circuit is emptied...

Page 85: ...ct It also has a filter that retains the coarser impurities the fuel may contain The electric power source voltage rating is necessarily identical to that of the vehicle circuit The body of the solenoid valve is tested at the internal pressure of 45 bar The unit consists of a reservoir containing the filter and two input and outlet unions The magnetic coil is installed on top of the reservoir The ...

Page 86: ...he regulations leaving the regulator with the sole task of supplying gas at a constant pressure as the engine requires It consists of the following parts a casing more or less the original shape of the carburetor or intake manifold so that it can be easily fixed in place an appropriately sized fixed Venturi shaped choke with a series of gas outlet holes in its narrow part Owing to the effect of th...

Page 87: ...ng time Mod 093 change over switch installation Change over switch Mod 093 can be installed in two different ways 1 in the conventional way using the relative bracket with screws 2 by fitting into the dashboard after having made a rectangular hole in it of the required size approx 25x28 mm using the relative cutter Install the change over switch where it is protected from water Priming time settin...

Page 88: ...g If there is no exhaust gas analyzer it is advisable to 1 max speed adjustment Regulate the adjuster on the reducer mixer pipe Keep the engine accelerated approx 2 3 rds of its r min speed and turn the adjuster screw clockwise until the engine speed varies as the mixture becomes leaner Now turn the same screw very slowly in an anticlockwise direction until the engine r min speed increases If you ...

Page 89: ... occur without carburation vacuums These are particularly noticeable when the engine is accelerated very slowly adjuster too tight Meanwhile the reducer must remain tight and must not leak gas each time the engine is switched off adjuster too slack Proceed in the following way to adjust the sensitivity 1 Remove the tube that conveys the gas from gas outlet tube C to the mixer 2 Fully tighten sensi...

Page 90: ...system shaft bearing locking screw Intake manifold fixing screw LGW 523 Oil sump fixing screws MAIN DRIVING TORQUES Tightening without torque wrench tighten the spark plug fully on to the head by hand Tighten to a 90 angle using the relative wrench Tighten when the engine is cold Lubricate under the screw head and pulley centering with Molyslip Note Comply with the following general regulations wh...

Page 91: ...5 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 7 150 228 347 435 605 734 940 0 37...

Page 92: ...N SERIAL N SERIAL N SERIAL N SERIAL N DENOMINATION DENOMINATION DENOMINATION DENOMINATION DENOMINATION Tool to mount the intake and exhaust valve guide seal Tool to adjust the timing belt tension Crank shaft locking tool Shim to insert main bearings into the engine block 7170 1460 047 7170 1460 049 7107 1460 051 7107 1460 053 SPECIFIC TOOLS ...

Page 93: ...COMPILER TECO ATL REG CODE 1 5302 509 MODEL N 50778 DATE OF ISSUE 10 06 99 REVISION 00 ENDORSED DATE 10 06 99 93 NOTES ...

Page 94: ...ardini reserves the right to modify the information in this publication at any moment Lombardini vorbehält alle Rechte diese Angabe jederzeit verändern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación 94 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...

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