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Lombardini 9 LD 625-2 EPA, Руководство по ремонту

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- 6 -

9LD Workshop Manual _ cod. 1.5302.286 - 

3° ed

_rev. 

02

-

Chapter  index

Crankshaft journal radius .................................................................................................................................................. 43
Crankshaft lubrication ducts .............................................................................................................................................. 42
Crankshaft removal ........................................................................................................................................................... 42
Crankshaft timing gear ...................................................................................................................................................... 41
Cylinder ............................................................................................................................................................................. 36
Cylinder head .................................................................................................................................................................... 33
Dimensions and clearance between guides and valves .................................................................................................... 35
Dimensions of camshaft journals and housings ............................................................................................................... 45
Dry air cleaner .................................................................................................................................................................. 27
Dry air cleaner, Donaldson type ........................................................................................................................................ 27
Electronic speed governor ................................................................................................................................................ 49
Exhaust manifold .............................................................................................................................................................. 28
External alternator blower control belt - Disassembly ....................................................................................................... 29
External alternator blower control belt - Reassembly ........................................................................................................ 29
External alternator blower control belt – Tension check .................................................................................................... 29
External alternator control belt .......................................................................................................................................... 29
Flywheel ............................................................................................................................................................................ 31
Fuel tank ........................................................................................................................................................................... 29
Governor springs with rocker arm system ........................................................................................................................ 49
Governor springs with single-spring system ..................................................................................................................... 49
Head seal thickness .......................................................................................................................................................... 39
How to measure camshaft journals and housings ............................................................................................................ 45
How to measure intake/exhaust cam height ..................................................................................................................... 46
How to measure main bearing inside diameter ................................................................................................................. 43
Hub .................................................................................................................................................................................... 30
Hydraulic pump ................................................................................................................................................................. 47
Hydraulic pump components (1 P) .................................................................................................................................... 48
Hydraulic pump p.t.o ......................................................................................................................................................... 47
Injector .............................................................................................................................................................................. 32
Injector for EPA and 97/68 CE engines ............................................................................................................................. 33
Injector projection .............................................................................................................................................................. 33
Intake manifold .................................................................................................................................................................. 28
Internal alternator .............................................................................................................................................................. 30
Main bearing and connecting rod big end bearing inside diameter .................................................................................... 44
Main bearing housings ...................................................................................................................................................... 44
Main bearing support, flywheeI side ................................................................................................................................... 41
Main bearing support, gear side ........................................................................................................................................ 41
Main bearing supports ....................................................................................................................................................... 41
Main bearíng supports - Dimensions ................................................................................................................................. 44
Main journal and crank pin diameter .................................................................................................................................. 43
Manifolds, intake/exhaust .................................................................................................................................................. 28
Mechanical speed governor .............................................................................................................................................. 48
Mechanical speed governor components .......................................................................................................................... 48
Oil  vapour separator ......................................................................................................................................................... 28
Oil-bath air cleaner ............................................................................................................................................................ 26
Piston ................................................................................................................................................................................ 37
Piston - Refitting ................................................................................................................................................................ 39
Piston clearance ............................................................................................................................................................... 39
Piston rings - End gaps (mm) ........................................................................................................................................... 38
Piston rings - Fitting sequence .......................................................................................................................................... 38
Piston weight ..................................................................................................................................................................... 38
Pistons ringis - Clearance between grooves (mm) ........................................................................................................... 38
Pulley guard - Shroud - Side plates ................................................................................................................................... 30
Pushrod tube ..................................................................................................................................................................... 36
Recommendations for disassembling and assembling .................................................................................................... 26
Recommendations for overhauls and tuning ..................................................................................................................... 26
Rocker arm assembly ....................................................................................................................................................... 32
Rocker arms ..................................................................................................................................................................... 31
Shroud support (Gear cover plate) .................................................................................................................................... 31
Speed governor wiring diagram ......................................................................................................................................... 50
Table “Clearance between main bearings and main bearing housings” ............................................................................ 45
Table “Piston and cylinder types and sizes" ...................................................................................................................... 37
Valve / Rocker arm clearance ........................................................................................................................................... 31
Valve guide insertion ......................................................................................................................................................... 35
Valve guides and valve guide housings ............................................................................................................................. 35
Valve material ................................................................................................................................................................... 34

Содержание 9 LD 625-2 EPA

Страница 1: ...cod 1 5302 286 9 LD Engine Series WORKSHOP MANUAL ...

Страница 2: ......

Страница 3: ...sesses adequate hand and LOMBARDINI special tools to safely and professionally perform the subject service operation 3 The person or people performing service work on LOMBARDINI series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand This manual was written by the manufacturer to provide technical and operating informat...

Страница 4: ...008 CUSE ATLO 1 5302 286 50494 Drafting body Document code Edition Issue date Review date Model N Revision REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Endorsed ...

Страница 5: ...es and their symptoms 12 Technical specifications 16 Trouble shooting 12 3 MAINTENANCE RECOMMENDED OIL TYPE REFILLING _______________________________ 22 25 ACEA Regulations ACEA Sequences 23 API MIL Sequences 23 Extraordinary maintenance 22 Fuel recommendations 25 International specifications 23 Lubricant 23 Ordinary maintenance 22 Prescribed lubricant 24 Routine engine maintenance 22 SAE Classifi...

Страница 6: ...tor 32 Injector for EPA and 97 68 CE engines 33 Injector projection 33 Intake manifold 28 Internal alternator 30 Main bearing and connecting rod big end bearing inside diameter 44 Main bearing housings 44 Main bearing support flywheeI side 41 Main bearing support gear side 41 Main bearing supports 41 Main bearíng supports Dimensions 44 Main journal and crank pin diameter 43 Manifolds intake exhaus...

Страница 7: ...it with fuel filter inside the fuel tank 56 Fuel feeding injection circuit with fuel filter inside the fuel tank and double solenoid valve 56 Fuel feeding injection circuit 56 Fuel feeding pump components 58 Fuel filter 57 Fuel filter inside fuel tank 57 Fuel filter external 57 Fuel lift pump 57 How to check injection pump delivery valve sealing 60 How to check plunger and barrel for internal leak...

Страница 8: ...nal 71 Voltage regulator 12V 30A with W terminal 71 8 SETTINGS _______________________________________________________________________ 76 79 Full speed setting in no load conditions standard 76 Idling speed setting in no load conditions 76 Injection pump delivery setting 76 Injection pump delivery setting with dynamometric brake 77 lnjection pump delivery limiting and extra fuel device 76 lnjectio...

Страница 9: ...s deriving from the engine use or from both the total or partial impossibility of use is excluded The repair or replacement of any component will not extend or renew the warranty period Lombardini warranty obligations here above described will be cancelled if Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected and altered Lombardi...

Страница 10: ...nding starting only is not permitted even in an emergency Make sure that the machine is stable to prevent the risk of overturning Become familiar with how to adjust the rotation speed and stop the engine Never start the engine in a closed place or where there is insufficient ventilation Combustion creates carbon monoxide an odourless and highly poisonous gas Lengthy stays in places where the engin...

Страница 11: ... SAFETY DURING OPERATING PHASES The procedures contained in this manual have been tested and selected by the manufacturer s technical experts and hence are to be recognised as authorised operating methods Anumberofproceduresmustbecarriedoutwiththeaidofequipmentandtoolsthatsimplifyandimprovethetimingofoperations Alltoolsmustbeingoodworkingconditionsothatenginecomponentsarenotdamagedandthatoperation...

Страница 12: ...ollowing table contains the possible causes of some failures which may occur during operation Always perform these simple checks before removing or replacing any part PROBLEM Engine does not start Engine starts but stops No acceleration Non uniform speed Black smoke White s m o k e Oil preassure too low Excessive oil consumption COOLING CIRCUIT Incorrect governor linkage adjustment Governor spring...

Страница 13: ...ssive oil consumption Excessive idle operation Incomplete run in Overloaded engine Non conforming engine oil Damaged blocked or dirty injector Injection pump valve damaged Injector not adjusted Hardened pump control rod Broken or loose supplementary start up spring Worn or damaged pumping element Incorrect tuning of injection components delivery balancing advance Extra fuel control level sticking ...

Страница 14: ...Manufacturer sidentity B Enginetype C Engine serial number D Maximumoperatingspeed E Number of the customer version form K F Approvaldata Approvaldata The approval reference directives EC are on the engine identification plate The data plate for EPA Standards is applied on the air intake cowling It contains the following information 1 Currentyear 2 Enginedisplacement 3 Rated power measured in kW 4...

Страница 15: ... 6 7 8 9 10 11 12 Technical information MAIN COMPONENTS Components 1 Fuel tank 2 Injectors 3 Air cleaner 4 Starting motor 5 Oil filter 6 Rocker arm cover 7 Oil dipstick 8 Throttle and stop controls 9 Oil drain plug 10 Fuel feeding pump 11 Flywheel 12 Injection pump ...

Страница 16: ...rocker arms Driving shaft degrees Oil bath air cleaner with cyclonic prefilter or dry air cleaner Air fan integral to the flywheel Counter clockwise from flywheel side 2 in line Four stroke diesel POWER AND TORQUE CONSUMPTION AT MAXIMUM POWER GENERALDETAILS Operating cycle Cylinders Bore x stroke Displacements Compression rate Intake Cooling Crankshaft rotation Combustion sequence Timing system Va...

Страница 17: ...tor Internal Optional nominal voltage Alternator External Optional nominal voltage Alternator Internal Standard nominal current Alternator Internal Optional nominal current Alternator External Optional nominal current Starter motor power Bosh GF Starter motor power Bosh DW R Type of lubrication Circuit supply Maximum oil quantity Maximum oil quantity Oil pressure at min speed oil temperature 120 C...

Страница 18: ... 18 9LD Workshop Manual _ cod 1 5302 286 3 ed_rev 02 9 LD 625 2 EPA 3000 r p m 9 LD 625 NR 2800 r p m 9 LD 625 3000 r p m 9 LD 626 2 3000 r p m 2 Technical information PERFORMANCEDIAGRAM ...

Страница 19: ...h constant speed and constant load C NB Specific fuel consumption at NB power Mn Torque at 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 tolerance is 5 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C above 25 C Note Consult LOMBARDINI for power torq...

Страница 20: ...561 2 9 LD561 2 L 9 LD 625 2 9 LD 626 2 9 LD 626 2 NR 2 A B C D 198 425 E F 434 397 I L 340 168 G H O P 421 178 207 542 599 633 557 217 DIMENSIONI mm MESURES mm DIMENSION mm EINBAUMAßE mm DIMENSIONE mm DIMEN0ÇÕES mm M N OVERALL DIMENSION Technical information ...

Страница 21: ... 21 9LD Workshop Manual _ cod 1 5302 286 3 ed_rev 02 2 Technical information ...

Страница 22: ...ERNAL CARTRIDGE PARTIAL TOTAL Engine oil replacement Oil filter replacement EXTRAORDINARY MAINTENANCE AFTERTHEFIRST 50WORKINGHOURS ORDINARY MAINTENANCE OPERATIONDESCRIPTION FREQUENCYxHOURS CHECK REPLACEMENT OVERHAUL AFTER6CHECKSWITHCLEANING In case of low use every year In case of low use every 2 years The period of time that must elapse before cleaning or replacing the filter element depends on t...

Страница 23: ...for instance is more performing than a SE oil but less performing than a SG one API MIL Sequences Petrol A1 Low viscosity for frictions reduction A2 Standard A3 High performances Light duty diesel engines B1 Low viscosity for frictions reduction B2 Standard B3 High performances indirect injection B4 High quality direct injection Heavy duty diesel engines E1 OBSOLETE E2 Standard E3 Heavy conditions...

Страница 24: ... to the engine because a sudden increase in engine rpm could be caused by its combustion Use proper lube oil preserve your engine Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and...

Страница 25: ...ustralia FUEL TYPE For best results use only clean fresh commercial grade diesel fuel Diesel fuels that satisfy the following specifications are suitable for use in this engine ASTM D 975 1D or 2D EN590 or equivalent FUELS FOR LOW TEMPERATURES It is possible to run the engine at temperatures below 0 C using special winter fuels These fuels reduce the formation of paraffin in diesel at low temperat...

Страница 26: ...NS FOR OVERHAULS AND TUNING Important To locate specific topics the reader should refer to the index Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine Before carrying out an...

Страница 27: ...ng valve 5 Cap complete with clamp Scavenging valve 4 must be positioned as in figure 4 Danger Attention During repair operations when using compressed air wear eye protection The cartridge can be cleaned by blowing compressed air breadthways outside and inside the cartridge at a pressure not greater than 5 atmospheres or in necessity case by knocking the front of the cartridge several times again...

Страница 28: ...manifold To avoid flange breakage check that heads are in line before tightening nuts Check flange surface for warpage and correct if necessary Replace gaskets Tighten nuts at 25 Nm Note In case of low temperature starting we can supply a manifold with possibility of fitting a glow plug with air preheating Oil vapour separator Fitted on engines with dry air cleaner Screw it out of the air conveyor...

Страница 29: ... pressure of 10 kg External alternator blower control belt Reassembly Install the belt and the belt guard Force the alternator outwards and temporarily tighten the fastening bolts Make sure that the belt tension is within the required parameters see External alternator blower control belt Tension check Fig 11 Tighten the fastening bolts to a final torque of 30 Nm 8x1 25 and 50 Nm 10x1 50 FUEL TANK...

Страница 30: ...tator bolts at 10 Nm  See page 67 69 for alternator characteristics Cooling fan Carefully clean and check all blades and inserts Replace the fan even if there is only a single damaged blade or only a single released insert  See page 16 for cooling air flow Tighten the fan s fixing screws at a torque of 10 Nm Pulley guard Shroud Side plates Components 1 Pulley guard 2 Shroud 3 Side plates The pul...

Страница 31: ...t surfaces Insert the ring gear into its seat and place it carefully on the rim of the flywheel Leave to the ring gear to cool gently before reassembling the flywheel Disassembly Reassembly Shroud support Gear cover plate Loosen screws and remove shroud support very carefully to avoid damage to the oil seal ring When refitting check that gaskets A and oil seal ring B are well inside their housings...

Страница 32: ...y matches with the journal bore On slow engines which are set to 1 500 1 800 rpm the rocker arms differ from the standard version in the upper part of the lubrication channel Tighten the rocker arm shaft fastening screws to the head at a torque of 25 Nm Compression release optional Bring piston to top dead center on the compression stroke Unscrew rocker arm cover side plug and measure clearance A ...

Страница 33: ...hat the rubber seals of the tappet hose are assembled and inserted correctly into their seats Always replace copper head gasket see page 39 for choosing the right thickness Progressively tighten nuts in the 1 2 3 4 sequence at 55 Nm Injector projection The end of nozzle A should project 3 0 3 5 mm from the cylinder head plane Adjust injector projection by means of copper shims B measuring 0 5 1 00...

Страница 34: ...th the same type of grease insert the valves into the guides rotating them particularly as they enter the sealing ring Valve springs Measure free length with a gauge Using a dynamometer check that the spring length under two dìfferent loads corresponds to the values below Free length A 52 mm Length B compressed by a 210 6 N 35 8 mm Length C compressed by a 340 6 N 25 8 mm Replace spring if length ...

Страница 35: ...th made of phosphoric cast iron Components 1 Exhaust valve guide 2 Intake valve guide Valve guides with outside diameter increased by 0 5 mm are also available in such cases valve guide bore C shouid also be increased by 0 5 mm Valve guide insertion Heat cylinder head up to 160 180 C Press guides considering the A and B distances from the head plane Dimensions and clearance between guides and valv...

Страница 36: ...ube When refitting cheek that gaskets A and rocker arm lubricatíon tube C are well inside their seats Valve seat grinding After cutting grind valve seats with fine emery paste in oil suspension The sealing surface S should not exceed 2 mm Valve recess after grinding D 0 75 1 25 mm maximum worn limit 1 65 mm CYLINDER Checks and cylinder roughness Fins must be intact Cross hatch pattern must range b...

Страница 37: ... case wear exceeds 0 10 mm bore the cylinder and fit oversize piston and rings In case of less wear replace piston rings only Note Oversize pistons of 0 5 and 1 0 mm are available only for standard and 97 68 CE engines Important The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up The cylinder and piston must be replaced with a new cylinder and pis...

Страница 38: ...imensions mm Ref Piston rings Fitting sequence A 1 Chromium plated ring B 2 Torsional internal tapered ring C 3 Oil control ring Important Before fitting the piston into the cylinder stagger the ring gaps at 120 Pistons ringis Clearance between grooves mm Piston rings End gaps mm Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap Piston weight Weigh pist...

Страница 39: ...iston clearance Piston clearance 0 65 0 70 mm for standard engines 0 55 0 60 mm for 97 68 CE and EPA engines The piston in the TDC top dead centre position may extend or be short of the upper surface of the cylinder Use a dial indicator to measure the difference between the two surfaces piston crown and upper cylinder surface and use a suitable thickness copper gasket B for the cylinder head to ad...

Страница 40: ...ecting rod weight Weigh connecting rods when replacing them in order to avoid unbalance Important The difference in weight should not exceed 10 g Connecting rod alignment Check alignment of small end and big end bearing bores using fitted mandrels axial mis alignment A 0 02 mm maximum limit 0 05 mm Connecting rod small end bushing Dimensions and clearance mm C 25 020 25 030 with machined bushing i...

Страница 41: ...art N 7271 1460 119 Note To avoid deformation it is not recomended to replace the bearing bushing complete assembly s of bushing and support are available in standard 0 25 mm and 0 50 mm undersize configurations as spare parts When refitting tighten the screws at 30 Nm  See page 44 45 for dimensions CRANKSHAFT TIMING GEAR Disassembly Use tool 1 Part N 7560 4000 052 and puller 2 Part N 7271 1460 1...

Страница 42: ...g compressed air wear eye protection Remove plugs clean duct A with a pointed tool and blow in compressed air Screw plugs again and check for sealing Crankshaft removal To pull out the crankshaft tap lightfy on the timing side end using a copper headed hammer When refitting align center main bearing support so that the locating screw hole coincides with the crankcase hole CRANKSHAFT Center main be...

Страница 43: ...aring inside diameter Use an inside micrometer gauge Disassembly Reassembly Dimensions mm Ref Main journal and crank pin diameter Checking main journals and crank pins Use an outside micrometer gauge Crankshaft journal radius The radius R connecting journals to shoulders is 2 8 3 2 mm Important When grinding external main journals restore the R value to original specification ...

Страница 44: ... O 0 1 0 6 7 0 9 9 5 7 P 0 2 0 0 6 0 0 0 0 6 Q 5 0 4 2 5 9 3 2 R 0 2 1 3 0 1 1 3 Disassembly Reassembly Limit value mm Clearance mm Ref Clearance between main journals crank pins and connecting rod bearings Main bearíng supports Dimensions 1 Flywheel side 2 Central 3 Gear side Dimensions mm Ref Dimensions mm Ref Main bearing housings Main bearing and connecting rod big end bearing inside diameter ...

Страница 45: ...rnals Clearance mm Limit value mm Dimensions mm Ref Dimensions of camshaft journals and housings Crankshaft end play When refitting crankshaft check end play by means of a thickness gauge this value should be 0 08 0 38 mm and can be set by changing the thickness of gasket A which is located on the flywheel side main bearings Gaskets with thickness of 0 30 and 0 50 mm can be supplied Important Repl...

Страница 46: ... at the same height Engage camshaft gear with crankshaft gear CAMSHAFT TIMING Fit camshaft gear by making timing mark 1 coincide with timing mark 2 on the crankshaft timing gear Tighten camshaft boll at 60 Nm Camshaft end play End play should be 0 10 0 25 mm check by means of a dial gauge pushing or pulling camshaft as required How to measure intake exhaust cam height A1 1 st cylinder intake cam S...

Страница 47: ...aulic pump of group 1 1P or 2 2P can be installed on the gear side 3rd p t o Valve timing check Check valve timing at the crankshaft The values shown are checked at the flywheel circumference with flywheel of 291 mm diameter each degree corresponds to 2 5 mm Set valve clearance at 0 65 0 70 mm after checking restore the value at 0 15 0 20 mm Set dial gauge on intake valve to a zero value by rotati...

Страница 48: ...rack control lever by a linkage A spring placed under tension by the accelerator control offset the weight centrifugal force Balance between the two forces keeps speed at an almost constant level in spite of load variations  See page 62 for timing MECHANICAL SPEED GOVERNOR Weight type governor housed inside the camshaft drive gear Hydraulic pump components 1 P 1 Seal ring 2 Centering ring 3 Coupl...

Страница 49: ... it on the reference pins and make sure that the injection pump rack rod pin is inside lever 1 Fix the plate by using the specific screws for its model Governor springs with rocker arm system The system features two springs anchored to a rocker arm and allows for minimal r p m changes at low speed levels The device is operated automatically when the engine is stopped spring 6 acts on injection pum...

Страница 50: ...e sure that the plunger has moved In this case you will hear the typical activated magnet sound 3 Feed actuator 6 with a tension of 12V put between the actuator and the 12V a 10 Amp fuse the actuator tension will cause the pump delivery control lever to move to the right 4 By the eccentric screw 3 place and check by sight that the lever in Max position is at the extreme right from this position al...

Страница 51: ... 51 9LD Workshop Manual _ cod 1 5302 286 3 ed_rev 02 4 Disassembly Reassembly ...

Страница 52: ...of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston rings to jam and will lead to rapid wear on the cylinder liner the bearings and all other moving parts Engine life will also be notably reduced The oil viscosity must suit the ambient temperature in which the engine operates Danger Attention Old engine oil can cause skin...

Страница 53: ...at not exceeding 0 15 mm Oil pump delivery at 3000 r p m is 9 liters min Lubrication system Components 1 Oil pressure gauge 2 Breather 3 Connecting rod big end bearing 4 Crankshaft main bearing on gear side 5 Cartridge filter 6 Oíl pressure relief valve 7 Oil pump 8 Internal filter 9 Oil fill plug 10 Rocker arm shafts 11 Pushrod protection tube 12 Hydraulic pump gear 13 Camshaft joumal on fiywheel...

Страница 54: ...ment 6 Bypass valve 7 Spring  For characteristics see page 17 Disassembly Before removing the oil pressure regulating valve remove the oil filter by using an appropriate wrench Remove the regulating valve using a hammer puller equipped with a M9x1 threaded terminal Reassembly Make sure that the valve seat is free of scratches and scores which could reduce the pressure seal Insert the entire oil p...

Страница 55: ...e with engine at full speed The curve is obtained at the oil filter level with engine working at 3000 r p m and max power at 25 C room temperature Pressure is given in bar and temperature in centigrades If the oil pressure value is below the indicated one please check all components indicated on page 52 53 OIL PRESSURE CHECK Once the engine is fitted fill with oil and fuel connect a 10 bar pressur...

Страница 56: ...eding tube 3 Fuel filter 4 Fuel lift pump 5 lnjection pump 6 High pressure pipe 7 Injector 8 Injector exhaust pipe Fuel feeding injection circuit with external fuel filter and double solenoid valve Components 1 Fuel tank 2 Solenoid valve 3 Fuel filter 4 Fuel lift pump 5 Solenoid valve 6 lnjection pump 7 High pressure pipe 8 Injector 9 Injector exhaust pipe 10 Non return valve Fuel feeding injectio...

Страница 57: ...a camshaft eccentric through a drive rod It features an external lever for manual operation Fuel filter external 1 Air relief valve 2 Support 3 Cartridge 4 Gasket 5 Filtering element  For characteristics see page 17  For maintenance see page 22 Fuel feeding injection circuit with external fuel filter and QSD Quick Stop System Components 1 Fuel tank 2 Fuel feeding tube 3 Fuel filter 4 Fuel lift p...

Страница 58: ...2 Tappet spring 5 Shim 13 Upper retainer 6 Valve spring 14 Lower retainer 7 Delivery valve 15 Tappet 8 Plunger and barrel assembly 16 Tappet roller INJECTION PUMP The injection system consists of a single body pump with plungers featuring constant stroke and feeding one cylinder each The pump mounted on the crankcase is directly operated by the camshaft Speed governor extra fuel and stop device ar...

Страница 59: ...lve assembly How to check plunger and barrel for internal leakage This operation is only indicative since pressure changes depending on the pumping speed Connect the delivery union with a 600 bar pressure gauge with safety valve Adjust rack rod at half stroke Turn flywheel according to its direction of rotation so that the plunger puts the circuit under pressure Replace plunger if the displayed pr...

Страница 60: ...essure drop should be 30 50 bar Replace the valve if pressure drop is below this value Repeat the same operation for the other plunger Fuel system Control rod max force Rod stroke from max deliv point R P M Delivery Max plunger difference Newton mm mm3 stroke mm3 stroke 0 50 10 1500 34 37 3 13 500 7 11 3 0 150 70 78 10 500 22 26 3 Control rod max force Rod stroke from max deliv point R P M Deliver...

Страница 61: ...hem at 35 40 Nm Fit plungers by making reference points E match with the sector gear D points Fix retainers and springs lock tappet with special stop Check that both plungers have the same delivery by performing the necessary measurements at the test bed if delivery is not the same set screw F Tighten screws at 25 Nm Check that rack rod slides smoothly if not the engine may fail to start or hunt H...

Страница 62: ...er is correctly placed on the intake valve collar 5 Place the auxiliary tank at a higher height than the one of the injection pump 30 40 cm 6 Connect the tank to the injection pump fuel supply hole 7 Slowly rotate the crankshaft clockwise keeping lever 1 lowered and the valve positioned on the piston crown until the dial indicator 2 shows the maximum measurement 8 Set the maximum measurement dial ...

Страница 63: ...l the detected value corresponds to the one indicated in the Table Conversion for establishing advance 2 Advanced Injection Advance add shims under the pump until the detected value corresponds to the one indicated in the Table Conversion for establishing advance Note By removing or adding a 0 1 mm shim under the pump it is possible to advance or delay the injection by about 1 Table Conversion for...

Страница 64: ...0 22 mm Clean nozzle tip with a brass brush Check that holes are not obstructed using a mandrel with steel wìre with 0 28 mm diam When refitting tighten ring nut at 60 Nm INJECTOR Size S Injector only for standard engines Components 1 Intake fitting 2 Nozzle holder 3 Shim 4 Spring 5 Pressure rod 6 Intermediate flange 7 Nozzle 8 Needle valve 9 Fixing flange 10 Taper pin 11 Gasket 12 System duct 13 ...

Страница 65: ...ure for 10 seconds Chek that setting pressure is 210 220 bar for standard engines 245 230 bar for EPA e CE engines make the required adjustments if any by modifying the adjusting shim height When replacing the spring setting should be performed at a 10 bar greater pressure 255 265 bar to allow for bedding during operation Replace nozzle in case of dripping Size P nozzle for 97 68 CE and EPA engine...

Страница 66: ... 4 Battery 5 Pressure switch 6 Oil pressure warning light 7 Key switch 8 Battery charging light Note Battery which is not supplied by Lombardini should feature 12 V voltage and capacity not below 70 Ah Components 1Alternator 2 Starting motor 3 Battery 4 Key switch 5 Pressure switch 6 Oil pressure warning light 7 Battery charging light Note Battery which is not supplied by Lombardini should feature...

Страница 67: ...ance between armature wìnding and inductor air gap must b 0 48 0 60 mm Alternator battery charger curve 12 V 18 A This curve is obtained at 25 C with 12 5 V battery voltage Alternator 24 V 6A Features a fixed armature winding mounted on the air shroud bracket The rotating permanent magnet inductor is located in the fan spindle There are the two yellow cables and one red cable at output Dimensions ...

Страница 68: ...es with the casing reference line Release slider if no attraction occurs the rotor is demagnetized in this case replace alternator Alternator 12 V 14 A Features a fixed armature winding mounted on the air shroud bracket The rotating permanent magnet inductor is located in the fan spindle There are the two yellow cables and one red cable at output Dimensions mm A 158 80 159 20 B 27 50 27 90 Note Cl...

Страница 69: ...ated from the ground Alternator external 12 V 33 A The alternator is of the claw pole rotor type with built in voltage regulator The rotating motion is conveyed by the engine through a V belt and sheave Features Rated voltage 12V Max current 33 A at 7000 alternator r p m min RH direction of rotation Tighten the nut 1 at a torque of 70 Nm Alternator battery charger curve external 12 V 33 A The curv...

Страница 70: ...couple of times until battery voltage drops below 13 V When battery voltage reaches 14 5 V the ammeter current suddenly drops down to almost zero Replace regulator if recharge current is zero with voltage below 14V Caution Warning When the engine is running do not disconnect battery cables or remove the key from the control panel Keep regulator away from heat sources since temperatures above 75 C ...

Страница 71: ... The voltage regulator is of the bridge type  See page 70 for tag dimensions Voltage regulator 12V 26A with W terminal W pole tab Width 4 75 mm Thickness 0 5 mm  See page 70 for tag dimensions Voltage regulator 12V 30A with W terminal W pole tab Width 4 75 mm Thickness 0 5 mm  See page 70 for tag dimensions ...

Страница 72: ... Motor terminal voltage in Volt P Power in kW C Torque in N m N Motor speed in r p m6 J A Absorbed current inAmpere STARTING MOTOR Important Made by MARELLI and BOSCH Apply to their distributors for any type of repair Bosch starting motor type GIF 12 V 1 7 kW RH direction of rotation A 29 5 31 5 mm B Ring gear plane C Flange plane Caution Warning Flywheel should not project from ring gear plane B ...

Страница 73: ... 5 mm B Ring gear plane C Flange plane Caution Warning Flywheel should not project from ring gear plane B Characteristic curves of the 24 V 1 6 kW starting motor The curves have been measured at a 20 C temperature with an 88 Ah battery V Voltage to the motor terminals in Volt P Power in kW C Torque in N m N Motor speed in rpm J A Absorbed current in Amperes ...

Страница 74: ...joint 7 Electromagnet 8 Stop control lever 9 Axial joint 10 Stop control electromagnet support Adjustment Carry out the adjustments by screwing and unscrewing the joints Adjust the device so as to make the electromagnet get to the end of the stroke before the STOP lever reaches its limit stop after performing the operation stroke When the electromagnet is excited put the stop lever at about 1 0 1 ...

Страница 75: ...ension 12V Power coil absorption 41 A Hold coil absorption 0 5 A Setting Screw drive rod 1 to the end of the thread on the electromagnet piston Excite the electromagnet and leave the stop lever in normal operation position Bring drive rod 1 in contact with the stop lever and tighten lock nut 2 Electric System ...

Страница 76: ... Limiting device C limits the injection pump maximum delivery It also acts as a torque setting device since spring N opposes the resistence of spring M inside the cylinder through lever L The torque setting device allows lever L to move over stroke H corresponding to 0 15 0 25 mm This consequently increases injection pump delivery with torque reaching its peak value Note In generator sets and powe...

Страница 77: ...ts decreasing 7 Lock screw C using a lock nut 8 Carry out the fuel consumption check again 9 Release the dynamometric brake and detect the rotation speed of the stabilized engine maximum idle speed 10 Bring the engine to minimum idle speed Carry out engine setting when the engine is stabilized 11 Switch off the engine and let it cool down 12 Check the valve rocker arm clearance see Setting valve r...

Страница 78: ...0 Setting the stop limit stop 1 Remove the throttle lever cover 1 Completely turn lever C counter clockwise and keep it in this position Retainer F should not be in contact with lever C 2 Unscrew nut G and bring retainer F in contact with lever C 3 Push retainer F so that lever C is moved backwards clockwise by 1 0 mm 4 Lock retainer F by screwing nut G Note In this condition the limit stops of th...

Страница 79: ... 79 9LD Workshop Manual _ cod 1 5302 286 3 ed_rev 02 8 Settings ...

Страница 80: ...ngine housingAGIP RUSTIAC protective oil up to the maximum level 2 Fill up with fuel containing 10 AGIP RUSTIANT 3 Start the engine and keep it idle at minimum speed for some minutes 4 Bring the engine to of the maximum speed for 5 10 minutes 5 Turn off the engine 6 Empty out completely the fuel tank 7 Spray SAE 10W on the exhaust and intake manifolds 8 Seal the exhaust and intake ducts to prevent...

Страница 81: ...eck the correct movement and smoothness of the mechanical parts 8 Refill the tank with fresh fuel 9 Make sure that the oil is up to the maximum level 10 Start the engine and after some minutes bring it to of the maximum speed for 5 10 minutes 11 Turn off the engine 12 Remove the oil drain plug see Oil replacement and discharge the AGIP RUSTIA NT protective oil while the engine is hot 13 Pour new o...

Страница 82: ... Accelerator cover Governor control cover Air conveyor shroud Alternator cable clamp High pressure fuel line clamp Air cleaner Hydraulic pump flange Air conveyor shroud gasket Headinjector Camshaft gear Oil pump gear Air conveyor sheet Internal oil filter pierced plate Breather sheet Starting motor Blower hub Nippl radiator Rocker arm shaft Injection pump control lever pivot Speed governor externa...

Страница 83: ...16x1 5 20x1 5 30 7 15 40 55 10 160 300 Loctite 242 Loctite 270 Loctite 270 Fuel tank bracket Alternator stator Crankase lubrification plug Oil drain plug Cylinder head Blower Cooling fan hub fixing screw Flywheel Torque specifications and use of sealant POSITION Diam and pitch mm Torque Nm Sealant ...

Страница 84: ... 12x1 25 M 12x1 5 M 14x1 5 M 16x1 5 M 18x1 5 M18x2 M 20x1 5 M20x2 M 22x1 5 M24x2 M27x2 M30x2 R 400N mm2 R 500N mm2 R 600N mm2 R 800N mm2 R 1000N mm2 R 1200N mm2 Nm 10 21 20 36 38 56 84 122 117 173 164 229 293 431 600 Nm 14 28 26 48 45 75 113 163 157 230 218 305 390 575 800 Nm 13 26 24 45 42 70 105 153 147 213 204 287 367 533 750 Nm 17 35 33 59 56 94 141 203 196 288 273 381 488 719 1000 Nm 20 42 39...

Страница 85: ... SPECIAL TOOLS SPECIAL TOOLS DESCIPTION Part N Special tools and equipment for maintenance Valve lowering tool for static injection timing check 1 Spacers h 40mm 2 Dial gauge indicator 3 Dial gauge extension Static timing tool Tool for valve stem O ring assembly Flywheel puller Timing control gear extractor fork ...

Страница 86: ... 86 9LD Workshop Manual _ cod 1 5302 286 3 ed_rev 02 ...

Страница 87: ... 87 9LD Workshop Manual _ cod 1 5302 286 3 ed_rev 02 ...

Страница 88: ...mbardini behält sich alle Rechte vor diese Angabe jederzeit zu verändern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación 42100 Reggio Emilia Italia ITALY Via Cav del Lavoro Adelmo Lombardini 2 Cas Post 1074 Tel 39 0522 3891 Telex 530003 Motlom I Telegr Lombarmotor R E A 227083 Reg Impr RE 10875 Cod fiscale e Partita IVA 01829970357 CEE Code IT 018299...

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