1 - 5302 - 838 - Rev 00 - MO - LDW 442 CRS - GB PDF
1 - 5302 - 838 - Rev 00 - MO - LDW 442 CRS - GB PDF
1 - 5302 - 838 - Rev 00 - MO - LDW 442 CRS - GB PDF
PREFACE
- Every attempt has been made to present within this service manual, accurate and up to date technical informa-
tion.
However, development on the LOMBARDINI series is continuous.
Therefore, the information within this manual is subject to change without notice and without obligation.
- The information contained within this service manual is the sole property of LOMBARDINI.
As such, no reproduction or replication in whole or part is allowed without the express written permission of
LOMBARDINI.
1 - The person or people performing service work on LOMBARDINI series engines is properly trained and equip-
ped to safely and professionally perform the subject operation;
2 - The person or people 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 people performing service work on LOMBARDINI series engines has read the pertinent infor-
mation regarding the subject service operations and fully understands the operation at hand.
- This manual was written by the manufacturer to provide technical and operating information to authorised
LOMBARDINI after-sales service centres to carry out assembly, disassembly, overhauling, replacement and
tuning operations.
- As well as employing good operating techniques and observing the right timing for operations, operators must
read the information very carefully and comply with it scrupulously.
- Time spent reading this information will help to prevent health and safety risks and financial damage.
Written information is accompanied by illustrations in order to facilitate your understanding of every step of the
operating phases.
Manuale officina LDW 442 CRS _ cod. 1.5302.838 - 1° ed_ rev. 00 -3-
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the following table.
5 DISASSEMBLY......................................................................................................................... 56-79
RECOMMENDATIONS FOR DISASSEMBLY.................................................................................................................. 56
Balance Countershafts...................................................................................................................................................... 85
Camshaft........................................................................................................................................................................... 96
7 REASSEMBLY...................................................................................................................... 102-132
RECOMMENDATIONS FOR REASSEMBLY................................................................................................................. 102
9 SPECIFIC TOOLS........................................................................................................................136
10 DIAGNOSIS.......................................................................................................................... 138-143
- The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24 months
from the date of delivery to the first end user.
- For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed within the
setting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned period (24 months) is
not expired.
- If no hour-meter is fitted , 12 working hours per calendar day will be considered.
- For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling system,
sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above mentioned
period (24 months) is not expired.
- For correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the
documentation supplied with each engine.
- To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be carried out
by qualified personnel only.
- The list of the Lombardini authorized dealers is reported in the “Service” booklet, supplied with each engine.
- Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump), filtering
system, turbo-charged models, will require special written warranty agreements.
- Within the above stated periods Lombardini Srl directly or through its authorized network will repair and/or replace free of
charge any own part or component that, upon examination by Lombardini or by an authorized Lombardini agent, is found to
be defective in conformity, workmanship or materials.
- Any other responsibility/obligation 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 replacement of any component will not extend or renew the warranty period.
- Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected
and altered.
- Lombardini engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied with
each engine.
- Any seal affixed to the engine by Lombardini has been tampered with or removed.
- Spare parts used are not original Lombardini.
- Feeding and injection systems are damaged by unauthorized or poor quality fuel types.
- Electrical system failure is due to components, connected to this system, which are not supplied or installed by Lombardini.
- Engines have been disassembled, repaired or altered by any part other than an authorized Lombardini agent.
- Following expiration of the above stated warranty periods and working hours, Lombardini will have no further responsibility for
warranty and will consider its here above mentioned obligations for warranty complete.
- Any warranty request related to a non-conformity of the product must be addressed to the Lombardini Srl service agents.
2 - All data presented are in metric format. That is, dimensions are presented in millimeters (mm), torque is presented in New-
ton-meters (Nm), weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) and pressure
is presented in barometric units (bar).
For clarity, here are the definitions of a number of terms used recurrently in the manual.
Caution – Warning
- Important remarks and features of the text are highlighted This indicates that it is necessary to take proper precau-
using symbols, which are explained below: tions to prevent any risk to the health and safety of indivi-
duals and avoid financial damage.
Danger – Attention
This indicates situations of grave danger which, if igno- Important
red, may seriously threaten the health and safety of indi- This indicates particularly important technical information
viduals. that should not be ignored.
SAFETY REGULATIONS
• Lombardini Engines are built to supply their performances in a safe and long-lasting way.
To obtain these results, it is essential for users to comply with the servicing instructions given in the relative manual along with
the safety recommendations listed below.
• The engine has been made according to a machine manufacturer's specifications and all actions required to meet the essential
safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit.
All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined
by Lombardini which thus declines all liability for any accidents deriving from such operations.
• The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine ope-
ration in particular, along with the relative routine maintenance work.
• The user must read these instructions carefully and become familiar with the operations described.
Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the
vicinity of the machine.
• The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and
the deriving dangers.
This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the latter
case, must only be carried out by persons specifically trained by Lombardini and who work in compliance with the existing
documentation.
• Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal of seals,
demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve
Lombardini from all and every liability for deriving accidents or for failure to comply with the laws in merit.
• On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ.
In the case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous
objects, also considering the movements made by the operator.
Pull-starting with a free cord (thus excluding self-winding 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 engine freely exhausts this gas can lead to unconsciousness and death.
• The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is dust that
can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been certified for the
machine.
• To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.
• Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their
operation.
• Fuel is inflammable.
The tank must only be filled when the engine is off.
Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil.
Make sure that no soundproofing panels made of porous material are soaked in fuel or oil.
Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil.
• Fully tighten the tank plug each time after refuelling.
Do not fill the tank right to the top but leave an adequate space for the fuel to expand.
• Fuel vapour is highly toxic.
Only refuel outdoors or in a well ventilated place.
• Do not smoke or use naked flames when refuelling.
• The engine must be started in compliance with the specific instructions in the operation manual of the engine and/or machine
itself.
Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).
• Before starting, remove any tools that were used to service the engine and/or machine.
– 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.
– A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of
operations.
– All tools must be in good working condition so that engine components are not damaged and that operations are carried out
properly and safely.
It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual.
– Holes must be lined up methodically and with the aid of suitable equipment. Do not use your fingers to carry out this
operation to avoid the risk of amputation.
– Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding
the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.
– Do not use flammable liquids (petrol, diesel, etc.) to degrease or wash components. Use special products.
– Use the oils and greases recommended by the manufacturer.
Do not mix different brands or combine oils with different characteristics.
– Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.
– Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.
Every organisation has a duty to implement procedures to In order to minimise the impact on the environment, the manu-
identify, assess and monitor the influence of its own activities facturer now provides a number of indications to be followed
(products, services, etc.) on the environment. by all persons handling the engine, for any reason, during its
Procedures for identifying the extent of the impact on the envi- expected lifetime.
ronment must consider the following factors:
- All packaging components must be disposed of in accor-
- Liquid waste dance with the laws of the country in which disposal is ta-
- Waste management king place.
- Soil contamination - Keep the fuel and engine control systems and the exhaust
- Atmospheric emissions pipes in efficient working order to limit environmental and
- Use of raw materials and natural resources noise pollution.
- Regulations and directives regarding environmental impact - When discontinuing use of the engine, select all compo-
nents according to their chemical characteristics and dispo-
se of them separately.
Important
- Before removing the engine from the vehicle on which it is installed, disconnect the power supply, detach the fuel and
coolant supply, and all connections including the mechanical ones.
- Hook the lifting device in the engine lifting points, as shown in the figure.
- Before lifting, make sure the weight is correctly balanced by checking its barycentre.
- Close all engine openings accurately (exhaust, intake, etc.), then wash the outside and dry with a jet of compressed
air.
Important
The bracket of the lifting points have been designed to lift
the engine only. They are not intended nor approved to lift
additional weights.
Do not use different methods to lift the engine than those
described herein. In case different methods are used, no
warranty shall be granted for any consequential damage.
Main Components
6 16
15
1
10
4 12
7 2
8
9
11 3
5
13
14
1) Cylinder Head 9) Oil Filter
2) Engine Block 10) Exhaust Manifold
3) Crankcase 11) Oil Dipstick
4) Timing System 12) Starter Motor
5) Flywheel 13) Oil Sump
6) Intake Assembly 14) Oil drain plug
7) Vent Circuit 15) Acoustic Insulation Panel
8) Alternator 16) Oil Refill Plug
Description
TROUBLE
Engine starts but stops
Engine does not start
Excessive oil
Black smoke
performance
consumption
Inadequate
POSSIBLE CAUSE
is ignited
Clogged fuel hoses
Lack of fuel
Flat battery
ELECTRIC
SYSTEM
Incomplete running-in
TROUBLE
Excessive oil
Black smoke
performance
consumption
Inadequate
POSSIBLE CAUSE
is ignited
Excessive oil level
Damaged injector
INJECTION
Insufficient coolant
OVERALL DIMENSIONS
DIMENSIONS (mm)
A 318 D 189,1 G 525,7 M 220,5
B 157,2 E 475,1 H 350,6 N 500
GENERAL INFORMATION
Operating cycle Four strokes Diesel
Cylinders n. 2 in-line
Bore x stroke mm 68x60,6
Displacement cm3 440
Compression rate 20:1
Suction Dry-type air filter
Cooling Liquid
Crankshaft rotation Anticlockwise (seen from flywheel side)
Combustion sequence Crankshaft degrees 360°
Timing System Single shaft driven by synchronous toothed belt
Valves n. 2 for cylinder
Shaft overhead camshaft
Tappets hydraulic
Injection electronically-controlled direct injection (Common Rail)
Engine dry weight Kg 48.5
Maximum tilt during operation less than 1 minute 25°
Maximum tilt during operation less than 30 minutes 15°
Volume of sucked air (4,400 rpm) l/min 820
Minimum volume of radiator cooling air m3/h 880
(at static pressure of 0 mm H2O)
POWER AND TORQUE
Peak rpm giri/min. 4'400
Peak power kW 8,5
(NB 80/1269/EEC - ISO 1585 - DIN 7020)
Maximum torque (N power at 2,000 rpm) Nm 21
Admissible axial load on crankshaft Kg 80
A) Manufacturer identification
B) Engine type
C) Engine serial number
D) Peak rpm
E) Customer version number (K no.)
F) Approval data
PERFORMANCE GRAPH
Legend
N* (80/1269/EEC-ISO 1585) = Power curve. - These power rates are reduced by approx. 1% every 100m
Automotive power: discontinuous services at variable of altitude and by 2% for every 5°C exceeding 25°C.
RPM and load.
MN* = Torque curve Note: Please contact Lombardini for power, torque, and
C* = specific consumption curve specific consumption curves at different speeds from
the above.
* The above curves are approximate since they depend on
applications and on engine mapping.
Caution – Warning
- The above power levels refer to the engine equipped with Non-approval by Lombardini for any modifications
air filter, muffler, fully broken-in suction fan, and ambient releases the company from any damages incurred by the
conditions of 20°C and 1 bar. engine.
- The maximum power is guaranteed with a tolerance of 5%.
Important
Non compliance with the operations described in the table involves the risk of technical damages to the engine and
vehicle. Any non compliance makes the warranty become null and void.
CHANGE
- Engine oil
ONLY AFTER FIRST 1,000 KM - Oil filter
CHECK
EVERY 2,500 km
Coolant level
Alternator belt tension
Engine oil
Oil filter
Fuel filter
Air filter cartridge (**)
CHANGE
Coolant
Alternator belt
Timing belt (*)
Tightening pulley
Fuel hoses and safety filter
Important
Even if the prescribed km have not been covered, the following items must be changed or replaced:
- engine oil, after one year
- coolant, after two years
- alternator belt, after four years
- timing belt, after four years
(*) Once removed, the timing belt must be replaced, even if it has not reached its prescribed service life.
(**) The period of time that must elapse before cleaning or replacing the filter element depends on the environment in
which the engine operates. The air filter must be cleaned and replaced more frequently under very dusty conditions.
COOLANT
An anti-freeze protection liquid (eg. AGIP ANTIFREEZE SPEZIAL) – mixed with 50% decalcified water – must be used.
As well as lowering the freezing point, the permanent liquid also raises the boiling point and protects the whole circuit from
corrosion.
FUEL RECOMMENDATIONS
Purchase diesel fuel in small quantities and store in clean, approved containers. Clean fuel prevents the diesel fuel injectors and
pumps from clogging. Do not overfill the fuel tank.
Leave room for the fuel to expand. Immediately clean up any spillage during refueling.
Never store diesel fuel in galvanized containers; diesel fuel and the galvanized coating react chemically to each other, producing
flaking that quickly clogs filters or causes fuel pump or injector failure.
High sulfur content in fuel may cause engine wear. In those countries where diesel has a high sufur content, its is advisable to
lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more
frequently. The regions in which diesel normally has a low sulfur content are Europe, North America, and Australia.
PRESCRIBED LUBRICANT
Fuel with low sulphur content API CF4 - CG4
Fuel with high sulphur content API CF
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.
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 temperatures. If paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.
BIODIESEL FUEL
Fuels containing less than 20% methyl ester or B20, are suitable for use in this
engine. Biodiesel fuels meeting the specification of BQ-9000, EN 14214 or equi-
valent are recommended. DO NOT use vegetable oil as a biofuel for this engine. EMISSION CONTROL INFORMATION
Any failures resulting from the use of fuels other than recommended will not be
LOW SULFUR FUEL OR
warranted.
ULTRA LOW SULFUR FUEL ONLY
AVIATION FUEL
Aviation fuels suitable for use in this engine include JP5, JP4, JP8 and, JET-A (if EPA /CARB emission label must be
5 percent oil is added). attached near the fuel inlet.
Engine oil capacity Oil volume at max. level (including oil filter) Litres 2,1
SAE classification
- - - - - - - - + + + + + + + + + +
In the SAE classification oils are identified according 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50
to viscosity without considering any other qualitative SAE 10W*
characteristic.
SAE 20W*
The first number refers to the viscosity when cold, for use
during winter (W= winter), while the second number is for SAE 30*
viscosity at high temperatures. SAE 40*
The criteria for choosing an oil must include the minimum SAE 10W-30**
ambient temperature to which the engine is to be exposed SAE 10W-40**
during the winter and the maximum temperature during SAE 10W-60**
operation in the summer.
SAE 15W-40 **
Monograde oils are generally used when the operating
SAE 15W-40 **
temperature varies little.
Multigrade oils are less sensitive to temperature variations. SAE 20W-60 **
SAE 5W-30 ***
SAE 5W-40 ***
SAE 0W-30 ***
* Mineral base
** Semi-synthetic base
*** Synthetic base
MIL L- 46152 D / E
Key to abbreviations
Rif. Description
1 Tank (not supplied)
2 Electric fuel pump
3 Fuel filter
4 Safety in-line filter
5 Common Rail
6 High-pressure pump
7 Electronic injectors
8 Return pressure regulating valve
9 Distributor
10 Pressure sensor
11 Pressure regulator
Components
Description Value
Filtering surface 2.400 cm2
Filtering capacity 2 µm
2 1
Max operating pressure 2.0 Bar
Max delivery 190 litres/hour
FUEL DISTRIBUTOR
Key to components:
ELECTRIC PUMP
Features:
Voltage: ������������������������������������������ 12 V;
Max absorbed current: ������������������� 1.5 A;
Min pump delivery: ������������������������ 24 l/h
Self-adjusting pressure: ������������������ 0.50 bar
Operating pressure: ������������������������ 0.20 bar
Working temperature ���������������������� -30/+70°C.
INLET OUTLET
INJECTION PUMP
Description Value
Pumping element Ø 5.5 mm
Total stroke 5.7 mm
Working stroke 3.5 mm
Pre-stroke 2.2 mm
inlet return
Rif. Description
1 Pressure switch
2 Oil sump suction
3 Oil filter cartridge
4 Oil pump
5 Oil pressure regulating valve
6 Oil drain plug
7 Oil return line
8 Oil dipstick
9 Vent system
10 Oil filler cap
OIL PUMP
Features:
Closing
plate
Pump type: lobe pump
Pump drive:
gear driven by
crankshaft and installed on left balance shaft
Upper
crankcase Pressure regulating valve: installed on crankcase
Key
Internal lobe
Rif. Description
1 Cab heating
2 Thermostatic valve
3 Liquid circulating pump suction
4 Liquid circulating pump
5 Liquid outlet from engine
6 Water temperature sensor
Features:
THERMOSTATIC VALVE
Air bleeding hole
Features:
INTAKE SYSTEM
AIR FILTER
The air filter is a dry-type one, with a replaceable paper filter car-
tridge.
The filter intake must be positioned in a cool area.
The temperature of the air sucked must never exceed ambient
temperature by more than 10°C (if you are using a pipe, check
that pipe length is 400 mm max and that it is the straightest pos-
sible).
Components:
1. Filter body
2. Filtering cartridge
3. Cover
4. Dust exhaust valve
5. Articulated fastener
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Power relay
Electric
Engine revolutions fuel pump relay
Accelerator
Glow plug relay
(2 gangs)
Rail pressure
Vehicle speed
regulator
(on gearbox)
Water temperature
Key (15/54) indicator light
Injection failure
Idle position indicator light
(ON/OFF)
Diagnosis
TRAVEL DIRECTION
ENGINE COMPARTMENT
CABIN
Key to components:
A = ECU A Connector
The dotted parts are not supplied B = ECU B Connector
by Lombardini. C = Vehicle interface connector
E = Accessory connector (radiator electric fan, water
in fuel filter sensor and electric fuel pump)
M = Diagnostic connector
G = Instrument panel
H = Accelerator pedal support equipped with potentiometer
H2 = Remote accelerator potentiometer (as an accessory)
L = Relay and fuse boxes (for engine)
S = Service connector
R = Battery
Z = Battery connector
Wiring diagram of the instrument panel with accelerator pedal (for engines equipped with accelerator potentiometer
inside the cabin)
STARTER FUSE 25 A
FUSE 5 A
Switch STOP
IDLE
STARTER RELAY switch
MAIN FUSE
Key to components:
Wiring diagram of the instrument panel without accelerator pedal (for engines with accelerator potentiometer as an
accessory)
STARTER FUSE 25 A
FUSE 5 A
Switch STOP
IDLE
STARTER switch
RELAY
MAIN FUSE
Key to components:
- 34 -
E = accessory interface onnector
Electronic C = cabin interface connector
control unit B = ECU B Connector
Fuse/relay M = diagnostic interface connector
S = service interface connector
R1 = fan 30A relay
R3 = electric fuel pump relay 30A
R4 = general 30A relay
R4 = glow plugs 70A relay
F2 / F3 / F6 = 10A fuse
Engine electrical control
F5 / F4 / F1 = 15A fuse
F9 / F10 = 25A fuse
Z+/Z- = battery connectors
ELECTRONIC ENGINE CONTROL WIRING DIAGRAM
G = yellow
N = black
GR = gray
R = red
BL = blue
M = brown
V = green
Fuse/relay wiring diagram for engines with accelerator potentiometer inside the cabin
B = white
C = light blue
A = orange
RA = pink
VI = purple
E = accessory interface
connector
Electronic C = cabin interface connector
control unit B = ECU B Connector
Fuse/relay M = diagnostic interface
connector
S = service interface connector
R1 = fan 30A relay
R3 = electric fuel pump
relay 30A
R4 = general 30A relay
R4 = glow plugs 70A relay
F2 / F3 / F6 = 10A fuse
F5 / F4 / F1 = 15A fuse
F9 / F10 = 25A fuse
Z+/Z- = battery connectors
VI = purple
Engine electrical control
3
- 35 -
3 Engine electrical control
Key 50
Odometer control
Revolution indicator control
Control for alternator indicator light
Control for oil low pressure indicator light
Control for glow plug indicator light
Control for injection failure indicator light
Control for coolant high temperature indicator light
Control for water in fuel indicator light
6-gangs accelerator pedal
Signal for stop pressed
Signal for gearbox in idle position
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Key
Odometer Revolution indicator (optional)
Idle 6-gangs
position Stop
accelerator pedal
Rif. Description
F1 Fan relay
F2 Electric fuel pump relay
F3 ECU B 50 - Diagnosis 16
F4 ECU B 4 - 6
F5 ECU B 5
F6 Diagnosis 1 - ECU B 23
F9 Glow plugs
F10 Glow plugs
Rif. Description
R1 Fan relay
R3 Electric fuel pump relay
R4 General relay
RC Glow plug relay
Description
Rif.
ALT Alternator
CN1 Glow plug 1
CN2 Glow plugs 2
G Speed sensor (connected to gearbox)
H Oil pressure sensor
MOT 50 of starter motor
S Service connector
V ECU A alternator wiring harness
- 40 -
ENGINE WIRING DIAGRAM
Engine electrical control
L = Crankshaft sensor (RPM) J.P.T. FExFE black - high spring TW = "twisting" 40 spires/m Key to cable colours
(30) = Battery
T = Rail pressure regulator - Bosch Purple (50) = Key G = yellow
N = Cylinder 1 injector - Bosch Purple (15-54) = Key - first trip N = black
GR = gray
O = Cylinder 2 injector - Bosch Purple R = red
P = H2O temperature sensor J.P.T. FExFE gray - low spring BL = blue
V = alternator PIN "IG" M = brown
V = green
Q = Phase sensor - Bosch Purple B = white
R = Rail pressure sensor - Bosch Yellow C = light blue
A = ECU A
Rif. Description
A ECU A engine
L Speed sensor
N Electronic injector connector
O Electronic injector connector
P Coolant temperature
Q Phase sensor
R Rail pressure sensor
T Rail pressure regulator
V Alternator management on service wiring harness
WATER IN FUEL
SENSOR
FUEL PUMP
WATER IN FUEL
SENSOR
G = yellow
N = black
GR = gray
R = red
BL = blue
M = brown
V = green
B = white
C = light blue
A = orange
RA = pink
VI = purple
FUEL PUMP
Important
- Never disconnect the battery cables immediately after engine stop.
Important
The control unit must be used only with the calibration
defined by Lombardini s.r.l. for every single engine.
Dissipator
Cover Air valve
1. Engine type
2. Approval code
3. Customer version number (K no.)
4. Engine s/n bar code
5. Engine s/n
Installation prescriptions
COMMON RAIL
Components:
1. Pressure sensor
2. Pressure regulator
3. Common rail
4. High-pressure pump
5. Pressure regulator return line
1 - Pressure sensor
2 - Pressure regulator
3 - Rail
ELECTRONIC INJECTORS
During the test phase, the characteristics of the injectors are tested under different conditions of pressure/delivery.
Any injector that does not comply with a specific standard is discarded. The approved injectors are classified using a 9-digits
alphanumeric code (IMA code), marked by means of laser-writing on the upper part of the electromagnet (pos. A).
This procedure allows combining the manufacturing characteristics of each injector with a specific software strategy of the engine
control unit, thus improving the injector performances and reducing the polluting emissions.
The IMA procedure allows recovering the manufacturing tolerances of each injector tested.
Any time one or more injectors (or the ECU itself) are replaced, the new codes have to be stored in the memory to implement the
corrections.
When installing the control unit, the single code has to be stored. In case of replacement of one or more injectors, the diagnostic
tool must be used to enter the code of the new injector (see IMA code storing on page 142).
A IMA code
1. Pressure rod
2. Needle
3. Nozzle
4. Coil
5. Pilot valve
6. Ball valve
7. Control area
8. Supply volume
9. Control volume
10. Fuel return (low pressure)
11. Control line
12. Supply line
13. Electrical connection
14. High-pressure fuel inlet union
15. Spring
CHARACTERISTICS
Temp ° C Rm in K Ω Rm ax K Ω
-40 38.313 52.926
0 5.227 6.623
+140 0.067 0.076
Connector
KEY TO COMPONENTS
KEY TO COMPONENTS
Pre-heating time:
Post-heating time:
°C -20 -10 0 15 30 40
sec 120 120 120 90 60 30
SPEED SENSOR
ELECTRIC FAN
STARTER MOTOR
Features:
Measured after reaching thermal stabilization at 25°C and under constant voltage of 14 V.
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Important
The bracket of the lifting points have been designed to lift
the engine only. They are not intended nor approved to lift
additional weights.
Do not use different methods to lift the engine than those
described herein. In case different methods are used, no
warranty shall be granted for any consequential damage.
- If the engine is not to be used for extensive periods, check the storage area conditions and the type of packaging and
make sure that these are suitable for correct storage.
If necessary, cover the engine with a proper protective sheet.
- Avoid storing the engine in direct contact with the ground, in environments that are humid and exposed to bad weather,
near high voltage electric lines, etc.
Important
If, after the first 6 months, the engine is still not used, it is necessary to carry out a further measure to extend the pro-
tection period (see “Protective treatment”).
PROTECTIVE TREATMENT
1 - Pour in the engine housing AGIP RUSTIA C protective 11 - Treat non-painted parts with protective products (AGIP
oil up to the maximum level. RUSTIA NT).
2 - Fill up with fuel containing 10% AGIP RUSTIA NT. 12 - Loosen the alternator/fan belt.
3 - Make sure that the coolant is up to the maximum level. 13 - Cover the engine with a proper protective sheet.
4 - Start the engine and keep it idle at minimum speed for
some minutes.
5 - Bring the engine to ¾ of the maximum speed for 5÷10
minutes. Caution - Warning
6 - Turn off the engine. In countries in which AGIP products are not available, find
7 - Empty out completely the fuel tank. an equivalent product (with specifications: MIL-L-21260C).
8 - Spray SAE 10W on the exhaust and intake manifolds.
9 - Seal the exhaust and intake ducts to prevent foreign
bodies from entering.
Important
10 - Thoroughly clean all external parts of the engine using
Maximum every 24 months of inactivity, the engine must be
suitable products.
started up by repeating all “Engine Storage” operations.
After the storage period and before starting up the engine and mum level.
preparing it for operation, you need to perform certain opera- 14 - Replace the filters (air, oil, fuel) with original spare parts.
tions to ensure maximal efficiency conditions. 15 - Empty the cooling circuit completely and pour in the new
coolant up to the maximum level.
1 - Remove the protective sheet.
2 - Remove any sealing devices from the exhaust and inta- Caution - Warning
ke ducts. Over time, a number of engine components and lubricants
3 - Use a cloth soaked in degreasing product to remove the lose their properties, so it is important considering whether
protective treatment from the external parts. they need replacing, also based on age (see Replacement
5 - Inject lubricating oil (no more than 2 cm3) into the intake table).
ducts.
6 - Adjust the alternator/fan belt tension.
7 - Turn the engine manually to check the correct movement
Important
and smoothness of the mechanical parts.
Maximum every 24 months of inactivity, the engine must be
8 - Refill the tank with fresh fuel.
started up by repeating all “Engine Storage” operations.
9 - Make sure that the oil and the coolant are up to the ma-
ximum level.
10 - Start the engine and after some minutes bring it to ¾ 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 oil (see “Table of lubricants”) up to the maxi-
A
B
C
D
Cn1 - Cn2
10
11
12
13
EXHAUST MANIFOLD
Important
Replace the self-locking nuts and the metal gaskets
between the manifold and the cylinder head every time they
are disassembled.
14
1. Release the rubber clamp that fixes the air filter to the
support.
2. Use the special pliers to open the clamp of the air filter/inlet
manifold connection duct.
15
4. Use the special pliers to open the clamp and disconnect the
vent duct from the oil vapours decanting device.
16 17
18
19
INLET MANIFOLD
20
21 22
3. Release the belt from the pulleys and remove the alternator.
23
24
25
Push the split pin by its closed side against the return line fitting.
26
Keep the split pin in this position and disconnect the fittings from
the injectors by pulling them upwards. Pay attention to the O-
rings.
Caution - Warning
After removing the fittings, the split pin must automatically
return to the normal position.
If this does not happen, replace the split pin.
27
A Important
Seal all the openings of the return line and injectors, to
keep dirt or foreign bodies out of the engine.
28
B
29
30
Use the special plugs C to seal the fuel inlet and outlet holes.
31
Disconnect the hose D from the Rail and use a special plug E to
plug the union.
E
D
32
FUEL DISTRIBUTOR
33
Caution - Warning
G When unscrewing the high-pressure line union that
connects the pump to the rail, hold the union G on the high-
pressure pump with a wrench.
34
Important
After disassembling the high-pressure line, use the special
plugs to close the fuel passage holes on the high-pressure
L pump H and on the Rail L.
H
35
ELECTRONIC INJECTORS
0 1
Important
Before removing the injectors and/or the delivery hoses,
mark them (0 and 1, see photo) not to reverse the original
position of the cylinders during the reassembly phase.
If the position of the electronic injectors is changed, the
ECU will not detect the expected IMA codes. This will result
in poor engine performances (see page 46).
36
Caution - Warning
Unscrew the union of the high-pressure line M, by holding
the injector union N with a wrench, then unscrew union O.
Caution - Warning
N M Carry out the high-pressure line disassembly with care to
avoid damaging the cones and the sealing olives.
O
37
Caution - Warning
Seal the Rail outlets, injector union and high-pressure line
inlets.
38
1- Unscrew the screw 1 and remove the bracket 2 that fixes the
electronic injector to the cylinder head.
2- Manually rotate the electronic injector in its seat to extract it.
Make sure not to leave the copper gasket 3 in its seat on the
cylinder head.
Important - Warning
The protrusion of the nozzles from the cylinder head
1 surface depends on the seal 3. Use seals of different
thickness to obtain a different protrusion.
2 3 Match each seal with the corresponding injector.
Never use improper tools to extract the electronic injector
39 from the cylinder head.
RAIL
40
Disassemble the Rail and remove the columns that fix it to the
cylinder head.
41
GLOW PLUGS
42
43
44
Disassemble the sensor from its seat in the thermostat case and
check the condition of the O-ring.
OR
45
46
STARTER MOTOR
47
1
48
49
Caution - Warning
During the disassembly of the screws, pay attention not
to damage the acoustic insulating rubber seal between the
fastening screw and the cover.
50
TIMING SYSTEM
A
1. Unscrew the fastening screws and remove the external timing
belt guard A.
Key to components:
51
Important
B Every time the belt is disassembled it must be replaced
2
3 even if it has not reached the prescribed time for replace-
ment.
4
52
4. Fit the special tool 1 p/n 1460.300 to lock the camshaft timing
1 pulley.
5. Unscrew the fastening bolt.
Caution - Warning
When removing the pulley, pay attention not to drop the key
2.
2
6. Remove the timing pulley on the camshaft.
53
54
TIGHTENING PULLEY
55
56
WATER PUMP
Important
The water pump cannot be repaired. In case of failure it
must be replaced with a new one.
57
FLYWHEEL
58
3 Caution - Warning
During the disassembly phase, pay particular attention to
the cylindrical reference pin 2 between the flywheel and the
crankshaft.
59
SPEED SENSOR
Unscrew the two fastening screws and remove the speed sen-
sor.
Important
After disassembling the sensor, protect it against shocks,
humidity and any sources of high temperature.
60
61
Caution - Warning
Pull out the pump, paying attention not to drop the roller
tappet pad.
Important
The roller tappet pad B (fig.63) is available in different
thicknesses, since it determines the injection pump pre-
stroke.
62 When replacing the injection pump, the pad thickness has
to be determined again.
To determine the correct thickness of pad B (fig.63) refer to
page 98.
63
CAMSHAFT COVER
Important
In case of breakage or deformation of the camshaft cover,
replace the whole cylinder head.
64
CAMSHAFT
8 5 1 2
Key to components:
6 7 4
65
66
Important
If the phase sensor reference plate 1 (fig.65) is bent or
incorrectly assembled, the engine may have starting
problems and/or irregular performances.
67
68
69
Key to components:
1 1. Rocker arm
2. Tappet fastening clamp
2 3. Hydraulic tappet
3
For further specifications on the hydraulic tappet, refer to
page 95.
70
CYLINDER HEAD
Important
Do not disassemble the head while the engine is hot, to
avoid the risk of deformations.
71
Important
The cylinder head fastening bolts must be replaced at each
disassembly.
72
Important
The head gasket must be replaced every time it is
disassembled.
73
GEAR COVER
74
Key to components:
2
1. Balance shaft gear drive gear
5 2. Balance shaft gear
3. Oil pump
4. O-ring
5. Oil seal ring
Important
Check the integrity of the O-ring (4) and replace it if
necessary.
1 4
3 2
75
76
Unscrew the four fastening screws and remove the oil pump
plate.
77
OIL SUMP
Components:
1
1 Oil suction pipe
2 Oil sump return line from vent system
3 Oil pressure regulating valve
2
3
78
79
Important
The connecting rod half-bearings are made of special
material. Therefore, they must be replaced every time they
F are removed to avoid seizures.
Important
During the reassembly phase, the two centring pins F
on the connecting rod cap must coincide with the special
holes F on the big end.
F
80
PISTON
Press by hand on the connecting rod big end to pull out the
connecting rod - piston assembly.
81
Important
Mark some references on the connecting rods, caps,
pistons and gudgeon pins to avoid unintentionally mixing
up the components during the reassembly phase, since
this could result in engine malfunctioning.
82
CRANKCASE
83
Caution - Warning
When disassembling the lower crankcase, pay attention not
to damage the crankshaft half-bearings and the components
of the oil pressure regulating valve A.
A Important
The connecting rod half-bearings are made of special
material. Therefore, they must be replaced every time they
are removed to avoid seizures.
84
1. Remove the balance shaft together with the oil pump lobes.
85
86
CRANKSHAFT
Important
The connecting rod half-bearings are made of special
material. Therefore, they must be replaced every time they
are removed to avoid seizures.
87
ENGINE BLOCK
87 a
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– Information is given in a logical order in terms of timing and – Wash the components with special detergent and do not use
sequence of operations. The methods have been selected, steam or hot water.
tested and approved by the manufacturer’s technical ex-
perts. – Do not use flammable products (petrol, diesel, etc.) to degrease
or wash components. Use special products.
– This chapter describes procedures for checking, overhauling
and tuning assemblies and/or individual components. – Dry all washed surfaces and components thoroughly with a jet
of air or special cloths before reassembling them.
Important
To locate specific topics, the reader should refer to the – Apply a layer of lubricant over all surfaces to protect them
index. against oxidation.
– Before any intervention, the operator should lay out all equi- – Check all components for intactness, Wear limit, seizure, cracks
pment and tools in such a way as to enable him to carry out and/or faults to be sure that the engine is in good working con-
operations correctly and safely. dition.
– The operator must comply with the specific measures de- – Some mechanical parts must be replaced en bloc, together with
scribed in order to avoid errors that might cause damage to their coupled parts (e.g. valve guide/valve etc.) as specified in
the engine. the spare parts catalogue.
Shaft seals
– Clean the shaft thoroughly and make sure that it is not – Do not use a hammer directly on the gaskets during assembly,
damaged or scored or become oval-shaped in the areas of to avoid damaging them.
contact with the seals.
– Be careful not to damage the gaskets while joining them to the
– Lubricate the seal lips, and pointing them in the right direc- shaft.
tion, place them in their seat using a special pad.
O- rings
– Lubricate the seal before introducing it to its seat. – Avoid «rolling» the gasket during the attachment phase.
Important
Keep each connecting rod coupled with its piston and gudgeon
pin.
B
D
88
89
Important
Before replacing the pistons, check that the weight difference
between the two integral preassembled connecting rod/
piston/gudgeon pin assemblies does not exceed 8 g, to
prevent weight imbalances.
Protect the contact surfaces with lubricating oil, to prevent
90 them from rusting.
91
Important
– Seal rings cannot be replaced separately.
– Protect the contact surfaces with lubricating oil, to prevent
them from rusting.
CYLINDERS
Important
92 - The cylinders can be oversized by 0.25 and 0.50 mm, in
compliance with the Manufacturer's specifications.
- When reconditioning, make sure that the working angle is
45÷55° and that the average roughness is Ra=0.25÷0.5.
- Do not finish the internal surface of the cylinders using an
emery cloth.
- Protect the contact surfaces with lubricating oil, to prevent
them from rusting.
This table shows the reference values and their classification (only
valid for new engines).
Important
Pistons having a diameter as per their nominal value are
supplied as spare parts only for class (B). The oversized ones
(0.25 and 0.50 mm) have a reference (Ø 68.25 and Ø 68.50)
engraved on the upper section (crown) of the piston.
Place a seal ring in the cylinder and measure the ring end gap
using a thickness gauge (H).
Repeat for all the seal rings.
If the ring end gap does not correspond to the values indicated in
the table, replace the seal ring with an original spare part.
Install the seal rings on the piston in the order shown in the figure.
Important
Set the seal rings with their marking turned towards the piston
crown.
Important
Protect the contact surfaces with lubricating oil, to prevent
them from rusting.
94
CRANKSHAFT
Important
Protect the contact surfaces with lubricating oil, to prevent them from rusting.
Important
– Half-bearings cannot be replaced separately.
– If it is necessary to grind the crankshaft, define the diameters of the main journal and crankpin to choose the available
coupling measures for the new crankshaft and connecting rod half-bearings (see table "Connecting rod and crankshaft
half-bearings - Diameters").
– When grinding the crankshaft it is possible to undersize the main journals and crankpins by 0.25 and 0.50 mm.
Caution - Warning
The crankshaft and connecting rod half-bearings are made out of special lead-free material, and hence must strictly be
replaced with new ones every time they are removed in order to prevent seizure.
Protect the contact surfaces with lubricating oil, to prevent them from rusting.
Important
If the axial clearance between the crankshaft and the
crankcase is above 0.60 mm, it is necessary to replace the
whole engine block.
96
Couple the two engine blocks and tighten to the specified torque
(see on page 105). Using a dial gauge, measure the pin housing
internal diameters (1 and 2), see "Table for determining countershaft
housing and pin clearance".
1
97
4
98
Caution - Warning
The crankshaft and connecting rod half-bearings are made
out of special lead-free material, and hence must strictly be
replaced with new ones every time they are removed in order
to prevent seizure.
Assemble the cap (N) on the big end together with the new half-
bearings and then tighten the screws to a torque of 25 Nm.
Using a dial gauge, measure the diameters C - B.
100
A 109,98÷110,02
B 20,025÷20,035
B-D
C 19,995÷20,000 0,07
0,025÷0,04
D 39,027÷39,056
E 43,8÷44,0
101
Important
- Make sure that the connecting rod and crankshaft half-bearings are properly matched (see “Table of crankshaft and
connecting rod half-bearing dimensions”).
- The connecting rod half-bearings are supplied with undersized dimension, with respect to the nominal dimension of
0.25 mm e 0.50 mm.
- If the small end (B) diameter does not perfectly match with the one of the gudgeon pin (D), it is necessary to replace the
small end bearing to obtain the correct coupling (see "Connecting rod dimension table").
- Protect the contact surfaces with lubricating oil, to prevent them from rusting.
CONNECTING ROD
Important
Protect the contact surfaces with lubricating oil, to prevent
them from rusting.
Important
Before carrying out the pre-assembly, check that the weight
difference between the two connecting rod/piston/gudgeon
pin assemblies does not exceed 8 g, to prevent weight
(C) imbalances.
(A)
Lubricate the gudgeon pin (A) and the seat of the small end of
the connecting rod (B).
(B) Install the lock ring (C) on the piston complete with seal rings
(D).
(D)
(C) Important
(E) Insert the lock rings with their tips turned towards the piston
103 base (15° tolerance).
Insert the gudgeon pin (A) in the piston (D) and assemble the
connecting rod (B) (complete with cap (E)).
Insert the gudgeon pin completely and fasten it with the second
lock ring (C).
Important
Check that the lock rings are correctly housed in their seats.
Lubricate the coupling surfaces and the ones that are prone
to oxidation.
Important
The head gasket must be replaced every time it is
disassembled.
104
Clearance volume
A (mm) Number of holes (mm)
0,280÷0,380 1 0,340÷0,440
0,381÷0,480 2
0,481÷0,580 3 0,340÷0,439
0,581÷0,680 4
Unscrew the four fastening screws of the cover and remove it.
105
The vapours are discharged through the duct A and then reach
the first decanting chamber X.
The function of the metal filter element B is to slow down the
vapours in order to let them condense.
The drops of condensed oil, having a greater specific weight
than the vapours, flow back to the oil sump trough the same duct
A.
The vapours then pass from the decanting chamber X to
the chamber Y through a labyrinth that allows for further
condensation.
The vapours now condensed flow back to the sump through the
hole D. The vapour left will be conveyed trough the duct E to the
inlet manifold.
106
The reed valve C, that opens and closes according to the piston
alternate motion, allows for maintaining a constant vacuum
inside the engine block.
107
Important
When reassembling, always replace the gasket G.
Insert the metal filter element B in its housing and reinstall the
cover of the vapour recirculation vent.
B
Tighten the screws to a torque of 10 Nm.
108
109
110
111
3 2 1 Key to components
1. Plug
2. Spring
3. Piston
112
4
5 6
113
Oil pressure
Oil pres-
sure in
cylinder
head
Oil tem-
perature
114
Important
When disassembling the valves, keep the components of the
different valves together to allow correct reassembly of the
valves.
115
VALVE SPRINGS
116
Flatness check
Place the cylinder head on a surface plate and position it with the
corners on the stud bolts.
Use a dial gauge to check the cylinder head levelness.
Important
If the level deviation is greater than 0.10 mm, the cylinder head
must be ground, removing no more than 0.20 mm.
117
Important
Since the seats are prefinished, they are not to be worked
again after they have been driven in the head.
Important
Protect the contact surfaces with lubricating oil, to prevent
them from rusting.
118
Important
Carry out the measurements in different points to
119 detect any ovalization and/or concentrated wears.
The intake and exhaust guides are both made out of gray
iron with pearlitic phosphoric matrix and they have the same
dimensions:
D E
Dimensions (mm):
10,045÷10,054 10,000÷10,018
120
VALVES - Reassembly
tool
717-1460-047 Important
- Check that the cylinder head has been perfectly washed
and dried.
- Check that all components are intact and, if necessary,
replace them with original spare parts.
(A) 1- Generously lubricate the valve stem seal ring (A) and then fully
insert it on the valve guide using the tool “717-1460-047”.
2 - Lubricate the valve stem (B).
3 - Slide the valve into its seat.
(B)
121
4 - Assemble the cup (C), spring (D), collar (E) and cotters (F).
Half collets (F)
5 - Press hard on the collar (E) using the special tool to insert the
cotters (F) into the valve stem opening.
Cup (E)
6 - Release the tool and check that the cotters are correctly
Spring (D) positioned.
Collar (C) If the cotters are not correctly positioned, repeat the operation.
7 - Repeat the same operation on the other valves.
122
Description Value
Operating voltage 11 V
Voltage range 7÷13.5 V
Performance Single pole
Current Max 30A
123
TIMING SYSTEM
Components:
1 Hydraulic tappet
2 Rocker arm
3 Rocker arm pin
4 Camshaft
5 Valve
6 Cylinder head
7 Lubrication line
124
Important
For information purposes, the timing angle values are provided
below.
It must be pointed out that such values are not measurable on
the engine because of the presence of the hydraulic tappets.
They can be checked only when machining the camshaft.
125
83
Components:
1 Tappet body
2 Low pressure piston
3 High pressure piston
4 Spring
5 Non-return valve
A Low-pressure chamber
B High-pressure chamber
126
The operating principle of the hydraulic tappet is based on the incompressibility of liquids and on controlled leakage.
The oil under pressure enters the tappet chamber A, providing a constant supply of oil in the low-pressure chamber.
The oil can only enter the high-pressure chamber B through the non-return valve 5 and leave via the clearance between the
piston 3 and the tappet body 1 (controlled leakage).
The chamber B is filled when the rocker arm is on the base radius of the cam, and the spring 4 keeps the piston 3 against the
valve stem, thus eliminating any system plays. Because of the spring extension, the tappet "extends", thus creating a small
depression in the chamber B. Such depression makes the non-return valve 5 open, thus allowing the oil in the chamber A to
pass to chamber B to restore the correct oil quantity necessary to eliminate any plays in the valves.
For correct operation of the hydraulic tappets, the pressure chamber of piston 3 must always be filled with oil.
Under certain conditions this may not happen, since oil leakage, with engine stopped, can lead to complete emptying of the
tappets. This will result in valve plays entailing a characteristic sound, like a ticking, not to be confused with the normal ticking of
the injectors.
1 - With cold engine, the tappet filling time could be very long if the oil used is not suitable for the specific environmental
conditions (see prescribed oil on page 21).
2 - When the engine is hot, oil pressure may be low when running at idle, and small air bubbles could form up in the circuit.
Because of this, the lubricant becomes compressible, thus compressing the tappet and producing a valve play which is
responsible for the ticking sound.
However, the ticking sound should not last more than 5 minutes. If this is not the case, the problem is surely due to the
insufficient oil level, to Wear limit or to clogging of the ball valve and its seat in the piston preventing the tappet from operating
correctly. In this case, the only solution is to change the oil and replace the hydraulic tappets.
CAMSHAFT
Important
Failure to perform a proper tightening could result in
breakage or deformation of the camshaft bearing.
Important
The camshaft bearing is machined on the basis of the
cylinder head to which it is coupled. Therefore, it cannot be
127 supplied separately.
Important
In case of breakage or wear of the camshaft cover, replace
the whole cylinder head.
A Intake cam
B Exhaust cam
C High-pressure pump cam
If the dimensions of cam involutes are lower than the values shown
by 0.1 mm (maximum dimension), replace the camshaft with an
129 original spare part.
Important
Table of cam dimensions Protect the contact surfaces with lubricating oil, to prevent
them from rusting.
Assemble the camshaft on the cylinder head and check that the
Rif. Ø Dimensions (mm)
axial clearance is 0.05÷0.20.
A 33,738÷33,763 If the axial clearance does not comply with this value, replace the
cylinder head or the camshaft.
B 33,542÷33,567
C 23,950÷24,000
C1 35,350÷35,400
Important
If the phase sensor reference plate 1 is bent or incorrectly
1
assembled, the engine may have starting problems and/or
irregular performances.
130
HIGH-PRESSURE PUMP
Determining the thickness of the injection pump pad
Caution - Warning
The importance of determining the correct thickness of the
pad between the tappet and the injection pump is due to
the fact that such thickness represents the pre-stroke value
of the high-pressure pump. An incorrect pre-stroke value
will prevent reaching the correct fuel pressure and delivery
131 values in the Common Rail.
Key to components:
A Pump seal
B Cylinder head
C Pad
D Roller tappet
E Camshaft
F Distance value between pump level and pad
132
133
134
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– The instructions are provided in a sequential way, following a practical and chronological order. The working methods have
been selected, tested and approved by the Manufacturer's technicians.
– This chapter describes all the installation procedures for assemblies and /or single components after overhauling, testing and,
if necessary, replacement using original spare parts.
Important
- The operator must wash, clean and dry components and assemblies before installing them.
- The operator must make sure that the contact surfaces are intact, lubricate the coupling parts and protect those that are prone
to oxidation.
- 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.
- In order to operate safely and easily, we recommend positioning the engine on a rotating stand for engine overhauling.
- Before proceeding with operations, make sure that appropriate safety conditions are in place, in order to safeguard the operator
and any persons involved.
- In order to fix assemblies and/or components correctly, the operator must tighten the fastening elements in a criss-cross or
alternating pattern.
- For assemblies and/or components having a prescribed tightening torque, first tighten to a lower torque, then carry out the final
torque to the prescribed value.
UPPER CRANKCASE
Crankshaft half-bearings
Thoroughly clean the main bearings and install the new half-
bearings.
Caution - Warning
The crankshaft and connecting rod half-bearings are made
out of special lead-free material, and hence must strictly be
replaced with new ones every time they are removed in order
to prevent seizure.
139
Important
- The half-bearings cannot be replaced separately.
- If it is necessary to grind the crankshaft, define the diameters
of the main journal and crankpin to choose the available
coupling measures for the new crankshaft and connecting
rod half-bearings (see table "Connecting rod and crankshaft
half-bearings - Diameters").
- When grinding the crankshaft it is possible to undersize the
main journals and crankpins by 0.25 and 0.50 mm.
140
141
BALANCE COUNTERSHAFTS
Important
Carry out the timing of the balance countershaft gear and
crankshaft gear by aligning the two references on the gears.
142
143
144
B Important
The outer lobe must be installed with its reference B turned
towards the installer.
145
LOWER CRANKCASE
Caution - Warning
The crankshaft and connecting rod half-bearings are made
out of special lead-free material, and hence must strictly be
replaced with new ones every time they are removed in order
to prevent seizure.
146
Important
The O-rings on the three centring bushes must be replaced
before coupling the lower and upper crankcases.
OR
147
Caution - Warning
An excessive application of sealant may obstruct the
passages of the lubrication channels.
148
CRANKCASE - Fastening
Important
Pay attention to the oil pressure relief valve: if previously
installed, during the lower crankcase assembly, it may
protrude from its seat.
149
PHASE 1
150 PHASE 2
Tighten all the bolts to a torque of 25 Nm, except for the M6 bolts
(11-12-13-14).
PHASE 3
Important
Non compliance with the assembly specifications may result
in crankshaft blocking.
151
Generously lubricate the lobes and the delivery and suction pockets
of the oil pump, then assemble the plate.
152
153
2 1
154
Caution - Warning
Insert the centring washer A before tightening the screw.
A
Tighten the screw to a torque of 60 Nm.
155
Caution - Warning
The crankshaft and connecting rod half-bearings are made
out of special lead-free material, and hence must strictly be
replaced with new ones every time they are removed in order
156 to prevent seizure.
Caution - Warning
In order not to damage the seal rings and the contact areas
while inserting the piston into the cylinder, use the special
piston ring compression tool.
157
158
Caution - Warning
The crankshaft and connecting rod half-bearings are made
out of special lead-free material, and hence must strictly be
replaced with new ones every time they are removed in order
to prevent seizure.
159
Important
The screws of the connecting rod caps must be tightened in
an alternating pattern until reaching the prescribed torque
value.
160
OIL SUMP
Important
Always replace the O-ring (A) between the pipe and the
lower crankcase any time the pipe is disassembled.
161
Important
Always replace the O-ring (A) between the pipe and the
lower crankcase any time the pipe is disassembled.
162
To seal the oil sump surface, apply a bead of silicone liquid sealant
on the lower crankcase surface (p/n 4776.100 spare part.).
The diameter of the sealant bead must be approx. 2.5 mm.
Caution - Warning
An excessive application of sealant may obstruct the
passages of the lubrication channels.
2,5 mm
163
164
165
SPEED SENSOR
166
167
FLYWHEEL
1 2
168
Use a thickness gauge to check that the air gap between the speed
sensor and the phonic wheel is correct (0.25÷1.10).
To set the correct air gap, add or remove 0.5 mm shims.
169
CLEARANCE VOLUME
Important
The head gasket must be replaced every time it is
disassembled.
170
Clearance volume
A (mm) Number of holes (mm)
0,280÷0,380 1 0,340÷0,440
0,381÷0,480 2
0,481÷0,580 3 0,340÷0,439
0,581÷0,680 4
171
Important
The cylinder head fastening bolts must be replaced at each
disassembly.
Reassemble the rocker arm and the hydraulic tappet. Make sure
they are fully inserted.
173
CAMSHAFT
Important
Position the pistons at the top dead centre.
174
CAMSHAFT COVER
175
Important
Assemble the upper camshaft bearing with care, since the
hydraulic tappets may provoke a collision between valves
and pistons, if the latter are at their top dead centre.
Before fastening, bring the crankshaft to its BDC.
Important
176 In case of breakage or deformation of the camshaft cover,
replace the whole cylinder head.
Important
After correctly tightening all the screws, wait at least
30 minutes before starting the engine at an ambient
temperature of 20°C.
Before starting the engine, manually rotate the crankshaft to
check that the valves do not collide with the pistons.
Camshaft:
Install the seal ring A after generously lubricating it. Set the external
surface of the ring coplanar with the surface of the centring hub.
If the seal ring is worn out, the new oil seal ring must be installed
by moving it towards the bottom of the support, so that the seal
lip is moved by 1 mm from its previous position (first replacement
of the seal ring).
At the second replacement of the seal ring, it must be installed by
pushing it fully to the bottom.
The clearance available to move the seal ring from its original
position to the bottom position is 2 mm.
177
Install the seal ring C after generously lubricating it. Set the external
surface of the ring aligned with the end of the chamfered opening.
Respect the 2 mm indentation value with respect to the crankcase
surface.
If the seal ring is worn out, the new oil seal ring must be installed
by moving it towards the bottom of the support, so that the seal
lip is moved by 1 mm from its previous position (first replacement
of the seal ring).
In case the seal ring is replaced again, it must be installed further
in by 1 mm with respect to the previous time (second replacement
of the seal ring).
178
WATER PUMP
Important
Never apply an excess of sealant near the rotor to avoid pump
overheating.
179
180
Install the seal ring B after generously lubricating it. Set the external
surface of the ring coplanar with the surface of the centring hub.
If the seal ring is worn out, the new oil seal ring must be installed
by moving it towards the bottom of the support, so that the seal
lip is moved by 1 mm from its previous position (first replacement
of the seal ring).
In case the seal ring is replaced again, it must be installed further
in by 1 mm with respect to the previous time (second replacement
of the seal ring).
Do not move back the seal ring by more than 3 mm, since no
mechanical limit stop is provided to ensure the correct operation
of the ring.
181
GEAR COVER
Caution - Warning
When assembling the cover, pay particular attention not to
damage the oil seal ring B (fig.181) on the crankshaft.
Use the special tool C p/n 1466.299 to centre the gear cover on
the crankshaft.
Tighten the screws of the gear cover, by following the specified
order, at a torque of 10 Nm.
C
Important
The slightest non compliance with the specified tightening
182 order may result in deformations of the oil seal ring B.
Assemble the internal timing belt guard and tighten the screws in
a criss-cross pattern.
183
TIGHTENING PULLEY
184
185
186
187
Secure the crankshaft against rotation using the tool 1, see fig.168.
188
B Important
Every time the belt is disassembled it must be replaced
A even if it has not reached the prescribed time for replace-
ment.
Install the belt by aligning the belt references A with the corre-
C sponding references on the timing system internal guard B and
with the references on the camshaft pulley C and crankshaft
gear D.
189
A
D
190
Important
Remove the belt from its protective wrapping only when
ready for fitting.
3
191
192
193
194
195
OIL FILTER
Lubricate the rubber seal with engine oil and screw the oil filter
back in.
Important
It is compulsory to screw the oil filter manually.
196
Important
Always replace the O-ring.
197
THERMOSTATIC VALVE
Important
The air bleeding hole F must be turned upwards.
198
Important
Always replace the O-ring.
OR
199
Reassemble the coolant inlet flange on the engine with the duct
fitting.
200
Important
The glow plugs must be tightened using a torque wrench
only.
The glow plugs do not have a limit stop in the cylinder head.
Therefore, an incorrect tightening may result in serious head
damages (see on page 49) and could modify the glow plug
protrusion value in the combustion chamber.
201
ELECTRONIC INJECTORS
Important
Always replace the copper gasket 1 before reassembly.
202
Important
During the reassembly phase, always replace the screw 1
and the washer 2.
1
The washer has an assembly direction. The tapered surface A
must be in contact with the tapered surface of the bracket A.
203
1
Important
Reassemble the injector and/or delivery hoses paying
attention to the references on the injector and fuel delivery
hoses (0 and 1, see photo) marked during disassembly.
3 If the position of the electronic injectors is changed, the
ECU will not detect the expected IMA codes. This will result
in poor engine performances.
2
204
HIGH-PRESSURE PUMP
205
Loosen the screw A and introduce the tappet in the cylinder head,
with the slot B aligned with the screw A.
When the tappet roller comes in contact with the cam, tighten the
screw A.
To check if the tappet has been correctly assembled, it must not
rotate and allow a limited downstroke.
206
207
Important
During the reassembly phase, the pin 1 must be inserted in
the positioning slot 2.
Important
To avoid damaging the injection system, remove the
protection plugs only a moment before connecting to the
fittings.
208
Important
Insert the spherical washer respecting the assembly
direction and tighten the fastening nut to a torque of 25 Nm.
209
COMMON RAIL
210
Important
Assemble the Common Rail and screw in the fixing
columns without tightening them.
Important
To avoid damaging the injection system, remove the
protection plugs only a moment before connecting to the
fittings.
211
HIGH-PRESSURE LINES
Important
Assemble the high-pressure lines by manually screwing the
fittings, without tightening them.
Important
To avoid damaging the injection system, remove the
protection plugs only a moment before connecting to the
fittings.
212
213
214
215
216
217
Important
Before reassembling the rocker arm cover, always replace
the silicone seal between the cylinder head and the cover.
218
RAIL
Remove the plug D and fit the hose E on the Rail discharge fitting.
Important
D To avoid damaging the injection system, remove the
E protection plugs only a moment before connecting to the
fittings.
219
220
221
222
223
224
Use a plastic hose clamp to secure the return hose to the other
supply hoses, to avoid interferences with the acoustic insulation
cover.
225
Caution - Warning
Do not position the filter in a different position to avoid
problems to the supply system.
226
STARTER MOTOR
227
ALTERNATOR
228
Introduce the spacer B on the stud bolt that supports the alternator
in the lower part, and then fix the alternator to the upper bracket..
229
230
231
232
INLET MANIFOLD
Important
Before reassembling the manifold, always replace the
gaskets between cylinder head and manifold.
233
234
Reassemble the intake duct together with the oil vapours vent
duct.
Important
Always replace the clamps when reassembling.
235
AIR FILTER
Fasten the rubber clamp that fixes the air filter to the support.
236
EXHAUST MANIFOLD
Important
Before reassembling the manifold, always replace the
copper self-locking nuts and the metal gaskets between the
manifold and the cylinder head.
237
1. Install the accessory wiring harness (see page 38-39 for the
wiring diagram).
238
MOT
239
ALT
240
cn1 - 2
241
242
1. Install the accessory wiring harness (see page 40-41 for the
wiring diagram).
243
A Important
O Respect the original position: the engine will not work if the
connectors are changed.
244
245
246
247
C
Q
248
249
250
251
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The tables show the tightening torques for standard screws Tightening torques are provided again, along with method and
and the main components. sequence, in the instructions for assembling components and/
or assemblies
Table with tightening torques of the main components and use of sealant
Description
Diam. x pitch (mm) Torque (Nm) Sealant
Description
Diam. x pitch (mm) Torque (Nm) Sealant
Protection sleeve for assembling the gear cover oil seal ring 1460.296
Tool for intake and exhaust valve guide seal assembly 1460.047
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New diagnosis
Diagnosis
Service
Configuration
New diagnosis
Recent diagnosis
Start OBD
Demo
Automotive Marine
Automotive Automotive
Petrol Diesel
Automotive
Diesel
Lombardini
Automotive
Diesel
LOMBARDINI
ENGINE ELECTRONICS
LDW 442 CRS
--
6JF L3
08-
Automotive
Diesel
LOMBARDINI
ENGINE ELECTRONICS
Switch on the control panel
ENTER to continue
Parameters
Statuses
Information Now we are inside the diagnostic system.
Errors
Delete errors See "Diagnosis Menu"
Activations
Information It provides information concerning the programming of the ECU and the codes of the injector delivery class stored
in the ECU
Errors It lists the errors present and/or stored in the ECU, provides the description of the error and of its cause and suggests
the checks to be carried out.
Delete errors It allows deleting all the errors stored in the ECU
Activations It allows storing the injector delivery class codes in the ECU
ENTER to continue
Parameters
Statuses
Information
Errors
Delete errors
Activations
If the ECU is not recognized or in case of problems, the following message will be displayed
Service Menu
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Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication.
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