WORKSHOP MANUAL Engine Series 3 - 4 LD
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Drafting body DICOM/ATLO Document code Model N° Edition Revision Issue date Review date ED0053025560 50839 4° 3 01-94 15.06.2014 Endorsed Manual’s purpose • This manual contains the instructions needed to carry out a proper maintenance of the engine, therefore it must always be available, for future reference when required.
PREFACE Every attempt has been made to present within this use and maintenance, accurate and up to date technical information. However, development on the Lombardini series is continuos. Therefore, the information within this manual is subject to change without notice and without obligation. Carefully read and follow all instructions in this booklet as well as all those provided with the equipment on which this engine is used.
- INDEX This handbook provides the main information concerning the repair of the following LOMBARDINI Diesel engines 3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S, 4LD 640, 4LD 705, 4LD 820, which are air-cooled, provided with direct injection and revised on the 15-06-2014. 1 GENERAL REMARKS AND SAFETY INFORMATION........................................................................................Pag. 6 - 7 California Proposition 65 ............................................................................
Index - Valve guide dimensions and clearances .......................................................................................................................... 20 Valve guides insertion ...................................................................................................................................................... 20 Valve housings and seats ........................................................................................................................................
1 General remarks and safety information This manual contains safety precautions which are explained below. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored. CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored.
General remarks and safety information 1 . During operations which involve access to moving parts of . In order to move the engine simultaneously use the eyebolts fitted for this purpose by Lombardini. These lifting points are the engine and/or removal of the rotary guards, disconnect however not suitable for the entire machine, so in this case and insulate the positive cable of the battery so as to use the eyebolts fitted by the manufacturer.
1 General remarks and safety information GENERAL 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. A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations.
Workshop Manual_3 - 4 LD_cod. ED0053025560_4° ed_ rev.
2 TECHNICAL INFORMATION MANUFACTURER AND MOTOR IDENTIFICATION DATA - 10 - Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev.
2 Technical information ENGINE TYPE Cylinders Bore Stroke Displacement Compression ratio rpm N DIN 70020 - 80/1269/CEE - iso 1585 KW Power NB DIN 6271 - ISO 3046 - 1 IFN NA DIN 6271 - ISO 3046 - 1 ICXN Peak torque * Fuel specific consumption Oil consumption Dry weight Combustion air volume at 3000 rpm Cooling air volume at 3000 rpm Max. axial load permissible for drive shaft in two directions instantaneous Max. inclination extended to 1 h. permanent N. mm mm Cm³ Nm RPM l/h Kg/h Kg. l.
2 Technical information PERFORMANCE DIAGRAMS N (80/1269/EU - ISO 1585) NB (ISO 3046 - 1 IFN) NA (ISO 3046 - 1 ICXN) AUTOMOTIVES POWER : Discontinuous services at variable rpm and load. NON-OVERLOADABLE POWER:Continuous light services at constant rpm and variable load. CONTINUOUS OVERLOADABLE POWER: Continuous heavy-duty services at constant rpm and load.
Technical information 2 POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN: 1) 2) 3) 4) - The engine rpms suddenly increase and decrease - A sudden and unusual noise is heard - The colour of the exhaust fumes suddenly darkens - The oil pressure indicator light turns on while running. TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation.
2 Technical information ROUTINE ENGINE MAINTENANCE Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system MAINTENANCE ENGINES 3LD 450 - 510 - 450/S - 510/S 4LD 640 - 705 - 820 INTERVALS (HOURS) DETAIL 10 50 125 250 500 1000 2500 5000 AIR FILTER (OIL-BATH) (*) CLEANING HEAD AND CYLINDER FINS (*) FUEL TANK INJECTORS AIR FILTER OIL CHECK LEVEL SUMP OIL BATTERY LIQUID FUEL HOSE COUPLING FASTENING
2 Technical information LUBRICANT SAE Classification In the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken into account. The first number refers to the viscosity when the engine is cold (symbol W = winter), while the second considers viscosity with the engine at régime.
3 DISASSEMBLY / REASSEMBLY RECOMMENDATIONS FOR DISASSEMBLING Important To locate specific topics, the reader should refer to the index. – – – – 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.
Disassembly / Reassembly 3 Flywheel Clockwise unscrew nut 1 and remove the flywheel using the puller 2 Part. no. 7271-3595-050 for 3LD 450, 3LD 451/S, 3LD510, 3LD510/S, while for 4LD 640, 4 LD 705, 4LD 820 use puller with Part. no. 7271-3595-048. Check that the starter ring gear, when it is present, and the conic surface of the driving shaft coupling hole are intact. While reassembling, tighten the screws 1 at 170 Nm for 3LD 450, 3LD 450/S, 3LD510, 3LD 510/s and at 350 Nm for 4LD 640, 4LD 705, 4LD 820.
3 Disassembly / Reassembly Valve/rocker arm clearance Place the piston at the compression top dead centre. Place thickness gauge 1 between the valve stem and the rocker arm; cold-adjust the clearance at 0.15 ÷0.20 mm for both valves. Tighten the rocker arm box cap at 20 Nm.
Disassembly / Reassembly 3 Rocker arm pin and hole Dimensions (mm) A = 15.032 ÷ 15.050 B = 14.989 ÷ 15.000 Clearances (A-B) = 0.032 ÷ 0.061 (A-B) = worn limit = 0.120 12 13 Head Do not disassemble while it is hot as to avoid any possible distortion. If the head surface is distorted, smooth it by removing up to 0.3 mm thickness. Always replace the copper gasket, see picture 34 for the choice of thickness.
3 Disassembly / Reassembly Valves guides and housings 1 Exhaust valve guide 2 Intake valve guide Dimensions (mm): 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S A = 43.80 ÷ 44.20 C = 11.00 ÷ 11.018 B = 55.80 ÷ 56.20 D = 11.05 ÷ 11.06 4LD 640, 4LD 705, 4LD 820 18 A = 47.80 ÷ 48.20 C = 12.000 ÷ 12.018 B = 65.80 ÷ 66.20 D = 12.05 ÷ 12.06 Note: Valve guides with an external dia. increased of 0.5 mm can be used as spare parts; in this case it is necessary to increase the housing C of 0.5 mm for the assembly.
Disassembly / Reassembly 3 Valve housings and seats 3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S (mm); A = 34.99 ÷ 35.01 B = 35.10 ÷ 35.12 C = 30.99 ÷ 31.01 D = 31.10 ÷ 31.12 4LD 640, 4LD 705, 4LD 820 (mm): A = 42.99 ÷ 43.01 B = 43.12 ÷ 43.14 C = 36.99 ÷ 37.01 D = 37.10 ÷ 37.12 Drive the seats in the housings and mill at 45°. 20 Valve seat grinding After milling, grind with fine emery paste in engine oil bath. The S sealing surface shall not exceed 2 mm.
3 Disassembly / Reassembly Cylinder and piston Set a bore gauge to zero with a calibrated ring. Check the dia. Ø at points A and B at three different heights, see pictures 23 and 24. In case of wear exceeding 0.06 mm to the maximum value prescribed, grind the cylinder at the subsequent increased value. The increases suggested are 0.50 and 1.00 mm. Measure the piston Q dia.
Disassembly / Reassembly 3 Piston ring assembly order 3LD 450, 3LD 450/S, 3LD 510, 3LD 510/S, picture 30 A = slot for first piston ring (chromium plated) B = slot for piston ring segment (torsional) C = slot for third piston ring (oil scraper ring) 4LD 640, 4LD 705, 4LD 820, picture 31 A = slot for first piston ring (chromium plated) B = slot for second piston ring (torsional) C = slot for third piston ring(torsional) D = slot for fourth piston ring(oil scrarper ring) 30 Note: before inserting the piston
3 Disassembly / Reassembly Connecting rod equipped with bearings and piston pin For 3LD 450, 3LD 450/S, 3LD 510, 3LD 510/S Dimensions (mm) A = 144.05 ÷ 145.05 B = 23.02 ÷ 23.03 (with driven and machined bearing) C = 42.028 ÷ 42.052 (with bearing tightening at 3 Nm) D = 22.995 ÷ 23.000 For 4LD 640, 4LD 705, 4LD 820 Dimensions (mm) A = 162.95 ÷ 163.05 B = 28.02 ÷ 28.03 C = 55.40 ÷ 55.43 D = 27.995 ÷ 28.000 35 The connecting rod big end bearings are supplied either at nominal value and diminished to 0.
Disassembly / Reassembly 3 Side distributor port It can be found in engines equipped with industrial type drive shaft. The gaskets 3 and 5, thanks to their thickness, assure the oil seal and affect the camshaft axial clearance, as well. For the check, see information hereunder. Components For 3LD 450, 3LD 510 picture 40 1 Port 40 41 2 Bush 3 Gasket Fix the door at its base at 25 Nm. For 4LD 640, 4LD 705, 4LD 820 picture 41 4 Port 5 Gasket 6 Ball bearing Fix the port at its base at 40 Nm.
3 Disassembly / Reassembly Drive shaft There are two types of standard drive shafts: A Automotive type (agricultural machines) B industrial type (motor pumps generating set, etc.) Note: For left-handed engines, i.e 3LD 510/S, the drive shaft turns anticlockwise (seen from the flywheel position) and their thread is clockwise on the power takeoff side as well as on the flywheel side. 43 Drive shaft lubrication ducts Caution – Warning Always wear protective goggles if compressed air is used.
Disassembly / Reassembly 3 Drive shaft internal diam. crankshaft bearing / connecting rod head and clearances regarding their respective pins (mm) 3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S E = 40.040 ÷ 40.050 G = 42.04 ÷ 42.05 F = 42.028 ÷ 42.052 H = 30.07 ÷ 30.09 A, B, C, D, see picture 45 E-A= F-B= G-C= H-D= 46 0.040 ÷ 0.060 0.028 ÷ 0.065 0.040 ÷ 0.060 0.070 ÷ 0.10 worn limit 0.12 worn limit 0.13 worn limit 0.12 worn limit 0.18 4LD 640, 4LD 705, 4LD 820 E = 45.045 ÷ 45.070 F = 55.40 ÷ 55.
3 Disassembly / Reassembly Camshaft pin and housing dimensions (mm) A = 18.000 ÷ 18.018 (housing on the base) B = 17.945 ÷ 17.975 C = 18.000 ÷ 18.018 (housing on the port) D = 17.945 ÷ 17.975 A-B and C-D = 0.025 ÷ 0.073 Worn limit = 0.13 50 Camshaft intake and exhaust cam height. The two cam heights are different. Dimensions (mm) : H = 33.92 ÷ 34.02 (intake cam) H1 = 33.42 ÷ 33.52 (exhaust cam) If the cam wear exceeds the agreed minimum value of 0.1 mm for H and H1 , replace the camshaft.
Disassembly / Reassembly 3 Speed governor It has a centrifugal system with 6 balls housed in the gear, which is directly operated by the drive shaft. The balls, moved at the gear periphery by a centrifugal force, axially shift the bell 3, which actuates the fork 2 connected to lever 1 in order to determine the injection pump rack rod position. A spring with two plates 4, energized by the accelerator control 5, opposes the action of the governor cetrifugal force.
4 LUBRICATION CIRCUIT Danger – Attention The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed. Use suitable oil in order to protect the engine. Nothing more than lubrication oil can influence the performances and life of an engine.
Lubrication circuit 4 Oil pump Make sure that the gear teeth are intact and check that the clearance between the gear periphery and the pump case does not exceed 0.15 mm and that the drive shaft can easily turn with an axial clearance not exceeding 0.15 mm. Check that the gear lubrication holes 1 and 2 are not clogged. Tighten the pump case at 30 Nm. Tighten the pump control gear at 20 Nm.
4 Lubrication circuit Oil pressure check After the assembly operation, fill the engine with oil and fuel; connect a 10 bars pressure gauge to the fitting on the oil filter. Start the engine and check the pressure reaction according to oil temperature. Oil pressure curve with the engine at its maximum speed 65 - 32 - It is shown on the filter and obtained with the engine at 3000 rpm at N power; the pressure is expressed in bars and the temperature in degrees Celsius.
FUEL INJECTION CIRCUIT 5 Standard feeding/injection circuit Components: 1 Tank 2 Filter 3 Pump 4 Pipe 5 Injector 6 Injector waste pipe 66 Fuel filter inside the tank (standard) Details: 1 Spring 2 Disk 3 Ring 4 Cartridge 5 Gasket 6 Gasket 7 Cover 8 Ring 9 Bolt Cartridge features: Filtering degree = 7 µm Filtering surface = 390 cm2 67 Feeding pump (by request) Features: at 1500 rpm of the control eccentric, the minimum delivery is 60 l/h, while the automatic adjustment pressure is 4 ÷ 5 m
5 Fuel injection circuit Injection pump Components: 1 Delivery fitting 2 O-ring 3 Spring 4 Delivery valve 5 Gasket 6 Barrel 7 Pump case 8 Eccentric 9 Sector gear 10 Spring bearing cap 69 70 11 Spring 12 Pumping piston 13 Tappet case 14 External roller 15 Internal roller 16 Pin 17 Lock ring 18 Rack rod 19 Lock pin 20 Collar Tighten the pump at its base at 30 Nm. Injection pump assembly Insert the cylinder 6 in the pump case 7, engaging the slot A in the eccentric 8.
Fuel injection circuit 5 Advanced Injection references on the conveyor and flywheel protection disk A Piston reference at top dead centre B Injection advance reference as to A A ÷ B Distance in mm C Reference of piston in injection advance position α Reference in degrees D Flywheel protection disk diameter ENGINES (A-B) mm α mm 3LD 450, 451/S, 510, 510/S 58 ÷ 63 24° ÷ 26° 4LD 640, 705, 820 65 ÷ 70 4LD 820 a 2600 giri/1' 60 ÷ 65 74 D (3LD) D (4LD) 276 310 mm mm 22° ÷ 24° Note: 1° stands f
6 ELECTRIC CIRCUIT 12 V 14 A electrical ignition, diagram with voltage regulator , battery recharge lamp and manostat Components: 1 Alternator 2 Starting motor 3 Voltage regulator 4 Battery 5 Oil pressure switch 6 Oil pressure lamp 7 Ignition switch 8 Battery recharge lamp Note: The batteries, which are not supplied by Lombardini, shall have a 12 V voltage and the following capacity: 3LD 450, 3lD 451/S, 3LD 510, 3LD 510/S = 45 Ah 4LD 640 = 55 Ah 4LD 705 = 66 Ah 4LD 820 = 70 Ah 76 12.
6 Electric circuit Voltage regulator There are two different types of regulators: one with make SAPRISA, ALTECNA, NICSA and the other with make DUCATI. ALTECNA SAPRISA NICSA 79 80 Cable Colours DUCATI Tab dimensions Width Thickness ~ giallo G 6,25 0,8 R rosso R 9,50 1,2 + rosso B 9,50 1,2 LE verde L 4,75 0,8 marrone C 6,25 0,8 Voltage regulator, running check Make sure that the connections are in compliance with the diagram.
6 Electric circuit Characteristic curves for Bosch DW(L) 12V 1.1 kW type, starting motor 83 Bosch JF(L) 12V 2.5 kW type, starting motor For 4LD 640, 4LD 705, 4LD 820 Anticlockwise rotation (seen from the pinion side) A = 23 ÷ 25 mm -- 84 Characteristic curves for starting motor Bosch JF(L) 12V 2,5 kW type 85 - 38 - Workshop Manual__3 - 4 LD_cod. ED0053025560_4° ed_ rev.
ADJUSTMENT 7 Minimum rpm adjustment at idle running (standard) After filling the engine with oil and fuel, start and warm up the engine for 10 minutes. Actuating the adjusting screw 1, set the idling at 1150 rpm; then fasten the lock nut. 86 Peak rpm adjustment at idle (standard) After adjusting the minimum rpm, set the screw 2 and adjust the peak rpm at 3200 rpm at idle; then fasten the lock nut. Note: The peak rpm standard idle adjustment of 4LD 820 shall be carried out at 2800 rpm.
7 Adjustment Limiting device for injection pump delivery gearing device and torque It is housed in the pump control lever A and it is constituted of a spring on cam B, limiting the stroke of the same lever A. At the torque rate, the spring flexure, subject to the accelerator control action, allows a further stroke of lever A, thus an increased delivery of the injection pump. 89 Adjustment of injection pump delivery with braked engine 1) Bring the engine to its idling point .
STORAGE 8 - 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.
9 MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS 3LD 450 - 3LD 510 - 3LD 450/S - 3LD 510/S MAIN DRIVING TORQUES POSITION Injection pump union Connecting rod Clutch bearing bell bolt Flanging bell Clutch bell (industrial engine) Rocker arm box cap Oil sump Oil pump case Air filter Oil filter Oil pump gear Injector towards the head Rocker arm fulcrum pin for injection pump Gear pin for speed governor Engine foot Injection pump Distributor side port Oil pressure switch Starting pulley Main bearing on flywhee
9 Main torque specifications and use of sealants Table of tightening torques for standard screws (coarse thread) Resistance class (R) Quality/ Dimensions Diameter 4.6 4.8 R>400N/mm2 5.6 5.8 R>500N/mm2 6.8 8.8 10.9 12.
9 Main torque specifications and use of sealants USE OF DOPE FOR 3LD 450 - 3LD 510 - 3LD 451/S - 3LD 510/S TYPE OF SEALANT POSITION Clutch bearing bell and embedded hexagonal-head screws Control pin threading Coupling nipple for oil filter cartridge Stud bolt for clamping on engine head Stud bolt for clamping on main bearing flywheel side Stud bolt for clamping on distributor port side Stud bolt on engine bell Clamping screw for pin regulator Clamping screw for baffle on air conveyor Stud bolt for clampi
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WORKSHOP MANUAL cod. __ ED0053025560 La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione. Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication. Data reported in this issue can be modified at any time by Lombardini. Lombardini 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.
