workshop manual · 2014-10-01 · - attach the engine to a suitable lifting device (lifting beam)....
TRANSCRIPT
WORKSHOP MANUAL
cod. ED0053022860
9 LD Engine Series
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PREFACE
- Everyattempthasbeenmadetopresentwithinthisservicemanual,accurateanduptodatetechnicalinforma-tion.
However,developmentontheLOMBARDINIseriesiscontinuous. Therefore,theinformationwithinthismanualissubjecttochangewithoutnoticeandwithoutobligation.
- TheinformationcontainedwithinthisservicemanualisthesolepropertyofLOMBARDINI. Assuch,noreproductionorreplicationinwholeorpartisallowedwithouttheexpresswrittenpermissionofLOM-
BARDINI.
Informationpresentedwithinthismanualassumesthefollowing:
1- ThepersonorpeopleperformingserviceworkonLOMBARDINIseriesenginesisproperlytrainedandequip-pedtosafelyandprofessionallyperformthesubjectoperation;
2- ThepersonorpeopleperformingserviceworkonLOMBARDINIseriesenginespossessesadequatehandandLOMBARDINIspecialtoolstosafelyandprofessionallyperformthesubjectserviceoperation;
3- ThepersonorpeopleperformingserviceworkonLOMBARDINIseriesengineshasreadthepertinentinforma-tionregardingthesubjectserviceoperationsandfullyunderstandstheoperationathand.
- ThismanualwaswrittenbythemanufacturertoprovidetechnicalandoperatinginformationtoauthorisedLOM-BARDINIafter-salesservicecentrestocarryoutassembly,disassembly,overhauling,replacementandtuningoperations.
- Aswellasemployinggoodoperatingtechniquesandobservingtherighttimingforoperations,operatorsmustreadtheinformationverycarefullyandcomplywithitscrupulously.
- Timespentreadingthisinformationwillhelptopreventhealthandsafetyrisksandfinancialdamage. Writteninformationisaccompaniedbyillustrationsinordertofacilitateyourunderstandingofeverystepofthe
operatingphases.
9 LD Engine Series
9LD Workshop Manual _ cod. 1.5302.286 - 4° ed_rev. 03
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CUSE/ATLO
-
4° 06-883 01.09.2014
Drafting body
Document code Edition Issue date
Review date
ModelN° Revision
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Anymodificationstothisdocumentmustberegisteredbythedraftingbody,bycompletingthefollowingtable.
Endorsed
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
ED0053022860 50494
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-CHAPTER INDEX
TABLE OF CONTENTS
1 GENERAL REMARKS AND SAFETY INFORMATION ______________________________________ 9-11
CaliforniaProposition65WARNING..................................................................................................................................11Generalsafetyduringoperationgphases..........................................................................................................................11Generalservicemanualnotes............................................................................................................................................ 9Glossaryandterminology................................................................................................................................................... 9Regulationsforliftingtheengine......................................................................................................................................... 9Safetyandenvironmentalimpact.......................................................................................................................................11Safetyregulations............................................................................................................................................................. 10Warrantycertificate............................................................................................................................................................. 9
2 TECHNICAL INFORMATION _________________________________________________________ 12-21
Approvaldata.................................................................................................................................................................... 14Maincomponents.............................................................................................................................................................. 15Manufacturerandengineidentification............................................................................................................................. 14Overalldimension............................................................................................................................................................. 20Performancediagram................................................................................................................................................... 18-19Tableoflikelyanomaliesandtheirsymptoms................................................................................................................... 12Technicalspecifications................................................................................................................................................ 16-17Troubleshooting........................................................................................................................................................... 12-13
3 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING _____________________________ 22-25
ACEARegulations-Sequences....................................................................................................................................... 23API/MILSequences....................................................................................................................................................... 23Extraordinarymaintenance............................................................................................................................................... 22Fuelrecommendations...................................................................................................................................................... 25Internationalspecifications................................................................................................................................................ 23Lubricant........................................................................................................................................................................... 23Ordinarymaintenance...................................................................................................................................................... 22Prescribedlubricant.......................................................................................................................................................... 24Routineenginemaintenance............................................................................................................................................ 22SAEClassification............................................................................................................................................................ 23
4 DISASSEMBLY / REASSEMBLY ______________________________________________________ 26-51
Aircleaner......................................................................................................................................................................... 26Camshaft........................................................................................................................................................................... 45Camshaftendplay............................................................................................................................................................ 46Camshafttiming................................................................................................................................................................ 46Centermainbearingsupport,locatingscrew.................................................................................................................... 42Checkingmainjournalsandcrankpins............................................................................................................................ 43Clearancebetweenmainjournals/crankpinsandconnectingrodbearings..................................................................... 44Cloggingindicator............................................................................................................................................................. 28Compressionrelease....................................................................................................................................................... 32Connectingrod.................................................................................................................................................................. 39Connectingrodalignment................................................................................................................................................. 40Connectingrodbigendbearing........................................................................................................................................ 40Connectingrodsmallendbushing.................................................................................................................................... 40Connectingrodweight...................................................................................................................................................... 40Coolingfan........................................................................................................................................................................ 30Crankshaft......................................................................................................................................................................... 42Crankshaftcentermainbearingsupport........................................................................................................................... 42
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
ThismanualcontainspertinentinformationregardingtherepairofLOMBARDINIair-cooled,directinjectionDieselenginestype9 LD 625-2 - 625-2 EPA - 626-2 - 626-2 NR.
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- Chapter index
Crankshaftendplay.......................................................................................................................................................... 45Crankshaftjournalradius.................................................................................................................................................. 43Crankshaftlubricationducts.............................................................................................................................................. 42Crankshaftremoval........................................................................................................................................................... 42Crankshafttiminggear...................................................................................................................................................... 41Cylinder............................................................................................................................................................................. 36Cylinderhead.................................................................................................................................................................... 33Dimensionsandclearancebetweenguidesandvalves................................................................................................... 35Dimensionsofcamshaftjournalsandhousings................................................................................................................ 45Dryaircleaner................................................................................................................................................................... 27Dryaircleaner,Donaldsontype........................................................................................................................................ 27Electronicspeedgovernor................................................................................................................................................ 49Exhaustmanifold............................................................................................................................................................... 28Externalalternatorblowercontrolbelt-Disassembly....................................................................................................... 29Externalalternatorblowercontrolbelt-Reassembly........................................................................................................ 29Externalalternatorblowercontrolbelt–Tensioncheck.................................................................................................... 29Externalalternatorcontrolbelt.......................................................................................................................................... 29Flywheel............................................................................................................................................................................ 31Fueltank........................................................................................................................................................................... 29Governorspringswithrockerarmsystem......................................................................................................................... 49Governorspringswithsingle-springsystem..................................................................................................................... 49Headsealthickness.......................................................................................................................................................... 39Howtomeasurecamshaftjournalsandhousings............................................................................................................ 45Howtomeasureintake/exhaustcamheight..................................................................................................................... 46Howtomeasuremainbearinginsidediameter................................................................................................................. 43Hub.................................................................................................................................................................................... 30Hydraulicpump................................................................................................................................................................. 47Hydraulicpumpcomponents(1P).................................................................................................................................... 48Hydraulicpumpp.t.o......................................................................................................................................................... 47Injector.............................................................................................................................................................................. 32InjectorforEPAand97/68CEengines............................................................................................................................. 33Injectorprojection.............................................................................................................................................................. 33Intakemanifold.................................................................................................................................................................. 28Internalalternator.............................................................................................................................................................. 30Mainbearingandconnectingrodbigendbearinginsidediameter................................................................................... 44Mainbearinghousings...................................................................................................................................................... 44Mainbearingsupport,flywheeIside.................................................................................................................................. 41Mainbearingsupport,gearside........................................................................................................................................ 41Mainbearingsupports....................................................................................................................................................... 41Mainbearíngsupports-Dimensions................................................................................................................................ 44Mainjournalandcrankpindiameter................................................................................................................................. 43Manifolds,intake/exhaust.................................................................................................................................................. 28Mechanicalspeedgovernor.............................................................................................................................................. 48Mechanicalspeedgovernorcomponents......................................................................................................................... 48Oilvapourseparator......................................................................................................................................................... 28Oil-bathaircleaner............................................................................................................................................................ 26Piston................................................................................................................................................................................ 37Piston-Refitting................................................................................................................................................................ 39Pistonclearance................................................................................................................................................................ 39Pistonrings-Endgaps(mm)............................................................................................................................................ 38Pistonrings-Fittingsequence.......................................................................................................................................... 38Pistonweight..................................................................................................................................................................... 38Pistonsrings-Clearancebetweengrooves(mm)............................................................................................................ 38Pulleyguard-Shroud-Sideplates.................................................................................................................................. 30Pushrodtube..................................................................................................................................................................... 36Recommendationsfordisassemblingandassembling..................................................................................................... 26Recommendationsforoverhaulsandtuning..................................................................................................................... 26Rockerarmassembly....................................................................................................................................................... 32Rockerarms...................................................................................................................................................................... 31Shroudsupport(Gearcoverplate).................................................................................................................................... 31Speedgovernorwiringdiagram........................................................................................................................................ 50Table“Clearancebetweenmainbearingsandmainbearinghousings”........................................................................... 45Table“Pistonandcylindertypesandsizes"...................................................................................................................... 37Valve/Rockerarmclearance........................................................................................................................................... 31Valveguideinsertion......................................................................................................................................................... 35Valveguidesandvalveguidehousings............................................................................................................................ 35
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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-Chapter index
Valvematerial.................................................................................................................................................................... 34Valveseatgrinding............................................................................................................................................................ 36Valveseatsandhousings................................................................................................................................................. 36Valvesprings..................................................................................................................................................................... 34Valvestemsealingrings-Reassembly........................................................................................................................... 34Valvetiming-Angles......................................................................................................................................................... 47Valvetimingcheck............................................................................................................................................................ 47Valvetimingwithoutconsideringtimingmarks.................................................................................................................. 46Valves................................................................................................................................................................................ 34
5 LUBRICATION SYSTEM ____________________________________________________________ 52-55
Lubricationsystemandbreatherrecirculationsystem...................................................................................................... 52Lubricationsystemwithoilradiatorcircuit......................................................................................................................... 53Oilfiltercartridge(external)............................................................................................................................................... 54Oilpressurecheck............................................................................................................................................................ 55Oilpressurecurvewithengineatfullspeed..................................................................................................................... 55Oilpressurecurvewithengineatidlespeed.................................................................................................................... 55Oilpressurereliefvalve..................................................................................................................................................... 54Oilpump............................................................................................................................................................................ 53Oilradiator......................................................................................................................................................................... 55Standardlubricationsystemcircuit................................................................................................................................... 52
6 FUEL SYSTEM ____________________________________________________________________ 56-65
Fuelfeeding/injectioncircuitwithexternalfuelfilter........................................................................................................ 56Fuelfeeding/injectioncircuitwithexternalfuelfilteranddoublesolenoidvalve............................................................. 56Fuelfeeding/injectioncircuitwithexternalfuelfilterandQSD(QuickStopSystem)...................................................... 57Fuelfeeding/injectioncircuitwithfuelfilterinsidethefueltank....................................................................................... 56Fuelfeeding/injectioncircuitwithfuelfilterinsidethefueltankanddoublesolenoidvalve............................................ 56Fuelfeeding/injectioncircuit............................................................................................................................................. 56Fuelfeedingpumpcomponents........................................................................................................................................ 58Fuelfilter........................................................................................................................................................................... 57Fuelfilter(insidefueltank)................................................................................................................................................ 57Fuelfilter,external............................................................................................................................................................. 57Fuelliftpump..................................................................................................................................................................... 57Howtocheckinjectionpumpdeliveryvalvesealing......................................................................................................... 60Howtocheckplungerandbarrelforinternalleakage....................................................................................................... 59Howtomountinjectionpumpontheengine..................................................................................................................... 61Howtoreassembleinjectionpumpcomponents............................................................................................................... 61Injectionadvanceadjustment............................................................................................................................................ 63Injectionpump................................................................................................................................................................... 58InjectionpumpforEPAengines........................................................................................................................................ 59InjectionpumpforStandardand97/68CEengines......................................................................................................... 58Injectionpump/mechanicalspeedgovernortiming........................................................................................................... 62Injectionstaticadvanceadjustment.................................................................................................................................. 62Injector.............................................................................................................................................................................. 64Injectorsetting................................................................................................................................................................... 65Pistonfuelliftpump(onrequest)...................................................................................................................................... 58PlungerandBarrelAssembly............................................................................................................................................ 59SizePinjector,for97/68CEandEPAengines................................................................................................................. 65SizePnozzle,for97/68CEandEPAengines.................................................................................................................. 65SizeSInjector,onlyforstandardengines......................................................................................................................... 64SizeSNozzle,onlyforstandardengines......................................................................................................................... 64(Static)injectiontiming...................................................................................................................................................... 62Table“Conversionforestablishingadvance”.................................................................................................................... 63Testdataforinjectionpumpdelivery................................................................................................................................. 60
7 ELECTRIC SYSTEM ________________________________________________________________ 66-75
Alternator......................................................................................................................................................................... 67Alternator-12V,14A..................................................................................................................................................... 68
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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- Chapter index
Alternator-12V,18A........................................................................................................................................................ 67Alternator-24V,6A....................................................................................................................................................... 67Alternatorbatterychargercurve-24V,6A...................................................................................................................... 68Alternatorbatterychargercurve-external,12V,33A...................................................................................................... 69Alternatorbatterychargercurve(12V,18A).................................................................................................................... 67Alternatorbatterychargercurvestandard-12V,14A.................................................................................................... 68Alternator,external-12V,33A......................................................................................................................................... 69CharacteristiccurvesforstartingmotortypeBosch-12V,1.7kW.................................................................................. 72Characteristiccurvesofthe24V1.6kWstartingmotor................................................................................................... 73Checkingforcablecontinuity............................................................................................................................................ 69Directstopelectromagnet................................................................................................................................................. 75Directstopelectromagnets............................................................................................................................................... 74Electricstartinglayoutwithinternalalternator................................................................................................................... 66Electricalstartinglayoutwithexternalalternator............................................................................................................... 66Howtocheckvoltageregulatorforproperoperation........................................................................................................ 70Magnetizationcheckingtool.............................................................................................................................................. 68Pre-heatingglowplug....................................................................................................................................................... 74Reverseelectromagnet–FIREversion............................................................................................................................ 74Startingmotor.................................................................................................................................................................... 72StartingmotortypeBoschDW(R)12V,1.7kW............................................................................................................... 73Voltageregulator............................................................................................................................................................... 70Voltageregulator-12V,30A........................................................................................................................................... 71Voltageregulator-12V,26A,with“W”terminal............................................................................................................... 71Voltageregulator-12V,30A,with“W”terminal............................................................................................................... 71
8 SETTINGS _______________________________________________________________________ 76-79
Fullspeedsettinginno-loadconditions(standard)........................................................................................................... 76Idlingspeedsettinginno-loadconditions......................................................................................................................... 76Injectionpumpdeliverysetting.......................................................................................................................................... 76Injectionpumpdeliverysettingwithdynamometricbrake................................................................................................. 77lnjectionpumpdeliverylimitingandextrafueldevice....................................................................................................... 76lnjectionpumpdeliverysettingwithoutdynamometricbrake............................................................................................ 77Requiredsettings(asmostcommonlyapplies)................................................................................................................ 78Settingthestoplimitstop.................................................................................................................................................. 78Speedadjustments........................................................................................................................................................... 76
9 STORAGE ________________________________________________________________________ 80-81
Enginestorage.................................................................................................................................................................. 80Preparingtheengineforoperationafterprotectivetreatment........................................................................................... 81Protectivetreatment.......................................................................................................................................................... 80
10 TORQUE SPECIFICATIONS AND USE OF SEALANT ____________________________________ 82-84
Tableoftighteningtorquesforstandardscrews(coarsethread)...................................................................................... 84Tableoftighteningtorquesforstandardscrews(finethread)........................................................................................... 84Tableoftighteningtorquesforthemaincomponents.................................................................................................. 82-83
11 SPECIAL TOOLS _____________________________________________________________________85
Specialtoolsandequipmentformaintenance.................................................................................................................. 85
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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1GENERAL REMARKS AND SAFETY INFORMATION
WARRANTY CERTIFICATE
GLOSSARY AND TERMINOLOGY
Forclarity,herearethedefinitionsofanumberoftermsusedrecurrentlyinthemanual.
- Cylinder number one: isthetimingbeltsidepiston.- Rotation direction: anticlockwise«viewedfromtheflywheelsideoftheengine».
Regulations for lifting the engine-Beforeremovingtheenginefromthevehicleonwhichitisinstalled,disconnectthepowersupply,detachthefuelandcoolantsupply,andallconnectionsincludingthemechanicalones.
-Attachtheenginetoasuitableliftingdevice(liftingbeam).-Tomovetheenginesimultaneouslyusetheeyeboltsinstalled,theseliftingpointsarenotsuitablefortheentiremachine,thenusetheeyeboltsinstalledbythemanufacturer.
-Beforelifting,makesuretheweightiscorrectlybalancedbycheckingitsbarycentre.-Closeallengineopeningsaccurately(exhaust,intake,etc.),thenwashtheoutsideanddrywithajetofcompressedair.
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- TheproductsmanufacturedbyLombardiniSrlarewarrantedtobefreefromconformitydefectsforaperiodof24monthsfromthedateofdeliverytothefirstenduser.
- Forenginesfittedtostationaryequipment,workingatconstantloadandatconstantand/orslightlyvariablespeedwithinthesettinglimits,thewarrantycoversaperioduptoalimitof2000workinghours,iftheabovementionedperiod(24months)isnotexpired.
- Ifnohour-meterisfitted,12workinghourspercalendardaywillbeconsidered.- Forwhatconcerns thepartssubject to wearanddeterioration(injection/feedingsystem,electricalsystem,coolingsystem,sealingparts,non-metallicpipes,belts)warrantycoversamaximumlimitof2000workinghours,iftheabovementionedperiod(24months)isnotexpired.
- Forcorrectmaintenanceandreplacementoftheseparts,itisnecessarytofollowtheinstructionsreportedinthedocumentationsuppliedwitheachengine.
- Toensuretheenginewarrantyisvalid,theengineinstallation,consideringtheproducttechnicalfeatures,mustbecarriedoutbyqualifiedpersonnelonly.
- ThelistoftheLombardiniauthorizeddealersisreportedinthe“Service”booklet,suppliedwitheachengine.- Specialapplicationsinvolvingconsiderablemodificationstothecooling/lubricatingsystem(forex.:dryoilsump),filteringsystem,turbo-chargedmodels,willrequirespecialwrittenwarrantyagreements.
- WithintheabovestatedperiodsLombardiniSrldirectlyorthroughitsauthorizednetworkwillrepairand/orreplacefreeofchargeanyownpartorcomponentthat,uponexaminationbyLombardiniorbyanauthorizedLombardiniagent,isfoundtobedefectiveinconformity,workmanshipormaterials.
- Anyotherresponsibility/obligationfordifferentexpenses,damagesanddirect/indirectlossesderivingfromtheengineuseorfromboththetotalorpartialimpossibilityofuse,isexcluded.
- Therepairorreplacementofanycomponentwillnotextendorrenewthewarrantyperiod.
Lombardiniwarrantyobligationshereabovedescribedwillbecancelledif:
- Lombardinienginesarenotcorrectlyinstalledandasaconsequencethecorrectfunctionalparametersarenotrespectedandaltered.
- Lombardinienginesarenotusedaccordingtotheinstructionsreportedinthe“UseandMaintenance”bookletsuppliedwitheachengine.
- AnysealaffixedtotheenginebyLombardinihasbeentamperedwithorremoved.- SparepartsusedarenotoriginalLombardini.- Feedingandinjectionsystemsaredamagedbyunauthorizedorpoorqualityfueltypes.- Electricalsystemfailureisduetocomponents,connectedtothissystem,whicharenotsuppliedorinstalledbyLombardini.- Engineshavebeendisassembled,repairedoralteredbyanypartotherthananauthorizedLombardiniagent.
- Followingexpirationoftheabovestatedwarrantyperiodsandworkinghours,Lombardiniwillhavenofurtherresponsibilityforwarrantyandwillconsideritshereabovementionedobligationsforwarrantycomplete.
- Anywarrantyrequestrelatedtoanon-conformityoftheproductmustbeaddressedtotheLombardiniSrlserviceagents.
GENERAL SERVICE MANUAL NOTES
1- UseonlygenuineLombardinirepairparts. FailuretousegenuineLombardinipartscouldresultinsub-standardperformanceandlowlongevity.
2 - All data presented are in metric format. That is, dimensions are presented in millimeters (mm), torque is presented inNewton-meters (Nm),weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) andpressureispresentedinbarometricunits(bar).
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1 General remarks and safety information
Thismanualcontainssafetyprecautionswhichareexplainedbelow.
WARNINGWarningisusedtoindicatethepresenceofahazardthatcancause severe personal injury, death, or substantial propertydamageifthewarningisignored.
Safety regulation
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
GENERAL NOTES
. Lombardini engines are built to provide safe andlonglasting performances, but in order to obtain theseresults it is essential that the maintenance requirementsdescribed in the manual are observed along with thefollowingsafetyrecommendations.
.Theenginehasbeenbuilttothespecificationsofamachinemanufacturer, and it is his responsibility to ensure that allnecessaryactionistakentomeettheessentialandlegallyprescribedhealthandsafetyrequirements.Anyuseofthemachine other than that described cannot be consideredas complying with its intended purpose as specified byLombardini,which therefore declines all responsibility foraccidentscausedbysuchoperations.
. The following instructions are intended for the user of themachine in order to reduce or eliminate risks, especiallythoseconcerningtheoperationandstandardmaintenanceoftheengine.
.Theusershouldreadtheseinstructionscarefullyandgettoknow the operations described. By not doing so hemayplaceatriskhisownhealthandsafetyandthatofanyoneelseinthevicinityofthemachine.
. The engine may be used or mounted on a machine onlybypersonnelsuitably trained in itsoperationandawareofthedangers involved.This isparticularly true for standardand, above all, special maintenance work. For specialmaintenance contact personnel trained specifically byLombardini.Thisworkshouldbecarriedoutinaccordancewithexistingliterature.
. Lombardini declines all responsibility for accidents or forfailure to comply with the requirements of law if changesaremade to the engine’s functional parameters or to thefuel flow rate adjustments and speed of rotation, if sealsareremoved,orifpartsnotdescribedintheoperatingandmaintenance manual are removed and reassembled byunauthorizedpersonnel.
WARNING
. In addition to all othermachine specifications, ensure thatthe engine is in a near horizontal position when starting.lf startingmanually, ensure that the necessary operationscanbeperformedwithoutanyriskofstrikingagainstwallsordangerousobjects.Ropestarting(exceptforrecoilropestarting)isnotpermittedeveninemergencies.
.Checkthatthemachineisstablesothatthereisnoriskofitoverturning.
.Gettoknowtheenginespeedadjustmentandmachinestopoperations.
. Do not start the machine in closed or poorly ventilated
environments. The internal combustion process generatescarbon monoxide, an odourless and highly toxic gas, sospendingtoolongatimeinanenvironmentwheretheenginedischarges its exhaust products freely can lead to loss ofconsciousnessandevendeath.
. The engine may not be used in environments containingflammable materials, explosive atmospheres or easilycombustible powders, unless adequate and specificprecautions have been taken and are clearly stated andcertifiedforthemachine.
.Topreventtheriskoffire,keepthemachineatadistanceofatleastonemetrefrombuildingsorothermachines.
.Childrenandanimalsmustbekeptatasufficientdistancefromthemachinetopreventanydangerresultingfromitsoperation.
. Fuel is flammable, so the tank must be filled only when theengine is turned off. Dry carefully any fuel that may havespilled, remove the fuel container and any cloths soakedin fuel or oil, check that any sound-absorbing panels madeof porousmaterial arenot soakedwith fuel or oil, andmakesurethatthegroundonwhichthemachineislocatedhasnotabsorbedfueloroil.
. Before starting, remove any tools that have been used forcarrying out maintenance work to the engine and/or themachine and check that any guards removed have beenreplaced. In cold climates it is possible tomix kerosenewiththediesel fuel tomaketheengineeasier tostart.The liquidsmustbemixedinthetankbypouringinfirstthekeroseneandthen the diesel fuel. ConsultLombardini technical office formixture proportions. Petrolmay not be used because of theriskofitformingflammablevapours.
. During operation the surface of the engine reachestemperatures thatmay be dangerous. Avoid in particular allcontactwiththeexhaustsystem.
.The liquidcoolingcircuit isunderpressure. Donot carryoutany checks before the engine has cooled down, and eventhen open the radiator cap or the expansion tank cautiously.Wear protective clothing and glasses. lf there is an electricfan,donotapproachtheenginewhile it isstillhotasthefanmaycomeonevenwhentheengineisnotrunning.Cleanthecoolingsystemwiththeengineturnedoff.
. While cleaning the oil bath air filter, check that the oil isdisposed of in such a way as not to harm the environment.Any filtering sponges in the oil bath air filter should not besoakedwithoil. Thecyclonepre-filtercupmustnotbefilledwithoil.
.Since theoilmustbeemptiedoutwhile theengine isstillhot(approx. 80°C), particular care should be taken in order toavoidburns.Inanycasemakesurethatoildoesnotcomeintocontactwithyourskinbecauseofthehealthhazardsinvolved.
.Fuelvapoursarehighlytoxic,sofilluponlyintheopenairorinwellventilatedenvironments.
CAUTIONCautionisusedtoindicatethepresenceofahazardthatwillorcancauseminorpersonalinjuryorpropertydamageifthecautionisignored.
IMPORTANT This indicates particularly important technical information thatshouldnotbeignored.
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1General remarks and safety information
California Proposition 65WARNING
Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
GENERAL SAFETY DURING OPERATING PHASES– Theprocedurescontainedinthismanualhavebeentestedandselectedbythemanufacturer’stechnicalexperts,andhence
aretoberecognisedasauthorisedoperatingmethods.– Anumberofproceduresmustbecarriedoutwiththeaidofequipmentandtoolsthatsimplifyandimprovethetimingof
operations.– Alltoolsmustbeingoodworkingconditionsothatenginecomponentsarenotdamagedandthatoperationsarecarriedout
properlyandsafely. Itisimportanttowearthepersonalsafetydevicesprescribedbyworksafetylawsandalsobythestandardsofthismanual.– Holesmustbelinedupmethodicallyandwiththeaidofsuitableequipment.Donotuseyourfingerstocarryoutthis
operationtoavoidtheriskofamputation.– Somephasesmayrequiretheassistanceofmorethanoneoperator.Ifso,itisimportanttoinformandtrainthemregarding
thetypeofactivitytheywillbeperforminginordertopreventriskstothehealthandsafetyofallpersonsinvolved.– Donotuseflammableliquids(petrol,diesel,etc.)todegreaseorwashcomponents.Usespecialproducts.– Usetheoilsandgreasesrecommendedbythemanufacturer. Donotmixdifferentbrandsorcombineoilswithdifferentcharacteristics.– Discontinueuseoftheengineifanyirregularitiesarise,particularlyinthecaseofunusualvibrations.– Donottamperwithanydevicestoalterthelevelofperformanceguaranteedbythemanufacturer.
SAFETY AND ENVIRONMENTAL IMPACT
Everyorganisationhasadutytoimplementprocedurestoidentify,assessandmonitortheinfluenceofitsownactivities(products,services,etc.)ontheenvironment.Proceduresforidentifyingtheextentoftheimpactontheenvironmentmustconsiderthefollowingfactors:
- Liquidwaste -Atmosphericemissions - Wastemanagement -Useofrawmaterialsandnaturalresources - Soilcontamination -Regulationsanddirectivesregardingenvironmentalimpact
Inordertominimisetheimpactontheenvironment,themanufacturernowprovidesanumberofindicationstobefollowedbyallpersonshandlingtheengine,foranyreason,duringitsexpectedlifetime.
- Allpackagingcomponentsmustbedisposedofinaccordancewiththelawsofthecountryinwhichdisposalistakingplace.- Keepthefuelandenginecontrolsystemsandtheexhaustpipesinefficientworkingordertolimitenvironmentalandnoise
pollution.- Whendiscontinuinguseoftheengine,selectallcomponentsaccordingtotheirchemicalcharacteristicsanddisposeofthem
separately.
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
.Duringoperationswhich involveaccess tomovingpartsoftheengineand/orremovaloftherotaryguards,disconnectand insulate the positive cable of the battery so as topreventaccidentalshortcircuitsandactivationofthestartermotor.
.Checkthebelttensiononlywhentheengineisturnedoff.
IMPORTANT
.Tostart theengine follow thespecific instructionsprovidedin the engine and/or machine operating manual. Do notuseauxiliarystartingdevicesnotoriginally installedonthemachine(e.g.Startpilotsystemswhichutiliseetheretc.)
.Beforecarryingoutanyworkon theengine, turn itoffandallow it tocooldown. Donotperformanyoperationwhiletheengineisrunning.
. Check that the discharged oil, the oil filter and the oilcontained intheoilfilteraredisposedof insuchawayasnottoharmtheenvironment.
. Close the fuel tank filler cap carefully after each fílling
operation. Do not fill the tank right up to the top, but leavesufficientspacetoallowforanyexpansionofthefuel.
.Donotsmokeorusenakedflameswhilefilling.
.Takecarewhenremovingtheoilfilterasitmaybehot.
.Theoperationsofchecking,fillingupandreplacingthecoolingliquidmustbecarriedoutwiththeengineturnedoffandcold.Takeparticularcareifliquidscontainingnitritesaremixedwithothersnotcontaining thesecompoundsas thismaygiveriseto the formation of nitrosamines which are a health hazard.Thecooling liquid ispolluting,sodisposeof inamannerthatdoesnotdamagetheenvironment.
. In order tomove the engine simultaneously use the eyeboltsfittedforthispurposebyLombardini.Theseliftingpointsarehowever not suitable for the entiremachine, so in this caseusetheeyeboltsfittedbythemanufacturer.
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2
Obstructedfuelline
Fuelfilterclogged
Airorwaterleaksinfuelsystem
Thetankcapventholeisclogged
Nofuel
Faultyfuelfeedingpump
Extrafuelcontrollevelsticking
TROUBLE SHOOTING
FUEL
CIR
CU
IT
POSSIBLE CAUSE
SETT
ING
S R
EPA
IRS
Inad
equa
te p
er-
form
ance
Hig
h n
oise
leve
l
Ove
rhea
ts
THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:1) -Theenginerpmssuddenlyincreaseanddecrease;2) -Asuddenandunusualnoiseisheard;3) -Thecolouroftheexhaustfumessuddenlydarkens;4) -Theoilpressureindicatorlightturnsonwhilerunning.
TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMSThefollowingtablecontainsthepossiblecausesofsomefailureswhichmayoccurduringoperation.Alwaysperformthesesimplechecksbeforeremovingorreplacinganypart.
PROBLEMEn
gine
doe
s no
t sta
rt
Engi
ne s
tart
s bu
t sto
ps
No
acce
lera
tion
Non
-uni
form
sp
eed
Bla
ck s
mok
e
Whi
te s
mok
e
Oil
prea
ssur
e to
o lo
w
Exce
ssiv
e oi
l co
nsum
ptio
n
CO
OLI
NG
C
IRC
UIT
Incorrectgovernorlinkageadjustment
Governorspringbrokenorunhooked
Lowidlespeed
Ringswornorsticking
Worncylinder
Wornmainconrod-rockerarmbearingsBadlysealedintakevalve
Headtighteningnutsloose
Damagedcylinderheadgasket
Excessivevalve-rockerarmclearance
NoclearancebetweenvalvesandrockerarmsValvesstickingordamaged
Defectivetimingsystem
Bentrods
Crankshaftnotturningfreely
Cloggedairfilter
Coolingcircuitclogged
TECHNICAL INFORMATION
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 13 -
2
Dischargedbattery
CableconnectionuncertainorincorrectFaultystartingswitch
FaultystartingmotorELEC
TRIC
SYST
EMM
AIN
TEN
AN
CE
INJE
CTI
ON
LUB
RIC
ATIO
NC
IRC
UIT
POSSIBLE CAUSE
Inad
equa
te
perf
orm
ance
Hig
h n
oise
leve
l
Ove
rhea
ts
PROBLEM
Engi
ne d
oes
not s
tart
Engi
ne s
tart
s bu
t sto
ps
No
acce
lera
tion
No
n-u
nif
orm
sp
eed
Bla
ck s
mok
e
Whi
te s
mok
e
Too
low
oi
l pr
essu
re
Exce
ssiv
e oi
l co
nsum
ptio
n
Excessiveidleoperation
Incompleterun-in
Overloadedengine
Non-conformingengineoil
Damaged,blockedordirtyinjector
Injectionpumpvalvedamaged
Injectornotadjusted
Hardenedpumpcontrolrod
Brokenorloosesupplementarystart-upspringWornordamagedpumpingelement
Incorrecttuningofinjectioncomponents(deliverybalancingadvance)
Extrafuelcontrollevelsticking
Oilleveltoohigh
Oillevellow
Oilpressurevalveblockedordirty
Oilpressureregulatornotadjusted
Wormoilpump
Oilsumpsuctionlineclogged
FaultypressuregaugeorpressureswitchBlockeddrainingpipe
Technical information
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 14 -
2
A
F
D
E
B
C
2 34
76 5
1
24
65
13
Technical information
MANUFACTURER AND ENGINE IDENTIFICATION
The identificationplateshown in thefigurecanbe founddirectlyontheengine.Itcontainsthefollowinginformation:
A)Manufacturer’sidentityB)EnginetypeC)EngineserialnumberD) MaximumoperatingspeedE) Numberofthecustomerversion(formK)F)Approvaldata
Approval data
TheapprovalreferencedirectivesECareontheengineidentificationplate.
ThedataplateforEPAStandardsisappliedontheairintakecowling.Itcontainsthefollowinginformation:
1)Currentyear2)Enginedisplacement3)Ratedpower,measuredinkW4)EPAfamilyID5) Injectiontiming6) Injectionopeningpreassure7)Valveclearance
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 15 -
2
1 2 3
4
5
6
7
8 9 10
11
12
Technical information
MAIN COMPONENTS
Components:
1)Fueltank2)Injectors3)Aircleaner4)Startingmotor5)Oilfilter6)Rockerarmcover
7)Oildipstick8)Throttleandstopcontrols9)Oildrainplug10)Fuelfeedingpump11)Flywheel12)Injectionpump
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 16 -
180°
n°mmcm3
Kg
kW/CV
Nm/KgmKg
n°
g/kWh-g/CV1hKg/h
253-1860.013
11035°25°160026300
11035°25°160026300
11035°25°160026300
3000-
18.8/25.516.9/2367/6.8300
300020.7/2818.8/25.516.9/2373./7.4300
3000-
18.8/25.516.9/2368/6.9300
258-1900.013
258-1900.013
95x88124820.0:1
95x88124817.5:1
95x88124821.0:1
2
625-2 625/626-2 NR CE
625-2EPA
*2200rpmx9LD625-2;2000rpmx9LD625/626-2NR/CEand1700rpmx9LD625-2EPA
MomentaryUpto1hour
l/minl/min
2percylinder
SidecamshaftinthecrankcaseMechanicDirect
RodsandrockerarmsDrivingshaftdegrees
OilbathaircleanerwithcyclonicprefilterordryaircleanerAir(fanintegraltotheflywheel)
Counter-clockwise(fromflywheelside)
2inline
Four-strokediesel
POWER AND TORQUE
CONSUMPTION AT MAXIMUM POWER
GENERAL DETAILSOperatingcycleCylindersBorexstrokeDisplacementsCompressionrateIntakeCoolingCrankshaftrotationCombustionsequenceTiming system
ValvesShaftTappets
FuelinjectionDryweightofengineMaximumtiltwhileoperatingMaximumtiltwhileoperatingCombustionairvolumeat3000r.p.m.Coolingairvolumeat3000r.p.m.
Maximumoperatingspeed N(80/1269/CEE)ISO1585Maximumpower NBISO3046IFN NAISO3046ICXNMaximumtorque*Axialloadallowedoncrankshaft
SpecificfuelonsumptionOilconsumption
r.p.m.
TECHINICAL SPECIFICATIONS
Technical information
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
9 LD engine type
- 17 -
cm2
µm
cm2
µmbar
bar
barbarµmbarcm2
VVVAAAkWkW
3.12.80.6
0.3
132015
1.5÷1.7745
3.12.80.6
0.3
132015
1.5÷1.7745
3.12.80.6
0.3
132015
1.5÷1.7745
122412146331.71.6
122412146331.71.6
122412146331.71.6
4607
PF90450002÷34
4607
PF90450002÷34
4607
PF90450002÷34
2
625-2 625/626-2 NR CE
625-2EPA
FUEL SUPPLY CIRCUITFueltypeFuelsupplyFuel filter, internal Filtering surface Filter capacityFuel filter, external Filtering cartridge Filtering surface Filter capacity Maximum operating pressure
Alternator,InternalStandard(nominalvoltage)Alternator,InternalOptional(nominalvoltage)Alternator,ExternalOptional(nominalvoltage)Alternator,InternalStandard(nominalcurrent)*Alternator,InternalOptional(nominalcurrent)*Alternator,ExternalOptional(nominalcurrent)*Startermotorpower(BoshGF)Startermotorpower(BoshDW(R))
TypeoflubricationCircuitsupplyMaximumoilquantityMaximumoilquantityOilpressureatmin.speed(oiltemperature:120°C)Oil pressure switchOperating pressure (min. value)Oil filter cartridge, external Maximum operating pressure
Maximum combustion pressure Filter capacity By-pass valve setting Filtering surface
includingfilter(l)excludingfilter(l)
bar
CompletelyforcedGearpump
LUBRICATION CIRCUIT
ELECTRICAL SYSTEM
Automotivedieselfuel(minimumcetane:51)Mechanicalfuelliftpump(diaphragmorpistons)
*(see“Alternatorbatterychargercurve”page66÷69)
Unipolarsystem
Technical information
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
9 LD engine type
- 18 -
2
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.
Technical information
PERFORMANCE DIAGRAM
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 19 -
2
9 LD 626-2 B2 NR @ 2800 r.p.m. 9 LD 626 NR @ 3000 r.p.m.
Technical information
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
N (80/1269/CEE - ISO 1585):Automotiverating,intermittentoperationwithvariablespeedandvariableload.NB (ISO 3046/1 - IFN):Ratingwithnooverloadcapability, continuous lightdutyoperationwith constant speedandvariableload.NA (ISO 3046/1 - ICXN): Continuousratingwithoverloadcapability,continuousheavydutywithconstantspeedandconstantload.
C (NB) :SpecificfuelconsumptionatNBpowerMn :TorqueatN.
Theabovepowervaluesrefertoanenginefittedwithaircleanerandstandardmuffler,aftertestingandattheenvironmentalconditionsof20°Cand1bar.Max.powertoleranceis5%.Powerdecreasesbyapproximately1%every100mdialtitudeandby2%every5°Cabove25°C.
Note: ConsultLOMBARDINIforpower,torquecurvesandspecificconsumptionsatratesdifferingfromthosegivenabove.
Important
Non-approval by Lombardini for any modifications releases the company from any damages incurred by the engine.
- 20 -
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
9 LD 561-29 LD561-2/L9 LD 625-2
9 LD 626-29 LD 626-2 NR
OVERALL DIMENSION
Technical information
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 21 -
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2Technical information
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 22 -
10 125 250 500 1000 2500 5000
(***)
(***)
(**)
(***)
(*)
(*)
(*)
(**)
(**)
(***)
(***)
3
ENGINEOILLEVEL
OILBATHAIRCLEANER
DRYAIRCLEANER
FUELPIPES
EXTERNALALTERNATORBELTTENSION
COOLINGSYSTEMCLEANING
VALVE-ROCKERARMSCLEARANCEADJUSTMENT
SETTINGANDINJECTORSCLEANING
RUBBER INTAKEHOSE (DRYAIRCLEANER- INTAKEMANIFOLD)
FUELTANKCLEANING
ALTERNATORANDSTARTINGMOTOR
ENGINEOIL
EXTERNALOILFILTER
FUELFILTER
EXTERNALALTERNATORBELT
RUBBER INTAKEHOSE (DRYAIRCLEANER- INTAKEMANIFOLD)
FUELPIPES
DRYAIRCLEANEREXTERNALCARTRIDGE
DRYAIRINTERNALEXTERNALCARTRIDGE
PARTIAL
TOTAL
Engine oil replacement. Oil filter replacement.
EXTRAORDINARY MAINTENANCE
AFTER THE FIRST50 WORKING HOURS
ORDINARY MAINTENANCE
OPERATION DESCRIPTION FREQUENCY x HOURS
OVERHAUL
REPLACEMENT
CHECK
AFTER 6 CHECKS WITH CLEANING
(*) - 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 the environment in which the engine operates.
The air filter must be cleaned and replaced more frequently In very dusty conditions.
AFTER 3 CHECKS WITH CLEANING
ImportantFailure to carry out the operations described in the table may lead to technical damage to the machine and/or system
ROUTINE ENGINE MAINTENANCE
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 23 -
API CH-4 CG-4 CF-4 CF-2 CF CE CD CC
MIL L- 46152 D / E
- 40
- 35
- 30
- 25
- 20
- 15
- 10
- 5 0 +
5+ 10
+ 15
+ 20
+25
+30
+ 35
+ 40
+ 45
+ 50
SAE 10W-30**SAE 10W-40**
SAE 10W-60**SAE 15W-40 **
SAE 15W-40 **SAE 20W-60 **
SAE 5W-30 ***SAE 5W-40 ***
SAE 0W-30 ***
3Maintenance - Recommended oil type - Refilling
International specifications
Theydefinetestingperformancesandproceduresthatthelubricantsneedtosuccessfullyrespondtoinseveralenginetestingandlaboratoryanalysissoastobeconsideredqualifiedandinconformitytotheregulationssetforeachlubricationkind.
A.P.I :(AmericanPetroleumInstitute)MIL :EngineoilU.S.militaryspecificationsreleasedforlogisticreasonsACEA :EuropeanAutomobileManufacturersAssociation
Tablesshownonthispageareofusefulreferencewhenbuyingakindofoil.Codesareusuallyprinted-outontheoilcontainerandtheunderstandingoftheirmeaningisusefulforcomparingdifferentbrandsandchoosingthekindwiththerightcharacteristics.Usuallyaspecificationshowingafollowingletterornumberispreferabletoonewithaprecedingletterornumber.AnSFoil,forinstance,ismoreperformingthanaSEoilbutlessperformingthanaSGone.
LUBRICANT
SAE Classification
IntheSAEclassification,oilsdifferonthebasisoftheirviscosity,andnootherqualitativecharacteristicistakenintoaccount.Thefirstnumberreferstotheviscositywhentheengineiscold(symbolW=winter),whilethesecondconsidersviscositywiththeengineatrégime.Thecriteriaforchoosingmustconsider,duringwinter,thelowestoutsidetemperaturetowhichtheenginewillbesubjectandthehighestfunctioningtemperatureduringsummer.Single-degreeoilsarenormallyusedwhentherunningtemperaturevariesscarcely.Multi-degreeoilislesssensitivetotemperaturechanges. * Mineral base
** Semi-synthetic base*** Synthetic base
SAE- Grade
API / MIL SEQUENCES
ACEA REGULATIONS - SEQUENCES
LIGHT DUTY DIESEL ENGINESB1 = Low-viscosity,forfrictionsreductionB2 = StandardB3 = Highperformances(indirectinjection)B4 = Highquality(directinjection)
HEAVY DUTY DIESEL ENGINESE2 = StandardE3 = Heavyconditions(Euro1-Euro2engines)E4 = Heavyconditions(Euro1-Euro2-Euro3engines)E5 = Highperformancesinheavyconditions(Euro1-Euro
2-Euro3engines)
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 24 -
3.1
2.8
AGIP SUPERDIESELMULTIGRADE
10W40
API CF4 / SGACEA B2 - E2
MIL - L-4165 D/E
3
Litres
Litres
specifications
InthecountrieswhereAGIPproductsarenotavailable,useoilAPISJ/CFforDieselenginesoroilcorrespondingtothemilitaryspecificationMIL-L-4165D/E.Foratemperatureof-10°Canoilwitha5W40 viscosityisrecommended.Foratemperatureof-15°Canoilwitha0W30 viscosityisrecommended.
OIL VOLUME AT MAX LEVEL (OIL FILTER INCLUDED)
OIL VOLUME AT MAX LEVEL (WITHOUT OIL FILTER)
Danger - Attention- The engine may be damaged if operated with insufficient lube oil.- It is also dangerous to supply too much lube oil 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 other moving components increases significantly. - Always use oil with the right viscosity for the ambient temperature in which your engine is being operated.
Danger - Attention- The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.- Do not disperse the oil in the ambient, as it has a high pollution power.
PRESCRIBED LUBRICANT
Maintenance - Recommended oil type - Refilling
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
9 LD ENGINES OIL CAPACITY
- 25 -
10
3
Capacities standard fuel tank Litres
Maintenance - Recommended oil type - Refilling
API CF4 - CG4
API CF
Purchasedieselfuelinsmallquantitiesandstoreinclean,approvedcontainers.Cleanfuelpreventsthedieselfuelinjectorsandpumpsfromclogging.Donotoverfillthefueltank.Leaveroomforthefueltoexpand.Immediatelycleanupanyspillageduringrefueling.
Neverstoredieselfuelingalvanizedcontainers;dieselfuelandthegalvanizedcoatingreactchemicallytoeachother,producingflakingthatquicklyclogsfiltersorcausesfuelpumporinjectorfailure.
Highsulfurcontentinfuelmaycauseenginewear.Inthosecountrieswheredieselhasahighsufurcontent,itsisadvisabletolubricatetheenginewithahighalkalineoiloralternativelytoreplacethelubricatingoilrecommendedbythemanufacturermorefrequently.TheregionsinwhichdieselnormallyhasalowsulfurcontentareEurope,NorthAmerica,andAustralia.
FUEL TYPEForbestresults,useonlyclean,fresh,commercial-gradedieselfuel.Dieselfuelsthatsatisfythefollowingspecificationsaresuitableforuseinthisengine:ASTMD-975-1Dor2D,EN590,orequivalent.
FUELS FOR LOW TEMPERATURES
Itispossibletoruntheengineattemperaturesbelow0°Cusingspecialwinterfuels.Thesefuelsreducetheformationofparaffinindieselatlowtemperatures.Ifparaffinformsinthediesel,thefuelfilterbecomesblockedinterruptingtheflowoffuel.
Fuelcanbe: -Summer upto 0°C -Winter upto -10°C -Alpine upto -20°C -Arctic upto -30°C
BIODIESEL FUELFuels containing less than 20%methyl ester orB20, are suitable for use inthisengine.BiodieselfuelsmeetingthespecificationofBQ-9000,EN14214orequivalentare recommended. DONOTusevegetableoilasabiofuel for thisengine.Anyfailuresresultingfromtheuseoffuelsotherthanrecommendedwillnotbewarranted.
AVIATION FUELAviationfuelssuitableforuseinthisengineincludeJP5,JP4,JP8and,JET-A(if5percentoilisadded).
FUEL RECOMMENDATIONS
EMISSION CONTROL INFORMATION
LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY
EPA /CARB emission label must be attached near the fuel inlet.
Fuelwithlowsulphurcontent
Fuelwithhighsulphurcontent
PRESCRIBED LUBRICANT
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
Asforfilters,tanksandspecialcrankcasespleaserefertoLOMBARDINIinstructions.
- 26 -
1
4 DISASSEMBLY / REASSEMBLY
RECOMMENDATIONS FOR OVERHAULS AND TUNING
ImportantTo locate specific topics, the reader should refer to the index.
– Before any intervention, the operator should lay out allequipmentandtoolsinsuchawayastoenablehimtocarryoutoperationscorrectlyandsafely.
– The operatormust comply with the specificmeasuresdescribedinordertoavoiderrorsthatmightcausedamagetotheengine.
– Before carrying out any operation, clean the assembliesand/orcomponentsthoroughlyandeliminateanydepositsorresidualmaterial.
– Washthecomponentswithspecialdetergentanddonotusesteamorhotwater.
– Do not use flammable products (petrol, diesel, etc.) todegreaseorwashcomponents.Usespecialproducts.
– Dryallwashedsurfacesandcomponentsthoroughlywithajetofairorspecialclothsbeforereassemblingthem.
– Applyalayeroflubricantoverallsurfacestoprotectthemagainstoxidation.
– Checkallcomponentsforintactness,wearandtear,seizure,cracksand/or faults tobesure that theengine is ingoodworkingcondition.
– Somemechanicalpartsmustbereplaceden bloc,togetherwith their coupled parts (e.g. valve guide/valve etc.) asspecifiedinthesparepartscatalogue.
AIR CLEANER
Oil-bath air cleaner
Checkgasketsandreplaceifnecessary.Checkthatflangeweldisfreeofporosityordefectivespots.Carefully cleanbowl and filteringelement withDiesel oil andblowthroughwithcompressedair.Topupwithengineoiltothemark.
Whenrefittingtightennutsat25Nm.
Seepage22forperiodicmaintenancedetails.
RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
ImportantTo locate specific topics, the reader should refer to the index.
– Besidesdisassemblyandreassemblyoperationsthischapteralso includes checkingand setting specifications, dimen-sions,repairandoperatinginstructions.
– Alwaysuseoriginal LOMBARDINI spareparts for properrepairoperations.
– Theoperatormustwash,cleananddrycomponentsandassembliesbeforeinstallingthem.
– Theoperatormustmakesurethatthecontactsurfacesareintact,lubricatethecouplingpartsandprotectthosethatarepronetooxidation.
– Beforeanyintervention,theoperatorshouldlayoutallequi-pmentandtoolsinsuchawayastoenablehimtocarryoutoperationscorrectlyandsafely.
– Forsafetyandconvenience,youareadvisedtoplacetheengineonaspecialrotatingstandforengineoverhauls.
– Beforeproceedingwithoperations,makesurethatappro-priatesafetyconditionsareinplace,inordertosafeguardtheoperatorandanypersonsinvolved.
– Inordertofixassembliesand/orcomponentssecurely,theoperatormusttightenthefasteningpartsinacriss-crossoralternatingpattern.
– Assemblies and/or componentswith a specific tighteningtorquemust initiallybe fastenedata level lower than theassignedvalue,andthensubsequentlytightenedtothefinaltorque.
- 27 -
2
3
4
4Disassembly / Reassembly
Components:
1Bowl2Oillevelmark3Filteringelement4Sealring5Internalsealring6Cover7Clamp8Prefilter
Dry air cleaner, Donaldson type
Danger - AttentionNever clean the filter element using highly flammable solvents.It could cause an explosion!
Inordertoknowhowoftenyoushouldcheckandreplacetheairfiltercartridgeandtherubberhose(airfilter–intakemanifold)seepage22.
1Maincartridge2Safetycartridge3 Axialcover4Scavengingvalve5Capcompletewithclamp
Scavengingvalve4mustbepositionedasinfigure4.
Danger - AttentionDuring repair operations, when using compressed air, wear eye protection.
Thecartridgecanbecleanedbyblowingcompressedairbreadthwaysoutside and inside the cartridge, at a pressure not greater than 5atmospheres,orinnecessitycasebyknockingthefrontofthecartridgeseveraltimesagainstaflatsurface.Usealamptocheckthatthefilterelementisnotdamagedorinspectitagainstthelightwhileslanted.Incaseofdoubt,installanewcartridge.
Dry air cleaner
Components:1Handwheel2Cover3Cartridge4Sealring5 Bracket6Cloggingindicator
ImportantReplace cartridge immediately when indicator shows that is clogged.
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 28 -
5
6
8
9
7
4Clogging indicator
Components:1Resetbutton2Transparentindicator
Note: Indicatoriscalibratedat600÷650mmcolumnofwater.
Disassembly / Reassembly
Exhaust manifold
Checkthattheinsideisclean.Toavoidflangebreakagecheckthatheadsareinlinebeforetighteningnuts.Replacegaskets.
Tightennutsat20Nm.
MANIFOLDS, INTAKE/EXHAUST
Intake manifold
Toavoidflangebreakagecheckthatheadsareinlinebeforetighteningnuts.Checkflangesurfaceforwarpageandcorrectifnecessary.Replacegaskets.
Tightennutsat25Nm.
Note: Incaseof lowtemperaturestartingwecansupplyamanifoldwithpossibilityoffittingaglowplugwithairpreheating.
Oil vapour separator
Fittedonengineswithdryaircleaner.Screwitoutoftheairconveyorsupport,carefullywashwithgasolineinsideandblowoutwithcompressedair.Whenrefittingreplacethecoppergasketandconnecttheoilvapourseparatorwithintakemanifoldbymeansofthespecialrubberhose.
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 29 -
10
11
12
13
4Disassembly / Reassembly
EXTERNAL ALTERNATOR CONTROL BELT(only for engines with external alternator)
External alternator blower control belt - Disassembly
Releasethetwoalternatorfasteningbolts.Unscrewthefasteningnutsofthebeltguardandremoveit.RemovetheVbelt.
Seepage22forperiodicmaintenancedetails.
External alternator blower control belt – Tension check
ImportantCarry out checks only after isolating the positive battery cable to prevent accidental short-circuiting and, consequently, the activation of the starter motor.
Tension the belt if it flexesmore than 1 cm exerting a pressure of10kg.
External alternator blower control belt - Reassembly
Installthebeltandthebeltguard.Force the alternator outwards and temporarily tighten the fasteningbolts.Makesurethatthebelttensioniswithintherequiredparameters(see“Externalalternatorblowercontrolbelt–Tensioncheck”,Fig.11).
Tightenthefasteningboltstoafinaltorqueof30Nm(8x1.25)and50Nm(10x1.50).
FUEL TANK
After disconnecting the fuel pipes unscrew the anchoring brackets'screwsandremovethefueltank.Completelyemptythetankandcheckthatnoimpuritiesarefoundinside.If thefuel tankisfittedwthaninternal fuelfilterremoveandreplacethecartridge.Checkthatcapbreatherholeisnotclogged.Removethetanksupport.
Whenrefittingtightenthesupportscrewsat40Nmandthebracketscrewsat8Nm.
Seepage57forrefittinginternalfuelfilter.
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 30 -
15
16
17
14
4
Hub
Components:1Hub2Alternatorrotor3Fan4Bolt
Thehubholdsthealternatorrotorandthecoolingfan.
Unscrewtheboltclockwiseandtightenat160Nmwhenrefitting.
Disassembly / Reassembly
Internal alternator
Removestatorandplaceitinsidetherotortopreventmetalparticlesfrombeingattractedbythemagnets.
Whenrefittingtightenrotorscrewsandstatorboltsat10Nm.
Seepage67÷69foralternatorcharacteristics.
Cooling fan
Carefullycleanandcheckallbladesandinserts.Replacethefanevenifthereisonlyasingledamagedbladeoronlyasinglereleasedinsert.
Seepage16forcoolingairflow.
Tightenthefan'sfixingscrewsatatorqueof10Nm.
Pulley guard - Shroud - Side plates
Components:1Pulleyguard2Shroud3Sideplates
Thepulleyguardismadeofsounddeadeningmaterial:itreducesthenoisethatboththepulleyandthefantendtoamplify.ShroudandsideplatesaremadeofANTIFON,anelasticIayerwhichabsorbsthenoisecausedbytheplatevibrations.
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 31 -
19
21 22
20
18
4
FLYWHEEL
Removeflywheelwithpuller1 (partN°.7271-1460-119).Checkstarterringgearandtaperedcrankshaftmatingsurfaces.
Whenrefittingtightenboltal300Nm.
Inorder to replace the ringgear, it isnecessary todisassemble theflywheel.
Cuttheringgearinseveralplacesusingachiselandremoveit.
ImportantRemove any debris and carefully clean the ring gear.
Heatthenewringgearuniformlyandkeepitatatemperatureof300°Cfor15÷20minuti.
Danger – AttentionRisk of burning: be careful of hot surfaces.
Inserttheringgearintoitsseatandplaceitcarefullyontherimoftheflywheel.Leavetotheringgeartocoolgentlybeforereassemblingtheflywheel.
Disassembly / Reassembly
Shroud support (Gear cover plate)
Loosen screws and remove shroud support very carefully to avoiddamagetotheoilsealring.WhenrefittingcheckthatgasketsAandoilsealringBarewellinsidetheirhousings.
Tightenscrewsat25Nm.
ROCKER ARMS
Valve / Rocker arm clearance
ImportantSetting should be performed when the engine is cold.
Removerockerarmcoverandcheckgasketsforbreakage.
Bring each cylinder piston to top dead center on the compressionstrokeandsetclearanceAal0.15÷0.20mmforintakeand0.30÷0.35mmforexhaust.
Whenrefittingtightencoverscrewsby20Nm.
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24
26
25
23
4
INJECTOR
Cleaninjectorandcheckcalibratedpressureasindicatedonpage65.Whenrefittingcheckthatitcorrectlyprotrudesfromthecylinderheadplane.
Tightenthefixingnutsat10Nm.
Tightenthehigh-pressurepipeunionat25Nm.
Disassembly / Reassembly
Rocker arm assembly
Components:1Bore2Lubricationtube
Dimensions (mm):A=18.032÷18.050B=17.989÷18.000
Ifclearance(A - B)exceeds0.135mmreplaceshaftandrockerarms.
Caution – WarningWhen retitting check that lubrication tube perfectly matches with the journal bore.
Onslowengines,whicharesetto1,500–1,800rpm,therockerarmsdiffer from the standard version in the upper part of the lubricationchannel.
Tightentherockerarmshaftfasteningscrewstotheheadatatorqueof25Nm.
Compression release (optional)
Bringpistontotopdeadcenteronthecompressionstroke.UnscrewrockerarmcoversideplugandmeasureclearanceA betweenleverandrockerarm,whichmustbe0.30÷0.40mm.Forsettingpurposesremovetherockerarmcover,unscrewthelocknutCandsetclearanceAbychangingtheheightoftheshimsundertheplateB.Setthevalve/rockerarmclearance,see"Valve/Rockerarmclearance"onpage31.Reassembletherockerarmcoverandcheckthedecompressionleverclearanceagain.
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28
29
27
4Disassembly / Reassembly
CYLINDER HEAD
ImportantDo not remove it when hot to avoid deformation.The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up.
lfcylinderheadisdeformedlevelitoffbyremovingamaximumof0.3mm.Whenrefitting tightenonly ifsure that rockerarm lubrication tube iswellinsideitsholes,andthattherubbersealsofthetappethoseareassembledandinsertedcorrectlyintotheirseats.Alwaysreplacecopperheadgasket:seepage39forchoosingtherightthickness.
Progressivelytightennutsinthe1,2,3,4sequenceat55Nm.
Injector projection
Theendofnozzle Ashouldproject3.0÷3.5mm.fromthecylinderheadplane.AdjustinjectorprojectionbymeansofcoppershimsBmeasuring0.5,1.00and1.50mminthickness.
Injector for EPA and 97/68 CE engines
Theinjectorisattachedtothecylinderheadviaaforkedbracket.
Tightenthefixingbracketscrewat10Nm.
Fixthehigh-pressurehoseuniontotheinjectorunionat25Nm.
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30 31
32 33
34
35 36
4 Disassembly / Reassembly
Valves
Components:1 Intakevalve2Springseat3Valvestemsealring4Spring5Retainer6Halfcollets
Toremovehalfcolletsfirmlypressdownasshowninthefigure.
Valve stem sealing rings - Reassembly
Lubricate the inside of the sealing ringwithMolikoteBR2Plus andinsertthemallthewayontotheguidesusingtool1460-108.Topreventdeformationofthesealingring1asitisinsertedontothevalveguide2insertitontotool3.Lubricatevalvestemwiththesametypeofgrease;insertthevalvesinto the guides rotating them particularly as they enter the sealingring.
Valve springs
Measurefreelengthwithagauge.Usingadynamometercheckthatthespringlengthundertwodìfferentloadscorrespondstothevaluesbelow:
Freelength A=52mmLength Bcompressedbya210.6N=35.8mmLengthCcompressedbya340.6N=25.8mm
Replacespringiflengthis1mmormorebelowthestatedvalues.
Valve material
Intake valves AMaterial:X45CrSi9-3UNIEn100901Chromium-platedportiona45.5°÷45.75°
Exhaust valve BShaftandheadaremadeof2differentmaterials.2Weldedportion3Chromium-platedportion4PortionmadeofX45CrSi9-3UNIEN100905PortionmadeofX55CrMnNiN20-8UNIEN10090a45.5°÷45.75°
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A 02,13÷08,03
B 02,52÷08,42
A *040,8÷520,8550,0÷520,0 51,0
B 000,8÷589,7
38
39
37
A 0.24
B 84
C 810.41÷000.41
D 650.41÷540.41
4Valve guides and valve guide housings
StartingfromengineNo.2883619intakeandexhaustvalveguidesarebothmadeofphosphoriccastiron.
Components:1 = Exhaustvalveguide2 = Intakevalveguide
Valve guideswithoutsidediameterincreasedby0.5mm.arealsoavailable;insuchcasesvalveguidebore Cshouidalsobeincreasedby0.5mm.
Valve guide insertion
Heatcylinderheadupto160÷180°CPressguidesconsideringtheAandBdistancesfromtheheadplane.
Dimensions and clearance between guides and valves
*withdrivenguide.
Disassembly / Reassembly
Ref. Dimensions (mm)
Clearance(mm)
Limit value(mm)
Dimensions(mm)Ref.
Ref. Dimensions (mm)
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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A 610.04÷000.04
B 590.04÷180.04
C 610.43÷000.43
D 590.43÷180.43
40
41
43
42
44
125° ÷ 135°
4 Disassembly / Reassembly
Valve seats and housings
Pressvalveseatsintothehousingsandcutat45°.INTAKE vALvE
ExHAuSTvALvE
Ref. Dimensions (mm)
Pushrod tube
WhenrefittingcheekthatgasketsAandrockerarmlubricatíontubeCarewellinsidetheirseats.
Valve seat grinding
Aftercuttinggrindvalveseatswithfineemerypasteinoilsuspension.ThesealingsurfaceSshouldnotexceed2mm.Valve recessaftergrindingD=0.75÷1.25mm;maximumworn limit1.65mm.
CYLINDER
Checks and cylinder roughness
Finsmustbeintact.Cross hatch patternmust rangebetween125°÷135°: theymust beuniformandclearinbothdirections.Averageroughnessshouldrangebetween0.35and0.60µm.
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47 48
45 46
A *39.49÷29.4 *10.59÷00.59
90.0÷70.0B *49.49÷39.4 *20.59÷10.59
C *59.49÷49.4 *30.59÷20.599
9
9
*
4Disassembly / Reassembly
Measurediametersizebetween twodiametricallyopposedpointsatthreedifferentheights.
As per the cylinder sizes, see Table “Piston and cylinder typesandsizes".
* Incaseofdiameterwearabove0.05mmreplacepistonandpistonrings.
** Incasewearexceeds0.10mm,borethecylinderandfitoversizepistonandrings. Incaseoflesswearreplacepistonringsonly.
Note: Oversizepistonsof0.5and1.0mmareavailable(onlyforstandardand97/68CEengines).
ImportantThe 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 piston of the same class.
PISTON
Removecirclipsandremovepistonpin.Removepistonringsandcleangrooves.Measurediameterat17mmfromthebottomofskirt.
Table “Piston and cylinder types and sizes"
Clearance (mm)Ø Cylinder (mm)Ø Piston (mm)Class
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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A
°1 mm56.0÷mm04.0
°2 mm56.0÷mm04.0
°3 mm06.0÷mm03.050
51
53
52
49
A 0,07÷0,11 0,20B 0,05÷0,09 0,16C 0,04÷0,08 0,15
4 Disassembly / Reassembly
Chromium-platedring
Torsionalinternaltaperedring
Oilcontrolring
Limit value(mm)
Dimensions(mm)Ref.
Piston rings - Fitting sequence
A=1°Chromium-platedringB=2°Torsional(internaltapered)ringC=3°Oilcontrolring
ImportantBefore fitting the piston into the cylinder stagger the ring gaps at 120°.
Pistons rings - Clearance between grooves (mm)
Piston rings - End gaps (mm)
Placepistonringssquarelyintotheunwornpartofthelowercylinderandmeasuretheendgap.
Piston weight
Weighpistonswhenreplacingtheminordertoavoidunbalance.
ImportantThe difference in weight should not exceed 6 g.
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56
58
57
59
54 55
4
Distance between the piston at the top dead centre and the cylinder surface
Head seal thickness
Disassembly / Reassembly
CONNECTING ROD
Removetheoilsump.Removetheconnectingrodcap.
ImportantBoth connecting rod/piston units should be fitted back into the corresponding cylinders; mark them so as to identify the correct combination during reassembly.
Seepage40forspecificationsastothetighteningoftheconnectingrodbigendbearing.
Piston clearance
Pistonclearance =0.65÷0.70mm,forstandardengines =0.55÷0.60mm,for97/68CEandEPAengines
Thepiston in theTDC (topdeadcentre)positionmayextendorbeshortoftheuppersurfaceofthecylinder.Use a dial indicator to measure the difference between the twosurfaces (piston crown and upper cylinder surface) and use asuitablethicknesscoppergasketBforthecylinderheadtoadjusttheclearancevolumeA.
(Seeimagebelow)
Piston - Refitting
Connectpistontoconnectingrodinawaythatthecombustionchambercentrebisatrightangleundernozzletipa.Lubricatepistonpinandintroduceitintothepistonbyexertingpressurewithyourthumb.Checkthatbothcirclipsarewellinsidetheirseats.
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61
62
63 64
60
4 Disassembly / Reassembly
Connecting rod big end bearing
BothcenteringnotchesofthebearingsAandBmustbeonthesamesidewhenrefitting.
Tightenboltsat40Nm.
Seepage44fordimensions.
Connecting rod weight
Weighconnectingrodswhenreplacingtheminordertoavoidunbalance.
ImportantThe difference in weight should not exceed 10 g.
Connecting rod alignment
Checkalignmentofsmallendandbigendbearingboresusingfittedmandrels;axialmis-alignmentA=0.02mm;maximumlimit=0.05mm.
Connecting rod small end bushing
Dimensions and clearance (mm):C=25.020÷25.030(withmachinedbushinginplace)D=24.995÷25.000(C-D)=0.020÷0.035(C-D)maximumwornlimit=0.070
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66
67
65
1
2
4Disassembly / Reassembly
Main bearing support, flywheeI side
RemoveitbymeansoftwoM8x1.25screwswithfullythreadedlengthof40mm.Checkoilsealringandreplaceifwarped,hardenedorworn-out.
Whenrefitting,tightennutsat30Nm.
Seeendfloatonpage45forgasketreplacementdetaiis.
Seepage44÷45fordimensions.
MAIN BEARING SUPPORTS
Main bearing support, gear side
Removemain bearing bymeans of twoM8x1.25 screwswith fullythreadedlengthof40mmorapuller(PartN°.7271-1460-119).
Note: To avoid deformation it is not recomended to replace thebearingbushing,completeassembly'sofbushingandsupportare available in standard, 0.25mmand 0.50mmundersizeconfigurationsasspareparts.
Whenrefittingtightenthescrewsat30Nm.
Seepage44÷45fordimensions.
CRANKSHAFT TIMING GEAR
Disassembly:Usetool1(PartN°.7560-4000-052)andpuller2(PartN°.7271-1460-119)toremovethegear.
Reassembly:Heatthegearuniformlyandkeepitatatemperatureof300°Cfor15–20minutes.
Caution – WarningDanger of burning: pay attention to the hot surfaces.
Insert the gear into its seat by inserting the activation key into thegear opening and push until it comes into contact with the drivingshaft.Letitslowlycooldown.
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70
71 72
69
68
4 Disassembly / Reassembly
Crankshaft center main bearing support
Whenrefitting,bothcenteringnotchesAandBmustbelocatedonthesameside.
Tightenscrewsat25Nm.
Seepage44÷45fordimensions.
Crankshaft lubrication ducts
Danger - AttentionDuring repair operations, when using compressed air, wear eye protection.
Removeplugs,cleanductAwithapointedtoolandblowincompressedair.Screwplugsagainandcheckforsealing.
Crankshaft removal
Topullout thecrankshaft tap lightfyon the timingsideendusingacopper-headedhammer.Whenrefittingaligncentermainbearingsupportsothatthelocatingscrewholecoincideswiththecrankcasehole.
CRANKSHAFT
Center main bearing support, locating screw.
Straightenplate1andunscrewscrew2beforeremovingcrankshaft.
Whenassemblingtightenthescrewatatorqueof30Nm.
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A 059.45÷139.45
B 615.54÷005.54
C 053.55÷133.55
D 059.45÷139.45
75
76
73
74
4
How to measure main bearing inside diameter
Useaninsidemicrometergauge.
Disassembly / Reassembly
Dimensions (mm)Ref.
Main journal and crank pin diameter
Checking main journals and crank pins
Useanoutsidemicrometergauge.
Crankshaft journal radius
TheradiusRconnectingjournalstoshouldersis2.8÷3.2mm.
ImportantWhen grinding external main journals restore the R value to original specification.
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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A-E 980.0÷0500
0
0. 81.0
B-F 870.0÷230. 51.0
C-G 401.0÷450. 91.0
D-H 980.0÷050. 81.0
0
00
00
78
A 020,941÷000,941
B 020,741÷000,741
C 020,67÷000,67
79
80
E 020.55÷000.55
F 875.54÷845.54
G 534.55÷404.55
H 020.55÷000.55
77
I 020.941÷000.941
L 020.06÷000.06
M 810.741÷000.741
N 390.95÷470.95
O 010.67÷099.57
P 020.06÷000.06
Q 50.42÷59.32
R 02.13÷01.13
4 Disassembly / Reassembly
Limit value (mm)Clearance (mm)Ref.
Clearance between main journals/crank pins and connecting rod bearings
Main bearíng supports -Dimensions
1Flywheelside2Central3Gearside
Dimensions (mm)Ref.
Dimensions(mm)Ref.
Main bearing housings
Main bearing and connecting rod big end bearing inside diameter
Dimensions (mm)Ref.
Theabovedimensionsrefertodriveninortightenedbearings.
Note: Bothmainbearingsandconnectingrodbigendbearingsareavailablewithinsidediametersizemeasuring0.25and0.50mmlessthanthestandardversion.
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82
84
83
81
A-I -0,020÷0,020 0,03B-M -0,018÷0,020 0,03C-O -0,010÷0,030 0,04
A 41,940÷41,9600,040÷0,085 0,160
C 42,000÷42,025B 27,940÷27,960
0,040÷0,085 0,150D 28,000÷28,025
4Disassembly / Reassembly
CAMSHAFT
How to measure camshaft journals and housings
Useaninsidemicrometergaugeforhousingsandanoutsidemicrometergaugeforjournals.
Clearance (mm)
Limit value(mm)
Dimensions(mm)
Ref.
Dimensions of camshaft journals and housings
Crankshaft end play
When refitting crankshaft check end play bymeans of a thicknessgauge;thisvalueshouldbe0.08÷0.38mmandcanbesetbychangingthethicknessofgasketAwhichislocatedontheflywheel-sidemainbearings.Gasketswiththicknessof0.30and0.50mmcanbesupplied.
ImportantReplace the main bearings 1 and 3 (Fig. 79) if the axial clearance value still turns out to be too high even with a seal having a smaller thickness (fig. 79).
Ref. Clearance (mm) Limit value (mm)
Table “Clearance between main bearings and main bearing housings”
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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88
89
87
85 86
4 Disassembly / Reassembly
Valve timing without considering timing marks
Locatepiston1(onflywheelside)atthetopdeadcentre.PositiontwosmallcylindersAofthesameheightontothetappets.Rotatecamshaftstoppingwhencylinder1tappetsareinoverlapposition(intakeopen,exhaustclosed).BymeansofrulerBcheckthattappetsareatthesameheight.Engagecamshaftgearwithcrankshaftgear.
CAMSHAFT TIMING
Fitcamshaftgearbymakingtimingmark1coincidewithtiming-mark2onthecrankshafttiminggear.
Tightencamshaftbollat60Nm.
Camshaft end play
Endplayshouldbe0.10÷0.25mm;checkbymeansofadialgaugepushingorpullingcamshaftasrequired.
How to measure intake/exhaust cam height
A1 =1stcylinderintakecamS1=1stcylinderexhaustcamA2=2ndcylinderintakecamS2=2ndcylinderexhaustcam
ExhaustandintakecamsfeaturethesameheightH.
H=33.625÷33.650mm
ReplacecamshaftifHis0.1mmbelowthegivenvalue.
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91
92
90
4Disassembly / Reassembly
Valve timing - Angles
The angle values are determined by turning the driving shaftclockwise
S =PistonattopdeadcentreI =Pistonatbottomdeadcentreα =Intakevalveopenβ =Intakevalveclosedγ =Exhaustvalveopenδ =Exhaustvalveclosed
Timing angles for checking puposes(valve clearance = 0,65÷0,70 mm)
α =1°beforeSβ =21°afterIγ =23°beforeIδ =1°afterS
HYDRAULIC PUMP
Hydraulic pump p.t.o
Ahydraulicpumpofgroup1(1P)or2(2P)canbeinstalledonthegearside,3rdp.t.o.
Valve timing check
Checkvalvetimingatthecrankshaft.The values shownare checkedat the flywheel circumference (withflywheelof291mm.diametereachdegreecorrespondsto2.5mm).Setvalveclearanceat0.65÷0.70mm(aftercheckingrestorethevalueat0.15÷0.20mm).Setdialgaugeonintakevalvetoazerovalue;byrotatingthedrivingshaftaccordingtoitsdirectionofrotationyoucanmeasureα(intakevalveopeningadvancereferredto topdeadcentreS)andß (intakevalveclosingdelayreferredtobottom(I)deadcentre).Followthesameprocedureforexhaustvalvescheckingγ(exhaustvalveopeningadvance)andδ(exhaustvalveclosingdelay).
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94
95
93
4 Disassembly / Reassembly
Mechanical speed governor components
1 Gear 2Weight 3 Mobilebell 4 Stopring 5 Thrustwasher 6 Yoke7 Lever 8 Driverod9 Governorspring10 Rackcontrollever
Weightsaremovedtotheperipherybythecentrifugalforceandthusaxiallyshiftamobilebellconnectedtotheinjectionpumprackcontrolleverbyalinkage.Aspringplacedundertensionbytheacceleratorcontroloffsettheweightcentrifugalforce.Balancebetweenthetwoforceskeepsspeedatanalmostconstantlevelinspiteofloadvariations.
Seepage62fortiming.
MECHANICAL SPEED GOVERNOR
Weight-typegovernorhousedinsidethecamshaftdrivegear.
Hydraulic pump components (1 P)
1Sealring2Centeringring3Coupling4Halfcoupling 5Flange6Gear 7Bracket8Thrustwasher 9Stopring10Cover
Themaximumtotaltorqueisthus30Nmcorrespondingto12.5HPat3000r.p.m.Reductionratio1:1.
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96
97
98
4
1
2
3
6
7
6
1
2
3
4
5
99
16
53
4
7 2
4Disassembly / Reassembly
Governor springs with single-spring system
1Extrafuelspring2lnjectionpumpcontrollever3Governorspring4Throttlelever
ELECTRONIC SPEED GOVERNOR(optional)
1 lnjectionpumpcontrollever2 Electromagnet3 Eccentricscrew4Conicalplug5Conicalplug6Actuator7 Eccentricscrew
Assemble the entire plate by centring it on the reference pins andmakesurethattheinjectionpumprackrodpinisinsidelever“1”.Fixtheplatebyusingthespecificscrewsforitsmodel.
Governor springs with rocker arm system
Thesystemfeaturestwospringsanchoredtoarockerarmandallowsforminimalr.p.m.changesatlowspeedlevels.
Thedeviceisoperatedautomatically:whentheengineisstoppedspring6actsoninjectionpumpcontrolyoke7providingmaximumfueldelivery,untiltheenginestartsandthegovernorcontrolstheiniectionpumprack.
Components:
1Rockerarmforspringanchoring2Governorsprings3Plate4Link5Throttlelever6Supplementarystart-upfuelspring
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100
16
5
3
4
7
2
101
4 Disassembly / Reassembly
Adjustment of the stroke end (STOP):
1- Removetheconicalplug"5".2 - Through the eccentric "7" position and check by sight that the
leverinstoppositionisattheextremeleft.3 - From this position, always acting on the eccentric screw "7",
movethecontrollever1,0÷1,5mmtoright.4 - Lockthelocknutofthescrew"7".5 - Reassambletheconicalplug"5".
Adjustment of extra fuel delivery:
1- Removetheconicalplug"4".2 - Power theelectromagnet"2"witha12Vvoltageandmakesure
thattheplungerhasmoved.Inthiscaseyouwillhearthetypicalactivatedmagnetsound.
3 - Feedactuator"6"withatensionof12V(putbetweentheactuatorandthe12Va10Amp.fuse):theactuatortensionwillcausethepumpdeliverycontrollevertomovetotheright.
4 - Bytheeccentricscrew"3"placeandcheckbysightthattheleverinMaxpositionisattheextremeright;fromthisposition,alwaysactingonthescrew"3",movethedeliverycontrolleverby1,0÷1,5mmtotheleft.
5 - Lockthelocknutofscrew"3".6 - Removefeedingfromactuator"6"eelectromagnet"2".7 - Reassambletheconicalplug"4".
Speed governor wiring diagram
BlackRed
shielding
shielding
Black
RedViolet
Violet
WhiteBlack
Magneticsensor
24Velectriccontrolunit
Startingmotor
Red
Red
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4Disassembly / Reassembly
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102
1
2
3
4
6
5
7
9
10
11
12
13
14
15
8
5
Components:
1) Oilpreassuregauge2) Breather3) Connectingrodbigendbearing4) Crankshaftmainbearingongearside5) Cartridgefilter6) Oílpressurereliefvalve7) Oilpump8) Internalfilter
LUBRICATION SYSTEM
LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM
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.- Use of an inferior quality oil or failure to regularly change
the oil will increase the risk of piston seizure, will cause the piston rings to jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine life will 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 cancer if repeatedly left in
contact with the skin and for long periods of time. Wear protective gloves to avoid touching used oil.- If contact with the oil is unavoidable, you are advised to
wash your hands with soap and water as soon as possible. Dispose of old oil in the correct way as it is highly polluting.
9)Oilfillplug10) Rockerarmshafts11)Pushrodprotectiontube12)Hydraulicpumpgear13)Camshaftjoumalonfiywheelside14) Oìldipstick15)Oildrainplug
Standard lubrication system circuit
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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104 105
103
1
2
3
4
6
5
7
9
10
11
12
13
14
15
8
16
5
OIL PUMP
Checkthatthegearteethareintactandthatclearancebetweengearedgeandpumpbodydoesnotexceed0.15mm.Furthermorecheckthatthecontrolshaftisfreetorotatewithendfloatnotexceeding0.15mm.Oilpumpdeliveryat3000r.p.m.is9liters/min.
Lubrication system
Components:
1) Oilpressuregauge2) Breather3) Connectingrodbigendbearing4) Crankshaftmainbearingongearside5) Cartridgefilter6) Oílpressurereliefvalve7) Oilpump8) Internalfilter
9)Oilfillplug10) Rockerarmshafts11)Pushrodprotectiontube12)Hydraulicpumpgear13)Camshaftjoumalonfiywheelside14) Oìldipstick15)Oildrainplug16)Oilradiator
Lubrication system with oil radiator circuit
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5 Lubrication System
OIL PRESSURE RELIEF VALVE
Details:
1Plunger2Washer3Valvebody4Spring5Ringsnap6 M9x1threadingforpuller
Operationstartpressure.............................5bar.
OIL FILTER CARTRIDGE (EXTERNAL)
Components:1 Gasket2 Plate3Gommino4 Spring5Filterelement6Bypassvalve7Spring Forcharacteristicsseepage17.
Disassembly:
Beforeremovingtheoilpressureregulatingvalve,removetheoilfilterbyusinganappropriatewrench.
RemovetheregulatingvalveusingahammerpullerequippedwithaM9x1threadedterminal.
Reassembly:
Makesurethat thevalveseat is freeofscratchesandscoreswhichcouldreducethepressureseal.
Insert the entire oil pressure valve into its housing by keeping it inline.Make sure that the valve is completely assembled to the engineguardbymeansofapad.
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Oilpressure curve with engine at idle speed
Thecurveisobtainedattheoilfilterleverwithconstantenginespeedof1200r.p.m.inno-loadconditionsandataroomtemperatureof+25°C.Pressureisgiveninbarandtemperatureincentigrades.
If theoilpressurevalueisbelowtheindicatedone,pleasecheckallcomponentsindicatedonpage52÷53.
Oil pressure curve with engine at full speed
Thecurveisobtainedattheoilfilterlevelwithengineworkingat3000r.p.m.andmax.powerat+25°Croomtemperature.Pressureisgiveninbarandtemperatureincentigrades.
If theoilpressurevalueisbelowtheindicatedone,pleasecheckallcomponentsindicatedonpage52÷53.
OIL PRESSURE CHECK
Oncetheengineisfittedfillwithoilandfuel;connecta10barpressuregaugetothefitting.Starttheengineandcheckpressureasafunctionoftheoiltemperature.
OIL RADIATOR(on request)
Components:
1Radiator2Returnpipe3Oilfilter4Coppergasket5Deliveryhose6Union7Oildetectionflange8O-ring
Lubrication system
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6FUEL FEEDING / INJECTION CIRCUIT
Fuel feeding / injection circuit with fuel filter inside the fuel tank
Components:
1Fueltank2Fuelfilter3Fuelfeedingtube4Fuelliftpump5lnjectionpump6High-pressurepipe7Injector8Injectorexhaustpipe
Fuel feeding / injection circuit with external fuel filter
Components:
1Fueltank2Fuelfeedingtube3Fuelfilter4Fuelliftpump5 lnjectionpump6High-pressurepipe7 Injector8 Injectorexhaustpipe
Fuel feeding / injection circuit with external fuel filter and double solenoid valve
Components:
1 Fueltank 2 Solenoidvalve 3 Fuelfilter 4 Fuelliftpump 5 Solenoidvalve 6 lnjectionpump 7 High-pressurepipe 8 Injector 9 Injectorexhaustpipe10 Non-returnvalve
Fuel feeding / injection circuit with fuel filter inside the fuel tank and double solenoid valve
Components:
1 Fueltank 2 Fuelfilter 3 Solenoidvalve 4 Fuelliftpump 5 Solenoidvalve 6 lnjectionpump 7 High-pressurepipe 8 Injector 9 Injectorexhaustpipe10 Non-returnvalve
FUEL SYSTEM
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6Fuel system
FUEL FILTER
Fuel filter (inside fuel tank)
Components: 1Spring 2Disc 3Ring 4Cartridge 5Gasket 6Gasket 7Cap 8Ring 9Screw
Forcharacteristicsseepage17.
FUEL LIFT PUMP
Thefuelliftpumpisofthediaphgragmtypeoperatedbyacamshafteccentricthroughadriverod.Itfeaturesanexternalleverformanualoperation.
Fuel filter, external
1 Airreliefvalve2Support3Cartridge4Gasket5Filteringelement Forcharacteristicsseepage17.
Formaintenanceseepage22.
Fuel feeding / injection circuit with external fuel filter and QSD (Quick Stop System)
Components:
1Fueltank 2Fuelfeedingtube 3Fuelfilter 4Fuelliftpumpintaketube 5Fuelliftpumpdeliverytube 6Fuelliftpump 7lnjectionpump 8 High-pressurepipe 9 Injector10 Injectorexhaustpipe
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6Fuel feeding pump components
Components:
1Driverod:-length:32,55÷32,65mm -measuredprotrusionA:1,47÷2,07mm2Gasket3Camshafteccentric4Manualpriminglever
Characteristics:whenthecontroleccentricrotatesat1000r.p.m.minimumdeliveryis73l/hwhileself-regulationpressureis0.5÷0.7bar.
Injection pump for Standard and 97/68 CE engines
Components:
1 Pumpbody 9 Gasket2 Holder-deliveryvalve 10 Rack 3 O-ring 11 Meteringsleeve 4 Filter 12 Tappetspring 5 Shim 13 Upperretainer 6 Valvespring 14 Lowerretainer7 Deliveryvalve 15 Tappet 8 Plungerandbarrelassembly 16 Tappetroller
INJECTION PUMP
The injection systemconsists of a single-body pumpwith plungersfeaturingconstantstrokeandfeedingonecylindereach.The pump,mounted on the crankcase is directly operated by thecamshaft.Speedgovernor,extrafuelandstopdeviceareseparatefromthepump(seepages48,49,50and78).
Fuel system
Piston fuel lift pump (on request)
Characteristics:whenthecontroleccentricrotatesat1000r.p.m.minimumdeliveryis65l/hwhileself-regulationpressureis1.5÷2.5bar.
ImportantThe drive rod and its protrusion do not change in relation to the diaphragm pump.
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6Fuel system
Injection pump for EPA engines
Components:
1 Holder-deliveryvalve 2 Lockingnutclamp 3 Screw 4 Valve-Spring 5 ORing 6 Coppergasket7 Plungerandbarrelassembly 8 Pinspring9 Rack10 Seatspring11 Springtappet12 Seatphasing13 Ringsnap14 Tappetassemblyroller15 Pintappetdriver16 Pumphousing17 Meteringsleeve18 Pinbarrellocating19 Coppergasket20 Gasketfibreseal21 Threadedcap22 Deliveryvalveassembly
How to check plunger and barrel for internal leakage
Thisoperationisonlyindicativesincepressurechangesdependingonthepumpingspeed.Connectthedeliveryunionwitha600barpressuregaugewithsafetyvalve.Adjustrackrodathalf-stroke.Turnflywheelaccordingtoitsdirectionofrotationsothattheplungerputsthecircuitunderpressure.Replaceplungerifthedisplayedpressureisbelow300bar.Repeatthesameoperationfortheotherplunger.
Plunger and Barrel Assembly
1Barrel2Fuelfeedingport3Controlhelix4Plunger5Retardationnotch
Plungerdiameteris7.5mm.
ImportantEveryplungermatcheswithitsownbarrel.Forthisreasontheyarenotinterchangeable.
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9 LD 625-2 - 626-2 - 625/626 CE
9 LD 625-2 EPA
Fuel system
Controlrodmax.force
Rodstrokefrommaxdeliv.point
R.P.M. Delivery Max.plungerdifference
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
Controlrodmax.force
Rodstrokefrommaxdeliv.point
R.P.M. Delivery Max.plungerdifference
Newton mm mm3/stroke mm3/stroke
0,50
9.5 1500 34÷37 3
11.5 500 3÷7 3
0 150 60÷68 --------
9.5 500 13÷18 3
Test data for injection pump delivery
Check onlymaximum plunger difference by positioning rack rodaccordingtotheindicateddeliveryvalue.
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How to check injection pump delivery valve sealing
Components: 1Valves2Seat
Adjustpumprackathalf-stroke.Turnflywheelaccordingtoitsdirectionofrotationsothattheplungerputsthecircuitunderpressure.Duringthisoperationthedisplayedpressurewillgraduallyreachapeakfollowedbyasuddendropwhichcorrespondstovalveclosing.Pressuredropshouldbe30÷50bar.Replacethevalveifpressuredropisbelowthisvalue.Repeatthesameoperationfortheotherplunger.
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6Fuel system
How to reassemble injection pump components
After replacing theworn-out components, reassemble the pumpasfollows:
- IntroducesectorgearsintothepumpbodybymakingreferencepointsCmatchwiththeBpointsontherack.
- FixbarrelswiththeeccentricscrewsFonthepumpbody.
- Fitvalveswithseats,springs,fillersanddeliveryunionstighteningthemat35÷40Nm.
- FitplungersbymakingreferencepointsEmatchwiththesectorgearDpoints.
- Fixretainersandsprings;locktappetwithspecialstop.
- Checkthatbothplungershavethesamedeliverybyperformingthenecessarymeasurementsatthetestbed;ifdeliveryisnotthesamesetscrewF.
Tightenscrewsat25Nm.
Checkthatrackrodslidessmoothly:ifnot,theenginemayfailtostartorhunt.
How to mount injection pump on the engine
During reassembly,makesure theadjustment rodpin1 is correctlyinsertedintotheoppositeseatintheadjustmentlever.
See“Injectionadvanceadjustment”onpage63for thechoiceoftheseals2.
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Injection pump/mechanical speed governor timing
Loosenscrew1Moveinjectionpumplever2tomaximumdelivery(totheright).Check that drive rod3 closes the speedgovernor; keeping lever2pressedtotherightthedriverodshouldhavenoclearance.Tightenscrew1.
(STATIC) INJECTION TIMING
Injection static advance adjustment
1 Removerockerarmcoversandhigh-pressurepipes.
2 Selectthecylinderonwhichtheinjectionstaticadvancecheckwillbecarriedout.
3 Assemblethevalveloweringtool(1460.285)byfasteningittothefixingholesoftherockerarmcoverscrews.
4 Before tightening the tool fixing screws,make sure that the dialindicatortraceriscorrectlyplacedontheintakevalvecollar.
5 Place the auxiliary tank at a higher height than the one of theinjectionpump(~30-40cm).
6 Connectthetanktotheinjectionpumpfuelsupplyhole.
7 Slowly rotate the crankshaft clockwise keeping lever 1 loweredand the valve positioned on the piston crown, until the dialindicator2showsthemaximummeasurement.
8 Set the maximum measurement dial indicator to zero which isequivalenttothecompressiontopdeadcentre.
9 Assemble theadvance tester4 (serial number1460.024)on theinjectionpumpdeliveryunionofthecylindercorrespondingtotheoneonwhichthevalveloweringtoolhasbeenpreviouslyinstalled.
10Rotatethecrankshaftclockwisebyapproximately45°.
11Rotatethecrankshaftalternatelyuntilthefuelleaksoutfromtester4withacertainpressure.
12Position the stop lever3 half a stroke so that the plunger delaymarkisexcludedandkeeptheleverinthisposition.
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2/526DL90003 °1±°62
49.4°4243.5°5267.5°6212.6°722/626DL9
2/526DL9APE 0003 °1±°71
69.1°5122.2°6115.2°7118.2°81
2/526DL9RNEC 0003 °1±°81
15.2°7118.2°8121.3°91
2/626DL9RNEC 0082 °1±°71
22.2°6115.2°7118.2°81
Fuel system
Enginetype
Piston lowering value (mm)
Advance de-greesR.p.m.
Injection advance adjustment
Ifthevaluesindicatedinthetabledonotcorrespondtothedetectedones,followtheoperationsaswrittenbelow:
1) Delayed Injection Advance: remove the shims under the pumpuntil the detected value corresponds to the one indicated in theTable“Conversionforestablishingadvance”
2) Advanced Injection Advance: add shims under the pump untilthedetectedvaluecorresponds to theone indicated in theTable“Conversionforestablishingadvance”.
Note: By removingoraddinga0.1mmshimunder thepump, it ispossibletoadvanceordelaytheinjectionbyabout1°.
Table “Conversion for establishing advance”
* Checkvalues.
13Turn theflywheel slowlyandclockwise.Stop turningassoonasyounoticethatthefuelismovinginsidetester4.
14Movelever1againsoasto lowerthevalveandbringitagain incontactwiththepiston.
15Measure the piston lowering value and bring it again in contactwiththepiston.
16Convert the registered value from millimetres to degrees (seeTable"Conversionforestablishingadvance").
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Size S Nozzle, only for standard engines
Features:Holenumberanddiameter...................4x0.28mm.Jetangles.............................................160°.Needlevalveelevation.........................0.20÷0.22mm
Cleannozzletipwithabrassbrush.Checkthatholesarenotobstructedusingamandrelwithsteelwìrewith0.28mmdiam.
Whenrefittingtightenringnutat60Nm.
INJECTOR
Size S Injector, only for standard engines
Components: 1 Intakefitting 2 Nozzleholder 3 Shim 4 Spring 5 Pressurerod 6 Intermediateflange 7 Nozzle 8 Needlevalve 9 Fixingflange10 Taperpin11 Gasket12 Systemduct13 Sump
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6Fuel system
Size P injector, for 97/68 CE and EPA engines
Components:
1Injectorhousing2 Intakefitting3 Shim4 Spring5 Pressurerod6 Taperpin7 Nozzle8 Cup9 Needlevalve10 Sump11 Systemduct12 Overflowpipe
Injector setting
Connecttheinjectortoadieselinjectorcalibrationpump.Check needle valve sealing by slowlymoving hand pump untilapproximately180barandmaintainthispressurefor10seconds.Chekthatsettingpressureis210÷220barforstandardengines(245÷230barforEPAeCEengines);maketherequiredadjustments,ifany,bymodifyingtheadjustingshimheight.
Whenreplacing thespring,settingshouldbeperformedata10bargreaterpressure(255÷265bar)toallowforbeddingduringoperation.Replacenozzleincaseofdripping.
Size P nozzle, for 97/68 CE and EPA engines
Features:Holenumberanddiameter............. 5x0.23mm.Jetangles....................................... 150°.Needlevalveelevation................... 0.200÷0.205mm
Cleannozzletipwithabrassbrush.Checkthatholesarenotobstructedusingamandrelwithsteelwìrewith0.23mmdiam.
Whenrefittingtightenringnutat42÷48Nm.
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7Electric starting layout with internal alternator
ELECTRIC SYSTEM
Electrical starting layout with external alternator
Components:
1Alternator2Startingmotor3 Voltageregulator4Battery5Pressureswitch6Oilpressurewarninglight7Keyswitch8Batterycharginglight
Note: Battery,which is not suppliedbyLombardini, should feature 12Vvoltageandcapacitynotbelow70Ah.
Components:1Alternator2Startingmotor3Battery4Keyswitch5Pressureswitch6Oilpressurewarninglight7Batterycharginglight
Note: Battery,which isnotsuppliedbyLombardini, should feature 12Vvoltageandcapacitynotbelow70Ah.
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7ALTERNATOR
Alternator - 12 V, 18A
Featuresafixedarmaturewindingmountedontheairshroudbracket.Therotatingpermanentmagnetinductorislocatedinthefanspindle.Onlythetwoyellowcablesareatoutput.
Dimensions (mm):A =158.80÷159.20B=27.50÷27.90
Note: Clearancebetweenarmaturewìndingandinductor(airgap)mustb0.48÷0.60mm.
Alternator battery charger curve (12 V, 18 A)
Thiscurveisobtainedat+25°Cwith12.5Vbatteryvoltage.
Alternator - 24 V, 6 A
Featuresafixedarmaturewindingmountedontheairshroudbracket.Therotatingpermanentmagnetinductorislocatedinthefanspindle.Therearethetwoyellowcablesandoneredcableatoutput.
Dimensions (mm):A =158.80÷159.20B=27.50÷27.90
Note: Clearance between armaturewinding and inductor (air gap)shouldbe0.48÷0.60mm.
Electric System
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Amp.
7Alternator battery charger curve - 24 V, 6 A
Thecurvewasobtainedatroomtemperatureof+20°Cwith25Vbatteryvoltage.
Magnetization checking tool (Part No. 7000-9727-001)
Components: 1Casing2Slider3Casingreferenceline4Sliderreferenceline
Restthetoolendhorizontallyontothemagneticpoles.Holdslidersothatitsreferencelinecoincideswiththecasingreferenceline.Releaseslider:ifnoattractionoccurstherotorisdemagnetized,inthiscasereplacealternator.
Alternator - 12 V, 14 A
Featuresafixedarmaturewindingmountedontheairshroudbracket.Therotatingpermanentmagnetinductorislocatedinthefanspindle.Therearethetwoyellowcablesandoneredcableatoutput.
Dimensions (mm):A =158.80÷159.20B=27.50÷27.90
Note: Clearance between armaturewinding and inductor (air gap)shouldbe0.48÷0.60mm.
Alternator battery charger curve standard - 12 V, 14 A
Thecurvewasobtainedat room temperatureof+25°Cwith12,5Vbatteryvoltage.
Electric System
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7Electric System
Checking for cable continuity
Checkthatstatorwindingshavenounsolderedconnections,burntareasorgroundedwìres.Usinganohmmetercheckforcontinuitybetweentheredcableandthetwoyellowones.Furthermore,checkthattheyareinsulatedfromtheground.
Alternator, external - 12 V, 33 A
Thealternatorisoftheclaw-polerotortypewithbuilt-involtageregulator.Therotatingmotionisconveyedbytheenginethrougha"V"beltandsheave.
Features:Ratedvoltage......................12VMax.current.........................33A(at7000alternatorr.p.m./min.).RHdirectionofrotation.
Tightenthenut1 atatorqueof70Nm.
Alternator battery charger curve - external, 12 V, 33 A
Thecurvewasobtainedatroomtemperatureof+25°C.Batteryterminalvoltageis12.5V.Ther.p.m.shownonthetablereferstotheengine.
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~ 6.35 0.80R 9.50 1.12+ 9.50 1.12LE 4.75 0.50oo 6.35 0.80
7
How to check voltage regulator for proper operation
- Checkthatconnectionscorrespondtothelayout.- Disconnecttheterminalfromthebatterypositivepole.- Connectad.c.voltmeterbetweenthetwobatterypoles.- FitanammeterbetweenthepositivepoleandtheB+ofthevoltageregulator(correspondingtoref.1inthepicture).
- Startacoupleoftimesuntilbatteryvoltagedropsbelow13V.- Whenbatteryvoltagereaches14.5Vtheammetercurrentsuddenlydropsdowntoalmostzero.
- Replaceregulatorifrechargecurrentiszerowithvoltagebelow14V.
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 might damage it. - No electric welding on engine or application.
Electric System
VOLTAGE REGULATOR
TypeLOMBARDINI,suppliedbySAPRISAandDUCATI:Voltage12V,max.current26A.
Toavoidwrongconnections3differentsizesaresupplied.
ConnectionsDimensions (mm)
Width Thickness
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Voltage regulator - 12 V, 30 A
Thevoltageregulatorisofthebridgetype.
Seepage70fortagdimensions.
Voltage regulator - 12V, 26A, with “W” terminal
“W”poletab:Width=4,75mm;Thickness=0,5mm.
Seepage70fortagdimensions.
Voltage regulator - 12V, 30A, with “W” terminal
“W”poletab:Width=4,75mm;Thickness=0,5mm.
Seepage70fortagdimensions.
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P CV
N
J(A)
A
B
C
7
Characteristic curves for starting motor type Bosch - 12 V, 1.7 kW
Curvesareobtainedatroomtemperatureof+20°Cwith66Ahbattery.
V=MotorterminalvoltageinVoltP=PowerinkWC=TorqueinN/mN=Motorspeedinr.p.m6.J (A)=AbsorbedcurrentinAmpere.
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
RHdirectionofrotation.A=29.5÷31.5mmB=RinggearplaneC=Flangeplane
Caution – WarningFlywheel should not project from ring gear plane B.
Electric System
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7Electric System
Starting motor type Bosch DW (R) 12 V, 1.7 kW
RHdirectionofrotation.
A=29.5÷31.5mmB=RinggearplaneC=Flangeplane
Caution – WarningFlywheel should not project from ring gear plane B.
Characteristic curves of the 24 V 1.6 kW starting motor
Thecurveshavebeenmeasuredata20°Ctemperaturewithan88Ahbattery.
V = VoltagetothemotorterminalsinVoltP = PowerinkWC = TorqueinN/m N = MotorspeedinrpmJ (A) =AbsorbedcurrentinAmperes.
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V21 V42
V21 V82
A14 A31
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V21 V42
V21 V42
A04 A02
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7 Electric System
Pre-heating glow plug
Components: 1Sheath 2Regulationfilament 3Heatingfilament
Whenremountingtightenatatorqueof20Nm.
Note: Theglowplugisnotdamagedinanywayduetotheprolongedactivationtime.
Nominalvoltage
Current
Glow plug Type
DIRECT STOP ELECTROMAGNETS
Reverse electromagnet – FIRE version
Features:
Components:1Nut2Studbolt3Flatwasher4Screw5Spacer6Sphericaljoint7Electromagnet8Stopcontrollever9Axialjoint10Stopcontrolelectromagnetsupport
Adjustment:- Carryouttheadjustmentsbyscrewingandunscrewingthejoints.- Adjust thedevicesoastomaketheelectromagnetget totheendof the stroke before the STOP lever reaches its limit stop afterperformingtheoperationstroke.
- Whentheelectromagnetisexcited,putthestopleveratabout1.0–1.5mmfromitslimitstop.
- Onceadjustmentphaseiscompleted,tightennut1.
ImportantThe control cover should not present the return spring of the stop lever.Remove the stop lever return spring without replacing the control cover if the device is applied to engines that were originally not equipped with it.
Operatingtension
Powercoilabsorption
Electromagnet type
Holdcoilabsorption
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7Direct stop electromagnet
Features:Operatingtension............................................ 12V.Powercoilabsorption...................................... 41A.Holdcoilabsorption......................................... 0.5A.
Setting:- Screw drive rod1 to the end of the thread on the electromagnetpiston.
- Excite the electromagnet and leave the stop lever in normaloperationposition.
- Bringdriverod1incontactwiththestopleverandtightenlocknut2.
Electric System
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8SPEED ADJUSTMENTS
WARNING- Adjustments should be carried out by Lombardini authorised
personnel only.- Any tampering with the adjustment immediately makes the
warranty null and void.
Idling speed setting in no-load conditions
Afterfillingwithoilandfuel,starttheengineandletitwarmupfor10minutes.Adjust idlingspeedat1000÷1100r.p.m.by turningsetscrew 1; thentightenlocknut.
INJECTION PUMP DELIVERY SETTING
ImportantThis adjustment must be performed with the engine connected to the
dynamometric brake. Without this the regulation is approximate.
lnjection pump delivery limiting and extra fuel device
LimitingdeviceClimitstheinjectionpumpmaximumdelivery.It also acts as a torque setting device since springN opposes theresistenceofspringMinsidethecylinderthroughleverL.The torque setting device allows leverL tomove over strokeHcorrespondingto0.15÷0.25mm.Thisconsequentlyincreasesinjectionpumpdeliverywithtorquereachingitspeakvalue.
Note: Ingeneratorsetsandpowerwelders,thetorquesettingdeviceactsasadeliverylimiteronly.
ItthereforedoesnotfeaturespringMorstrokeH.
Full speed setting in no-load conditions (standard)
After setting idle speed turn screw2 and set full speed in no-loadconditionsat3200r.p.m.;thentightenlocknut.
Note: Whentheenginereachesthepre-setpowerfullspeedstabilizesat3000r.p.m.
SETTINGS
Not valid onEPAengines, onwhich it is not possible tomodify theadjustmentofthemaximum.
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8Settings
Injection pump delivery setting with dynamometric brake
1)Runtheengineandbringittotheoperatingtemperature.2)ReleasetheflowlimiterscrewCcompletely(seepage175).3)Bringtheenginetomaximumrotationspeed.4)Activate the dynamometric brake to bring the engine to the
maximumspeed.5)Checkthatfuelconsumptionisinlinewiththevaluesgiveninthe
table“Specificfuelconsumption”. If it is not in line with the indicated values, reduce the
dynamometricbrakeload.6)After a few operation minutes and when the engine has
stabilized, slowly fasten screwC until the rotation speed startsdecreasing.
7)LockscrewCusingalocknut.8)Carryoutthefuelconsumptioncheckagain.9)Releasethedynamometricbrakeanddetecttherotationspeedof
the“stabilized”engine(maximumidlespeed).10)Bringtheenginetominimumidlespeed.Carryoutenginesetting
whentheengineis"stabilized".11)Switchofftheengineandletitcooldown.12)Checkthevalve/rockerarmclearance(see"Settingvalve/rocker
armclearance").
lnjection pump delivery setting without dynamometric brake
LoosendeliverylimitingdeviceCby5turns.Bringenginetofullspeedinno-loadconditionsi.e.3200r.p.m..Tightenlimitingdeviceuntiltheengineshowsadropinr.p.m..UnscrewlimitingdeviceCby1and½turns.Tightenlocknut.
Note: lftheengine,underfullload,generatestoomuchsmoketightenC;ifnosmokeisobservedattheexhaustandtheenginecannotreachitsfullpowerunscrewC.
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0003 05.52BN)21.91( 36÷06 002÷091
)272÷852(
0081 05.81BN)6.31( 59÷09 181÷171
)642÷332(
0081 05.61AN)31.21( 011÷401 371÷361
)532÷322(
0051 08.41BN)88.01( 611÷011 581÷571
)252÷932(
0051 03.31AN)87.9( 231÷521 871÷961
)342÷032(
0003 75.52BN)08.81( 5.16÷5.06 491÷091
462÷952
0003 05.52BN)08.81( 06÷95 091
)852(
(18,80)
8
9LD 625-2
9LD 625-2
9LD 625-2
9LD 625-2
9LD 625-2
9LD 625-2 EPA
9LD 625-2CE
Setting the stop limit stop
1)Removethethrottlelevercover.1)Completelyturnlever Ccounter-clockwiseandkeepitinthisposition. RetainerFshouldnotbeincontactwithleverC.2)UnscrewnutGandbringretainerFincontactwithleverC3)PushretainerFsothatleverCismovedbackwardsclockwiseby
1.0mm.4)LockretainerFbyscrewingnutG
Note: Inthiscondition,thelimitstopsoftheinjectionpumpadjustmentrodwillnotbedamagedbytheviolentimpactscausedbythepossibleassemblyofelectrostop.
Settings
Engine R.p.m.Power
HP(kW)
Specific fuel consump-tion *
Time (sec) per 100 cm3
g/HP h(g/kW h)
Theindicatedspecificfuelconsumptionreferstotheperiodfollowingapproximately30workinghours.
Required settings (as most commonly applies)
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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8Settings
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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9
- When the engines are not for more than 6 months, they have to be protected performing the operations described in the following pages.
- Iftheengineisnottobeusedforextensiveperiods,checkthestorageareaconditionsandthetypeofpackagingandmakesurethatthesearesuitableforcorrectstorage.
Ifnecessary,covertheenginewithaproperprotectivesheet.- Avoidstoringtheengineindirectcontactwiththeground,inenvironmentsthatarehumidandexposedtobadweather,near
highvoltageelectriclines,etc.
ImportantIf, after the first 6 months, the engine is still not used, it is necessary to carry out a further measure to extend the protection period (see “Protective treatment”).
1 - PourintheenginehousingAGIPRUSTIACprotectiveoiluptothemaximumlevel.2 - Fillupwithfuelcontaining10%AGIPRUSTIANT.3 - Starttheengineandkeepitidleatminimumspeedforsomeminutes.4 - Bringtheengineto¾ofthemaximumspeedfor5÷10minutes.5 - Turnofftheengine.6 - Emptyoutcompletelythefueltank.7 - SpraySAE10Wontheexhaustandintakemanifolds.8 - Sealtheexhaustandintakeductstopreventforeignbodiesfromentering.9 - Thoroughlycleanallexternalpartsoftheengineusingsuitableproducts.10 - Treatnon-paintedpartswithprotectiveproducts(AGIPRUSTIANT).11 - Loosenthealternator/fanbelt(ifpresent).12 - Covertheenginewithaproperprotectivesheet.
Caution - Warning
In countries in which AGIP products are not available, find an equivalent product (with specifications: MIL-L-21260C).
Important
Maximum every 24 months of inactivity, the engine must be started up by repeating all "Engine Storage" operations.
ENGINE STORAGE
PROTECTIvE TREATMENT
STORAGE
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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9
PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIvE TREATMENT
Afterthestorageperiodandbeforestartinguptheengineandpreparingitforoperation,youneedtoperformcertainoperationstoensuremaximalefficiencyconditions.
1 - Removetheprotectivesheet.2 - Removeanysealingdevicesfromtheexhaustandintakeducts.3 - Useaclothsoakedindegreasingproducttoremovetheprotectivetreatmentfromtheexternalparts.5 - Injectlubricatingoil(nomorethan2cm3)intotheintakeducts.6 - Adjustthealternator/fanbelttension(ifpresent).7 - Turntheenginemanuallytocheckthecorrectmovementandsmoothnessofthemechanicalparts.8 - Refillthetankwithfreshfuel.9 - Makesurethattheoilisuptothemaximumlevel.10 - Starttheengineandaftersomeminutesbringitto¾ofthemaximumspeedfor5-10minutes.11 - Turnofftheengine.12 - Removetheoildrainplug(see“Oilreplacement”)anddischargetheAGIPRUSTIANTprotectiveoilwhiletheengineishot.13 - Pournewoil(see"Tableoflubricants")uptothemaximumlevel.14 - Replacethefilters(air,oil,fuel)withoriginalspareparts.
Caution - Warning
Over time, a number of engine components and lubricants lose their properties, so it is important considering whether they need replacing, also based on age (see Replacement table).
Important
Maximum every 24 months of inactivity, the engine must be started up by repeating all "Engine Storage" operations.
Storage
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 82 -
-404020252525610102010525
25
106035101010451604025151010102540252520103025128÷10151045401225102053030302520252525
-8x1.018x1.58x1.258x1.258x1.258x1.256x1.06x1.06x1.08x1.256x1.05x0.88x1.25
8x1.25-
6x1.010x1.510x1.56x1.06x1.06x1.010x1.514x1.514x1.58x1.258x1.258x1.258x1.258x1.258x1.2510x1.58x1.258x1.258x1.256x1.08x1.2512x1.510x1.58x1.2510x1.56x1.010x1.514x1.510x1.012x1.58x1.08x1.255x0.88x1.258x1.2510x1.58x1.258x1.258x1.258x1.258x1.25
Loctite270
Loctite495Loctite270
Loctite270Loctite242
Loctite270Loctite270Loctite270
10 TORQUE SPECIFICATIONS AND USE OF SEALANT
Table of tightening torques for the main components
Vibration-dampingtanksupportConnectingrodInjectionpumpdeliveryvalveunionRockerarmcoverCentermainbearingsupportIntakemanifoldExhaustmanifoldAirshroudAcceleratorcoverGovernorcontrolcoverAirconveyorshroudAlternatorcableclampHighpressurefuellineclampAircleaner
HydraulicpumpflangeAirconveyorshroudgasketHeadinjectorCamshaftgearOilpumpgearAirconveyorsheetInternaloilfilterpiercedplateBreathersheetStartingmotorBlowerhubNipplradiatorRockerarmshaftInjectionpumpcontrolleverpivotSpeedgovernorexternalcontrolleverpivotExternalstopcontrolleverpivotGovernorspringlowerleverpivotGearcoverplateEnginemountingfootFuelfeedingpumpInjectionpumpOilpumpNozzleholderOilpanOilpressureswitchStartermotorfixingstudFuelliftpumpfixingstudCylinderheadfixingstudCoolingfanguardStartingpulleyFuelfilterunionFuelliftpumpunionHighpressurefuellineunionFuelbleedinglineunionVoltageregulatorR.p.m.counterdrivinggearMainbearingsupport,gearcasesideMainbearingsupport,flywheelsideCentermainbearingsupportAirconveyorsupportHydraulicpumpgearsupportInjectionpumpcontrolleversupportGovernorleversupport(camshaftseal)Governorforksupport
POSITIONDiam. and pitch
( mm )Torque( Nm ) Sealant
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 83 -
8x1.255x0.88x1.25
14x1.510x1.56x1.016x1.520x1.5
30715
405510160300
Loctite242
Loctite270Loctite270
10
FueltankbracketAlternatorstatorCrankaselubrificationplug
OildrainplugCylinderheadBlowerCoolingfanhubfixingscrewFlywheel
Torque specifications and use of sealant
POSITION Diam. and pitch( mm )
Torque( Nm ) Sealant
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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M3M4M5M6M8M10M12M14M16M18M20M22M24M27M30
R>400N/mm2 R>500N/mm2 R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2
Nm0,71,53513254368105145205275355525725
Nm0,61,42,84,71223406398135193260333500680
Nm0,91,83,86,316315484131181256344444656906
Nm12,24,57,51937651011582183084135337881088
Nm1,42,961025498613521029041055071010501450
4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9
Nm0,51,12,33,89,418325179109154206266394544
Nm1,94,18,5143569120190295405580780100015002000
Nm2,34,910174183145230355485690930120018002400
M8x1M10x1M10x1,25M12x1,25M12x1,5M14x1,5M16x1,5M18x1,5M18x2M20x1,5M20x2M22x1,5M24x2M27x2M30x2
R>400N/mm2 R>500N/mm2 R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2
Nm10212036385684122117173164229293431600
Nm142826484575113163157230218305390575800
Nm132624454270105153147213204287367533750
Nm1735335956941412031962882733814887191000
Nm20423971681131692442353453274585858631200
Nm275652959015022532531346043661078011501600
Nm387973135125210315460440640615860110016002250
Nm4595881601502503805505307707401050130019502700
4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9
10
Table of tightening torques for standard screws (coarse thread)
Resistance class (R)
Quality/Dimensions
Diameter
Table of tightening torques for standard screws (fine thread)
Quality/Dimensions
Resistance class (R)
Diameter
Torque specifications and use of sealant
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
- 85 -
1460-285
1460-024
1460-119
1460-047
3
1
2
7560-4000-052
11SPECIAL TOOLS
SPECIAL TOOLS DESCIPTION Part N°.
Special tools and equipment for maintenance
Valve lowering tool for static injection timingcheck1Spacers,h=40mm2 Dialgaugeindicator3Dialgaugeextension
Statictimingtool
ToolforvalvestemO-ringassembly
Flywheelpuller
Timingcontrolgearextractorfork
9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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........................................................................................................................................................................9LD Workshop Manual _ cod. ED0053022860 - 4° ed_rev. 03
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cod. ED0053022860
9 LD Engine Series