Lombardini 11LD522-3 Series, Workshop Manual

Page 1: ...1 COMPILERTECO ATI ENDORSED DATE 14 07 2003 REG CODE 1 5302 616 MODEL N 50898 DATE OF ISSUE 07 03 REVISION 00 11 LD 522 3 1st Edition WORK SHOP MANUAL 11LD522 3 series engines p no 1 5302 616 ...

Page 2: ...gines have been adequately trained and outfitted to safely and professionally carry out the necessary tasks 2 the persons who service Lombardini engines possess the necessary skills and special Lombardini tools to safely and professionally carry out the necessary tasks 3 the persons who service Lombardini engines have read the specific information concerning the above mentioned Service operations ...

Page 3: ...cial written warranty agreements Within the above stated periods Lombardini Srl directly or through its authorized network will repair and or replace free of charge any own part or component that upon examination by Lombardini or by an authorized Lombardini agent is found to be defective in conformity workmanship or materials Any other responsibility obligation for different expenses damages and d...

Page 4: ..._______________ 15 16 IX DISASSEMBLY OF THE ENGINE ___________________________________________________ 17 Extracting crankcase bushes 18 Extracting fuel injectors 17 Extracting the oil pressure indicator plug 18 Extraction of crankshaft gear 18 Extraction of flywheel side main bearing 17 Extraction of the camshaft gear 18 Removing the flywheel 17 Removing the pulley 17 X CHECKS AND OVERHAUL ______...

Page 5: ..._____________________________________________________ Page 30 Checking electrical equipment 30 Checking the alternator 30 Plant specifications 30 XIII ENGINEASSEMBLY ___________________________________________________________ Page 31 Camshaft 31 Central main bearings 33 Checking injector protrusion 36 Connecting rods 35 Crankshaft 33 Crankshaft end float 34 Cylinder barrels 35 Cylinder heads 36 El...

Page 6: ... pressure 39 Dyno testing of engine 39 Speed adjustment 39 XV STORAGE ___________________________________________________________________ Page 41 How to prepare the engine for operation 41 Permanent protection over 6 months 41 Storage 41 Temporary protection 1 6 months 41 XVI QUICKREFERENCECHARTS ____________________________________________________ Page 42 Adjustments 42 Couplings 42 Standard scre...

Page 7: ...e idle operation Incomplete running in Engine overloaded Advanced injection Delayed injection Incorrect governor linkage adjustment Broken or loose governor spring Idle speed too low Worn or jammed piston rings Worn or scored cylinders Worn valve guides Jammed valves Worn bearings Governor linkage not free to slide Drive shaft not free to slide Damaged cylinder head gasket TROUBLE LUBRICATION POSS...

Page 8: ...ious danger for his personal safety and health and that of any persons who may be in the vicinity of the machine Theenginemayonlybeusedorassembledonamachinebytechnicianswhoareadequatelytrainedaboutitsoperation and the deriving dangers This condition is also essential when it comes to routine and above all extraordinary maintenanceoperationswhich inthelattercase mustonlybecarriedoutbypersonsspecifi...

Page 9: ...ever carry out any operation whilst the engine is running The coolant fluid circuit is under pressure Never carry out any inspections until the engine has cooled and even in this case only open the radiator plug or expansion chamber with the utmost caution wearing protective garments and goggles If there is an electric fan do not approach the engine whilst it is still hot as the fan could also sta...

Page 10: ...E 1 5302 616 MODEL N 50898 DATE OF ISSUE 07 03 REVISION 00 III MODEL NUMBER AND IDENTIFICATION ENGINE IDENTIFICATION R P M Customer s code Approval code Engine Serial Number MODEL NUMBER Nr Cylinders Displacement cc Diesel LOMBARDINI Engine group number ...

Page 11: ...1 LD522 3 TECHNICAL DATA CHARACTERISTICS ENGINE TYPE Number of cylinders Bore Stroke Swept volume Compression ratio 3000 RPM 3600 RPM 3000 RPM 3600 RPM 3000 RPM 3600 RPM Max torque Fuel consumption Oil consumption Capacity of standard oil sump Recommended battery 12V Dry weight Combustion air volume Cooling air volume Max permissible driving shaft axial continuous instantaneous Fan site continuous...

Page 12: ...OS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and constant load Mt N Torque at N power C Specific fuel consumption at N power U1 Standard utilization range of engines rated at 3000 rpm U2 Standard utilization range of engines rated at 3600 rpm The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental ...

Page 13: ...13 COMPILERTECO ATI ENDORSED DATE 14 07 2003 REG CODE 1 5302 616 MODEL N 50898 DATE OF ISSUE 07 03 REVISION 00 VI OVERALL DIMENSIONS Note Dimensions in mm ...

Page 14: ...0365R0010 00366R0060 00365R0880 00365R0910 00365R0930 00365R0770 00365R0940 00365R0430 Universalpuller Mainbearingextractor By passvalveextractor Central bearing assembly tool Valve guide rubber fitting tool Cylinder collar Ø 80 85 mm Injectionadvancecontroltool Injector test bench SPECIAL TOOLS TOOL CODE DESCRIPTION ...

Page 15: ...cedures cylinder and piston replacement seat guide and valve refacing crankshaft replacement or grinding bench bearing and connecting rod replacement To avoid explosions or fire outbreaks do not smoke or use naked flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the plug to prevent harmful ...

Page 16: ... The risk of piston seizure jammed piston rings and rapid wear of the cylinder liner the bearings and all moving parts increases if oil whose characteristics differ from the recommended type is used or if the oil is not regularly changed All this notably reduces engine life Oil viscosity must suit the ambient temperature in which the engine operates Old oil can cause skin cancer if repeatedly left...

Page 17: ...flywheel from dropping as this could seriously injure the operator Wear protective goggles when removing the flywheel ring IMPORTANT Do not tap the end of the extractor when removing the flywheel Removing the pulley The pulley can be removed manually as shown in figure 3 Extraction of flywheel side main bearing Withdraw the bearing using two M8 screws taking care to tighten them evenly alternative...

Page 18: ... removed manually as shown in figure 5 Extraction of the camshaft gear Use the extractor code 00365R0010 fig 6 Extracting crankcase bushes From crankcase fig 7 From main bearing fig 8 Use extractor code 00366R0060 Extracting the oil pressure indicator plug Remove the oil filter and extract the by pass valve using the extractor 00365R0880 fig 9 DISASSEMBLY OF THE ENGINE ...

Page 19: ...tion Clean heads of carbon deposits and check the cylinder mating surfaces if the are deformed they must be ground to a maximum of 0 3mm Check that there are no cracks or other imperfections in the heads If defects are encountered the heads must be renewed In this case consult the spare parts catalogue Valves Guides Seats Clean the valves with a wire brush and renew them if the valve heads are def...

Page 20: ... following table d fig 11 Fitting mm Max wearmm In the case of lower values the valve may strike the piston In the case of values in excess of 1 3mm the valve seat rings must be replaced Fitting of new seats or valves always requires preparatory grinding Valves are available with the external diameter increased by 0 5mm After grinding wash the valve and seat carefully with petrol or paraffin in or...

Page 21: ...ight surface scores on the cylinder it will be sufficient to change the piston rings Do not manually hone the cylinder bore surfaces with emery cloth or other means The cross hatch pattern should be at an angle of 90 120 lines should be uniform and clear in both directions Average roughness must range between 0 5 mm 1 µm The cylinder surface which comes into contact with piston rings should be mac...

Page 22: ...ing the piston Piston diameter check The diameter of the piston must be measured at approximately 18 mm from the base fig 23 Check the clearance between cylinder and piston if it is greater than 0 120 mm both cylinder and piston must be replaced Assembly clearance between piston pin and piston in millimetres Connecting rods The connection between the connecting rod small end and the wrist pin is w...

Page 23: ...t the necessary sizes without requiring any adjustment by boring Dimensions Crankshaft Whenever the engine is dismantled particularly for the replacement of cylinders and pistons due to wear caused by the aspiration of dust it is good practice to check the condition of the crankshaft 1 Remove the plugs A from the oil passages fig 26 2 Use an appropriately shaped steel punch to clean the inside of ...

Page 24: ...main bearings are of different external diameters fig 30 and are machined with a bevelled edge to assist their insertion into the crankcase Check the dimensions of the shells and renew them if they are worn or deformed Also check the condition of the oil passages and if necessary clean them with paraffin or petrol and dry with compressed air Oil seal rings Check that the rings have not hardened ar...

Page 25: ...s should be The push rods must be straight and with the spherical surfaces at either end in good condition fig 33 Make sure that the lubrication holes inside the tappets and push rods are free of dirt Injection pump plug nuts and control rods Renew the parts if the surface wear is greater than 0 10mm fig 34 Assembly clearance between control rods and their housings in the crankcase Fuel pump push ...

Page 26: ...nor N Supplement H Spring Fitting mm Max wearmm Fitting mm Max wearmm CHECKS AND OVERHAUL The clearance between the external rotor of the oil pump and the cover facing surface must be End float of rotors fig 37 Governor lever and spring Check that the shoes S fig 38 are level and that the springs have not lost their elasticity Renew any excessively worn parts after consulting the spare parts catal...

Page 27: ...for BOSCH pump type PF30 Checking injection pumps Before dismantling the injection pumps check for pressure leak of the pumping unit plunger and valve as follows 1 Connect a pressure gauge with 600 Kg cm full scale to the diesel delivery line fig 41 2 Set the control sleeve nr 12 fig 40 to a mid point delivery position 3 Turn the flywheel slowly until the plunger has completed a full compression s...

Page 28: ...en the delivery connection 3 Insert plunger with helical profile A fig 44 on the opposite side of the sleeve pin B fig 44 into the internal groove of the control sleeve make sure the helical profile is turned towards the fuel inlet and eccentric pin C fig 44 4 Complete pump assembly with plunger a fig 45 control sleeve b upper washer c retaining ring d spring f and secure all with the spring holde...

Page 29: ...s 20 Kg cm below the opening pressure of the needle valve The nozzle can be considered well sealed if there no Diesel fuel accumulates at the nozzle tip after 10 seconds Disassembly and re assembly of injectors Unscrew the ring nut on the injector nozzle using a ring wrench and a special tool as illustrated in figure 50serving to release the pressure exerted by the spring on the ring nut 1 Visual ...

Page 30: ...ng that resistance is zero and the insulation between the windings and ground fig 54 by ensuring that the ohmmeter gives a reading of infinite resistance If these readings are not obtained the stator must be renewed 2 with motor running use a multitester to check the charge current between the two yellow wires fig 55 Bring the engine up to 3000 rpm the multitester should give a reading of 80V If t...

Page 31: ...m damage Complete the external assembly with plate spring lever etc as shown in figure 56 3 Mount the timing system side bearing bush using either a standard press or a made to measure punch as shown in figure 57 Fit the bush by matching the groove with the seat on the crankcase Bushes with standard or smaller internal diameters can be ordered as required 4 Insert the complete oil pressure indicat...

Page 32: ...5 if you wish to check the rotors Fit the external oil pump rotor with the bevel toward the inside of the cover fig 63 Mount the pump to the crankcase ensuring that the locating pin is correctly seated Torque the fixing bolts to Assembly 1 Fit the tappets into their housings in the crankcase 2 Fit the governor lever and tie rod simultaneously with the camshaft into the crankcase fig 62 3 Insert th...

Page 33: ...gs flywheel side Fit the bush to the bearing using a normal punch of appropriate diameter as shown in figure 69 Insert the bush arranging the groove so that it is aligned with the seat on the bearing so that the oil passages will be correctly aligned Fit the oil seal ring to the bearing using a suitable diameter tubular punch Fit the bearing into the crankcase after having first interposed a gaske...

Page 34: ...ks match those on the camshaft gear fig 72 the pulley and the washer and then tighten the nut securing the pulley Use a feeler gauge to check the clearance between the clearance adjustment ring and the crankshaft fig 73 the value must be within the range Pulley and flywheel Tighten the pulley fixing bolt fig 75 to Timing cover Check that the timing references punched on the camshaft and crankshaft...

Page 35: ...120 with the end gap of the first compression ring aligned with the axis of the gudgeon pin The lower face of the cylinders are chamfered to permit the easy insertion of the piston rings The operation can be simplified however using a normal piston collar tool code 00365R0770 as shown in figure 79 Mount the cylinders to the crankcase as shown in figure 80 and then bring the pistons up to their res...

Page 36: ...g a cross pattern tighten the head nuts in increments of 1 kgm until you reach the value This value is adjusted by inserting copper washers between the injectors and the injector supporting faces on the heads fig 81 Valve clearance The clearance between valves and rockers with the engine cold fig 83 is This clearance is to be adjusted with the pistons at their respective TDC compression positions ...

Page 37: ... fig 85 to a position mid way between minimum and maximum 4 Fit the special tool p n 00365R0940 to the delivery valve holder timing case side as shown in figure 86 5 Turn the flywheel slowly until the column of diesel fuel inside the special tool starts to move This indicates the start of static injection For variable advance pumps the reference mark on the flange bell fig 87 must match the interm...

Page 38: ... not changed see pag 27 4 With the fuel feed pump cam in the rest position mount the pump and actuate it manually fig 92 Electric shut off If the engine is equipped with an electric shut off insert the electro magnet into the crankcase taking care to position the engine shut off lever in the STOP position make sure that the injection pump connection lever moves freely along its entire stroke Make ...

Page 39: ...ing for oil leaks 1 Remove the exhaust gas collection pipe from the inlet manifold and close the connection with a plug fig 96 2 Start the engine and let it run for a few minutes The high pressure generated in the crankcase will show up any oil leaks 3 Reconnect the exhaust gas collection pipe to the inlet manifold Dyno testing of engine After you have placed the engine on the brake fig 97 perform...

Page 40: ...00 ENGINE TESTING Running in table Load Time min RPM In order to check that the setting is correct without tools accelerate the engine a few times with no load and check the exhaust fumes Delivery of diesel fuel is correctly calibrated when the exhaust gas is slightly coloured by smoke change the adjustment if necessary by turning the adjustment screw fig 99 Engine power curves are reported at pag...

Page 41: ...njectors Spray oil type SAE 10W into exhaust and intake manifolds rocker arms valves tappet etc Grease all unpainted parts Loosen belt Wrap the engine in a plastic film Store in a dry place if possible not directly on the soil and far from high voltage electric lines Permanent protection over 6 months The following is recommended apart from the above instructions For the lubrication and injection ...

Page 42: ... mm 0 25 0 5 0 15 1 3 2 25 0 20 Couplings Camshaft and central bearings Camshaft and flywheel side bearing End gap of compression rings End gap of oil scraper rings Connecting rod and wrist pin Rocker arm and pin Fuel pump push rod and housing Injection pump tappets and housing Tappets and housings Oil pump rotor and housing Pistons and wrist pin Inlet valve guide to stem Exhaust valve guide to st...

Page 43: ... 30 35 40 44 40 61 80 74 90 96 00 Nm 6 11 9 20 4 33 50 64 2 88 7 150 228 347 435 605 734 940 R 800 N mm2 R 1000 N mm2 R 1200 N mm2 Nm 3 6 7 12 19 8 29 6 38 52 5 89 135 205 257 358 435 557 kgm 0 37 0 72 1 23 2 02 3 02 3 88 5 36 9 09 13 80 21 00 26 30 36 60 44 40 56 90 4 x 0 70 5 x 0 80 6 x 1 00 7 x 1 00 8 x 1 25 9 x 1 25 10 x 1 50 13 x 1 75 14 x 2 00 16 x 2 00 18 x 2 50 20 x 2 50 22 x 2 50 24 x 3 0...

Page 44: ...ation Data reported in this issue can be modified at any time by Lombardini Lombardini vorbehält alle Rechte diese Angabe jederzeit verändern La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación 42100 Reggio Emilia Italia ITALY Via Cav del Lavoro Adelmo Lombardini 2 Cas Post 1074 Tel 39 0522 3891 Telex 530003 Motlom I Telegr Lombarmotor R E A 227083 Reg I...