Lombardini 3LD 450 Instruction manual

WORKSHOP

MANUAL

3/4 LD, CODE1-5302-556 ENGINE SERIES

SERVICE

3LD 450

3LD 510

3LD 450/S

3LD 510/S

4LD 640

4LD 705

4LD 820

3rd edition

DATE

30.11.2001

TECO/ATL AUTHOR BOOK CODE

1-5302-556

MODEL No.

50839

DATEOFISSUE

01-94 REVIEW 02 APPROVAL 1

BOOK CODE

1-5302-556

MODEL No.

50839

DATEOFISSUE

01-94 REVIEW 02 DATE

30-11-2001

APPROVAL

TECO/ATL AUTHOR

INDEX OF CHAPTERS

IMODEL AND IDENTIFICATION

II CHARACTERISTIC CURVES

III MAINTENANCE

RECOMMENDED OIL, CAPACITIES

VI TROUBLE SHOOTING

VDISASSEMBLING AND REASSEMBLING

VI LUBRICATION CIRCUIT

VII FUEL/INJECTION CIRCUIT

VIII ELECTRIC CIRCUIT

IX ELECTRIC EQUIPMENT

XADJUSTMENTS

XI UPKEEPING

XII TECHNICAL DATA

XIII MAIN DRIVING TORQUES

XIV USE OF SEALANT

XV CLAMPING TORQUES

This handbook provides the main information concerning the repair of the following LOMBARDINI Diesel

engines 3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S, 4LD 640, 4LD 705, 4LD 820, which are air-cooled,

provided with direct injection and revised on the 30-11-2001.

Page 3

" 4

" 5

" 6

" 7

" 18

" 20

" 22

" 23

" 25

" 27

" 28

" 29

" 30

" 31

INTRODUCTION

DATE

30-11-2001

TECO/ATL AUTHOR BOOKCODE

1-5302-556

MODEL No.

50839

DATEOFISSUE

01-94 REVIEW 02 APPROVAL 3

REGISTRATION CODE AND IDENTIFICATION

Approval code

Engine serial number

Customer's code

Approval code

DIESEL

LOMBARDINI

Engine grup number

Displacement CC

DIESEL

Customer's code

Engine serial number

LOMBARDINI

Engine group number

BOOK CODE

1-5302-556

MODEL No.

50839

DATEOFISSUE

01-94 REVIEW 02 DATE

30-11-2001

APPROVAL

TECO/ATL AUTHOR

N (80/1269/EU - ISO 1585) AUTOMOTIVES POWER : Discontinuous services at variable rpm and load.

NB (ISO 3046 - 1 IFN) NON-OVERLOADABLE POWER:Continuous light services at constant rpm and variable load.

NA (ISO 3046 - 1 ICXN) CONTINUOUS OVERLOADABLE POWER: Continuous heavy-duty services at constant rpm and load.

The above mentioned power levels refer to the engine equipped with air filter, standard silencer, suction fan - which previously underwent a

breaking-in period - at 20°C ambient conditions, at 1 bar.

The maximum power is guaranteed with a 5% tolerance.

These powers are reduced of abt. 1% every 100 m height and of 2% for every 5°C exceeding 25°C.

C (NB): Specific fuel consumption at NB power

MT : Torque at N power

a: Continuous service field of use. For any purpose out of this field of use, please contact company LOMBARDINI.

CHARACTERISTIC CURVES CONCERNING POWER, TORQUES AND SPECIFIC

CONSUMPTION

Il CHARACTERISTIC CURVES

DATE

30-11-2001

TECO/ATL AUTHOR BOOKCODE

1-5302-556

MODEL No.

50839

DATEOFISSUE

01-94 REVIEW 02 APPROVAL 5

SAE 5W/30

SAE 10W/40

SAE 15W/40

SAE 15W/30

-20 -10 +10 +20 +30

-13 -4 514 23 32 41 86

50 59 68 77

SAE 40

°C

°F

SAE 30

SAE 20W/20

RATING

SAE 10W

CAPACITIES IN LITERS

Standard fuel tank

3LD450, 3LD510, 3LD451/S, 3LD510/S = 5.3

4LD 640, 4LD705, 4 LD 820 = 7.2

Standard oil sump:

3LD450, 3LD510, 3LD451/S, 3LD510/S =1.75

4LD640, 4LD705, 4LD 820 = 2.60

Air filter oil bowl = 0.3

For special filters, tanks and oil sumps, please

follow LOMBARDINI instructions.

INTERVALS (HOURS)

OPERATION DETAIL 10 50 125 250 500 1000 2500 5000

AIR FILTER (OIL-BATH) (*)

CLEANING HEAD AND CYLINDER FINS (*)

FUEL TANK

INJECTORS AIR FILTER OIL

CHECK LEVEL SUMP OIL

BATTERY LIQUID

FUEL HOSE COUPLING FASTENING

VALVE AND ROCKER ARM CLEARANCE

INJECTOR SETTING

AIR FILTER(**) (***)

CHANGE SUMP (***)

OIL FILTER CARTRIDGE

FUEL FILTER CARTRIDGE

OVERHAUL PARTIAL (****)

GENERAL

First replacement.

(*) In particular running conditions even every day.

(**) In particularly dusty environments every 4-5 hours.

(***) See prescribed oil.

(****) It includes the check of cylinders, segments, guides, valve seat springs and grindings, head and cylinder

descaling, injection pump and injector checks.

RECOMMENDED OIL

AGIP DIESEL SIGMA S SAE 30-40 MIL-L-2104 C

ESSOLUBE D3 specification, MIL-L-2104 D and

UNIFARM specification MIL-L-2104 C. For

Countries in which AGIP and ESSO products

are not available, the prescribed oil is API

SERVICE CD for diesel engines or oil which

should be in conformity with the MIL -L-2104 C

and MIL -L-2104D military specifications.

MAINTENANCE -PRESCRIBED OIL - REFUELLINGS III

BOOK CODE

1-5302-556

MODEL No.

50839

DATEOFISSUE

01-94 REVIEW 02 DATE

30-11-2001

APPROVAL

TECO/ATL AUTHOR

PROBABLE CAUSES

ELECTRICAL

EQUIPMENT

SETTINGS AND REPAIRINGS LUBRICATION FUEL CIRCUIT

Excessive oil

consumption

Low oil

pressure

Oil level

increase

Inconsistent

rpm

It does not ac-

celerate

It starts but does

not stop

It does not

start

This table shows some possible causes concerning malfunctions that could arise during the machine running. Always,

systematically carry out simpler checks before any disassembly or replacement.

Oil and fuel

leakage from the

exhaust

TROUBLE

Black

smoke

White smoke

Cylinder head gasket

MAINTENANCE

Clogged pipings

Clogged fuel filter

Presence of air in the fuel circuit

Clogged tank breather

Faulty fuel pump

Blocked injector

Blocked injection pump valve

Wrong injector setting

Plunger excessive leakage

Stuck injection pump delivery control

Wrong injection pump delivery setting

High oil level

Blocked pressure relief valve

Worn oil pump

Presence of air inside the oil intake pipe

Faulty pressure gauge or switch

Clogged oil intake duct

Discharged battery

Inefficient or wrong cable connection

Faulty starting switch

Faulty starting motor

Clogged air filter

Excessive idle operation

Incomplete running-in

Overloaded engine

Advanced injection

Delayed injection

Incorrect governor tinkage adjustment

Broken or loose govener spring

Low idling setting

Worn or stuck piston rings

Worn or scored cylinders

Worn valve guides

Sticking valves

Worn crankshaft-connecting rod bearings

Non-sliding speed governor leverage

Crank shaft not turning freely

TROUBLE SHOOTING

DATE

30-11-2001

TECO/ATL AUTHOR BOOKCODE

1-5302-556

MODEL No.

50839

DATEOFISSUE

01-94 REVIEW 02 APPROVAL 7

DISASSEMBLY AND REASSEMBLY

Apart from disassembly and reassembly operations, this chapter

also includes checks, setting up, dimensions, repairs and running

instructions.

It is necessary to use LOMBARDINI original spare parts for a correct

repair.

Oil-bath air filter (standard)

Oil-bath type with double filtering mass.

The lower mass is made of metal, while the upper is made of

polyurethan.

Check the gasket conditions and replace them in case they are

damaged.

Make sure that the weldings are not damaged.

Carefully clean the lower body and the filtering masses using

some gas oil, blow the lower mass with compressed air and dry

the upper mass by means of a cloth. Fill with engine oil filter to the

indicated level.

While reassembling, tighten the nuts at 25 Nm (3LD450, 3LD510,

3LD451/S, 3LD 510/S), at 30 Nm (4LD 640, 4LD 705, 4LD 820)

Details:

1Upper body 4External sealing ring

2Filtering mass made of polyurethan 5 Filterning mass

3 Internal sealing ring 6Bowl

Silencer (standard)

Make sure that it is free from any carbon and oily residues, if

contaminated, replace it. While reassembling it, replace the gaskets

and tighten the brass nuts at 25 Nm.

Flywheel

Clockwise unscrew nut 1and remove the flywheel using the puller

2Part. no. 7271-3595-050 for 3LD 450, 3LD 451/S, 3LD510, 3LD510/S,

while for 4LD 640, 4 LD 705, 4LD 820 use puller with Part. no. 7271-

3595-048.

Check that the starter ring gear, when it is present, and the conic

surface of the driving shaft coupling hole are intact.

While reassembling, tighten the screws 1 at 170 Nm for 3LD 450,

3LD 451/S, 3LD510, 3LD 510/s and at 350 Nm for 4LD 640, 4LD

705, 4LD 820.

Note: The flywheels of the left-hand engines (3LD 451/S, 3LD 510/

S) have a blading turned in the opposite direction and the nut

1shall be anticlockwise unscrewed.

DISASSEMBLY/REASSEMBLY V

BOOK CODE

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Starting pulley

In order to carry out any easier staring, it is necessary to place the

driving shaft at the TDC (Top dead center) and to assemble the pulley

with notch 1 moved back at ( 45°) according to the rotation direction of

the engine, as per picture 4 and 5 .

Tighten the screws at 35 Nm for 3LD 450, 3LD 451/S, 3LD510, 3LD

510/S, at 40 Nm for 4LD 640, 4LD 705, 4LD 820.

Vent plug

Components

1Vent plug and oil refiling

2O-ring

3Diaphragm

Valve/rocker arm clearance

Place the piston at the compression top dead centre.

Place thickness gauge 1between the valve stem and the rocker

arm; cold-adjust the clearance at 0.15 ÷0.20 mm for both valves.

Tighten the rocker arm box cap at 20 Nm.

Decompression (by request)

Components:

1Cover 6 Pin

2Gasket 7Ring

3 Lock ring 8Lever

4Spring 9 Pin

5 Shaft

The engine rocker arm cover can be equipped with a

decompression device which compresses the exhaust valve at the

TDC (top dead centre), lowering it of abt. 1mm. during the starting

phase. The lowering is adjusted by the gaskest thickness 2. Make sure

that the lever turns for abt. half a stroke before it actuates the valve.

Warning!

The use of decompression to stop the engine may cause serious

damages.

VDISASSEMBLY/REASSEMBLY

DATE

30-11-2001

TECO/ATL AUTHOR BOOKCODE

1-5302-556

MODEL No.

50839

DATEOFISSUE

01-94 REVIEW 02 APPROVAL 9

Rocker arm pin, extraction

Before extracting the rocker arm pin in 3LD 450, 3LD 451/S, 3LD

510, 3LD510S engines, unscrew screw 1, as per picture 10.

Extract the pin using tool 2 Part. no. 7276-3595-040, picture 11 also for

4LD 640, 4LD 705, 4LD 820 engines.

Rocker arm pin and hole

Dimensions (mm)

A= 15.032 ÷ 15.050

B = 14.989 ÷ 15.000

Clearances

(A-B) = 0.032 ÷ 0.061

(A-B) = worn limit = 0.120

Head

Do not disassemble while it is hot as to avoid any possible

distortion.

If the head surface is distorted, smooth it by removing up to 0.3 mm

thickness.

Always replace the copper gasket, see picture 34 for the choice of

thickness.

Gradually tighten the nuts according to the following order 1, 3, 2, 4,

at 50 Nm for 3LD 450, 3LD 451/S, 3LD 510, 3LD510/S, and at 80

Nm for 4LD 640, 4LD 705, 4LD 820.

Injector, projection

The projection of the nozzle ends Awith respect to the head surface

shall be:

2.5÷3 mm for 3LD 450, 3LD 451/S

3÷3.5 mm for 3LD 510, 3LD 510/S

3.5÷4 mm for 4LD 640, 4LD 705, 4LD 820

Adjust by means of a copper gasket B having a thickness of 0.5

mm, 1 mm, 1.5mm .

10 11

VDISASSEMBLY/REASSEMBLY

BOOK CODE

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MODEL No.

50839

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Valves

1Valve stem

2 Spring holding disk

3Spring

4Cap

5Cotters

Note: In order to remove the cotters, put a shim under the valve

head and strongly press, as shown in picture 16.

Valves guides and housings

1 Exhaust valve guide

2Intake valve guide

Dimensions (mm):

3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S

A= 43.80 ÷ 44.20 B = 55.80 ÷ 56.20

C = 11.00 ÷ 11.018 D= 11.05 ÷ 11.06

4LD 640, 4LD 705, 4LD 820

A = 47.80 ÷ 48.20 B = 65.80 ÷ 66.20

C = 12.000 ÷ 12.018 D= 12.05 ÷ 12.06

Note: Valve guides with an external dia. increased of 0.5 mm can be

used as spare parts; in this case it is necessary to increase

the housing Cof 0.5 mm for the assembly.

Valve guides insertion

Heat the head at 160° ÷ 180°. Force the guides according to A and

Bdistance with respect to the head surface.

3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S

A= 30.80 ÷ 31.2 B= 18.8 ÷ 19.2

4LD 640, 4LD 705, 4LD 820

A= 35.8 ÷ 36.2 B = 17.8 ÷ 18.2

Note: if the guides are supplied with the housing for the lock ring C,

insert the ring, then drive the guides without worrying about A

and B.

Valve guide dimensions and clearances

3LD 450, 3LD 451/s, 3LD 510, 3LD 510/S (mm):

D= 7.030 ÷ 7.050 E = 6.985 ÷ 7.000

(D-E) = 0.030 ÷ 0.065 (D-E) limit= 0.13

4LD640, 4LD 705, 4LD 820

D = 8.030 ÷ 8.050 E = 7.985 ÷ 8.000

(D-E) = 0.030 ÷ 0.065 (D-E) limit =0.13

Valve housings and seats

3LD 450, 3LD 451/S, 3LD 510, 3LD 510/S (mm);

A = 34.99 ÷ 35.01 C= 30.99 ÷ 31.01

B = 35.10 ÷ 35.12 D= 31.10 ÷ 31.12

4LD 640, 4LD 705, 4LD 820 (mm):

A = 42.99 ÷ 43.01 C= 36.99 ÷ 37.01

B = 43.12 ÷ 43.14 D= 37.10 ÷ 37.12

Drive the seats in the housings and mill at 45°.

DISASSEMBLY/REASSEMBLYV

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