WORK SHOP

MANUAL
CHD series engines, p.no. 1-5302-345

LDW 1503 CHD

LDW 1603 CHD
LDW 2004 CHD
LDW 2004/T CHD
LDW 2204 CHD
LDW 2204/T CHD

5th Edition

COMPILER TECO/ATLO REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

1-5302-345 50534 31.12.1989

REVISION 04 09.05.2006 1
FOREWORD

We have done all in our power to give up to date and accurate technical information in this manual. Lombardini
engines are, however, constantly developing thus the data in this publication may be liable to modification without
prior notice.

The information in this manual is the exclusive property of Lombardini. Neither partial nor total duplications or
reprints are therefore permitted without the express authorization of Lombardini.

The information in this manual is given on the assumption that:

1- the persons who service Lombardini engines 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 and that they have clearly understood the operations required.

GENERAL SERVICE NOTES

1 - Only use genuine Lombardini spare parts. Use of spurious spares may lead to incorrect performance and
shorten the life of the engines.

2 - The metric system is used to express all data, i.e. the dimensions are given in millimeters (mm), torque is
expressed in Newton-meters (Nm), weight in kilograms (Kg), volume in liters or cubic centimeters (cc) and
pressure in barometric units (bar).

COMPILER TECO/ATLO REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

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 WARRANTY CERTIFICATE

WARRANTY CERTIFICATE

The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24
months from the date of delivery to the first end user.
For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed
within the setting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned period
(24 months) is not expired.
If no hour-meter is fitted , 12 working hours per calendar day will be considered.
For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling
system, sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above
mentioned period (24 months) is not expired.
For correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the
documentation supplied with each engine.
To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be
carried out by qualified personnel only.
The list of the Lombardini authorized dealers is reported in the “Service” booklet, supplied with each engine.
Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump),
filtering system, turbo-charged models, will require special written warranty agreements.
Within the above stated periods Lombardini Srl directly or through its authorized network will repair and/or replace
free of charge any own part or component that, upon examination by Lombardini or by an authorized Lombardini agent,
is found to be defective in conformity, workmanship or materials.
Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine
use or from both the total or partial impossibility of use, is excluded.
The repair or replacement of any component will not extend or renew the warranty period.

Lombardini warranty obligations here above described will be cancelled if:

- Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not
respected and altered.
- Lombardini engines are not used according to the instructions reported in the “Use and Maintenance” booklet
supplied with each engine.
- Any seal affixed to the engine by Lombardini has been tampered with or removed.
- Spare parts used are not original Lombardini.
- Feeding and injection systems are damaged by unauthorized or poor quality fuel types.
- Electrical system failure is due to components, connected to this system, which are not supplied or installed by
Lombardini.
- Engines have been disassembled, repaired or altered by any part other than an authorized Lombardini agent.

Following expiration of the above stated warranty periods and working hours, Lombardini will have no further
responsibility for warranty and will consider its here above mentioned obligations for warranty complete.
Any warranty request related to a non-conformity of the product must be addressed to the Lombardini Srl service
agents.

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 INDEX

This manual gives the main instructions on how to repair LOMBARDINI diesel engines LDW
1503 - 1603 - 2004 - 2004/T - 2204 - 2204/T, fluid cooling circuit, updates as of May 9.2006.

INDEX CHAPTER

I TROUBLE SHOOTING .................................................................................................................................... 8-9

II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS .............................................................. 10-11

III ENGINE TYPE ............................................................................................................................................ 12-13

IV TECHNICAL DATA .................................................................................................................................... 14-15

V CHARACTERISTICS .................................................................................................................................. 16-17

VI OVERALL DIMENSIONS ........................................................................................................................... 18-20

VII MAINTENANCE - PRESCRIBED LUBRICANT - COOLANT - REFILLING ........................................ 21-24

VIII DISASSEMBLY/REASSEMBLY .............................................................................................................. 25-50

Air filter restriction switch ..................................................................................................................................... 26

Assembling and tightening the cylinder head on engines with hydraulic tappets ......................................... 37 - 38
Camshaft bushing replacement ........................................................................................................................... 47
Camshaft end play ............................................................................................................................................... 50
Camshaft gear - Speed governor counter weights .............................................................................................. 45
Camshaft journals and bushings in model LDW 1503 ........................................................................................ 47
Camshaft journals and bushings in models LDW 2004-2004/T .......................................................................... 47
Camshaft removal ............................................................................................................................................... 46
Camshaft timing ................................................................................................................................................... 48
Center main bearings ........................................................................................................................................... 39
Check clearance between main bearings and journals ....................................................................................... 40
Checking camshaft bushing internal diameter .................................................................................................... 47
Checking main journals and crank pins .............................................................................................................. 42
Connecting rod ..................................................................................................................................................... 38
Connecting rod alignment .................................................................................................................................... 39
Connecting rod and piston pin ............................................................................................................................. 38
Connecting rod weights ........................................................................................................................................ 38
Connecting rod/piston assemblies ...................................................................................................................... 39
Cooling fan ........................................................................................................................................................... 27
Crankshaft end play ............................................................................................................................................. 41
Crankshaft for engines with dynamic equalizer (only four-cylinder engines) ..................................................... 43
Crankshaft front and rear oil seal ........................................................................................................................ 41
Crankshaft lubrication ducts ................................................................................................................................ 42
Crankshaft timing gear ......................................................................................................................................... 41
Cylinder head ....................................................................................................................................................... 29
Cylinder head gasket .......................................................................................................................................... 36
Cylinder head tightening for engines without hydraulic tappets .......................................................................... 37
Cylinder head tightening steps ............................................................................................................................. 37
Cylinder roughness .............................................................................................................................................. 34
Cylinders .............................................................................................................................................................. 34
Dimensions for injection pump delivery control yoke adjustement ..................................................................... 44
Driving pulley (2a P.T.O.) .................................................................................................................................... 27
Dry air cleaner ...................................................................................................................................................... 25
Dry air components .............................................................................................................................................. 26
Dynamic balancer (on request) - Adjustment of clearance between teeth D and ring gear A ........................... 43

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 INDEX
Exhaust manifold ................................................................................................................................................ 26
Flywheel ............................................................................................................................................................... 28
Frame with idling speed governor spring ............................................................................................................. 45
Front cover ........................................................................................................................................................... 43
GR 1 and GR 2 hydraulic pump 3rd p.t.o. ........................................................................................................... 50
Hydraulic diagram for feeding the tappets ........................................................................................................... 32
Hydraulic pump p.t.o. ........................................................................................................................................... 50
Hydraulic tappet components .............................................................................................................................. 32
Hydraulic tappet operation ................................................................................................................................... 33
Hydraulic tappet valve control ............................................................................................................................. 32
Idler gear and hub ................................................................................................................................................ 44
Injection pump follower ........................................................................................................................................ 33
Intake manifold .................................................................................................................................................... 26
Intake, exhaust and injecton cam height for model LDW 1503 ........................................................................... 48
Main bearing and connecting rod big bearing inside diameter ............................................................................ 42
Main bearing caps timing side - flywheel side ..................................................................................................... 40
Main journal and connecting rod big end journal diameter .................................................................................. 42
Oil seal in the valves guides, (intake and exhaust) ............................................................................................. 31
Oil-bath air cleaner .............................................................................................................................................. 25
Oil-bath air cleaner components .......................................................................................................................... 25
Piston - Refitting .................................................................................................................................................. 36
Piston ................................................................................................................................................................... 34
Piston availability ................................................................................................................................................. 34
Piston cooling sprayer .......................................................................................................................................... 39
Piston position and clearance .............................................................................................................................. 36
Piston rings - Clearance between grooves ......................................................................................................... 35
Piston rings - End gaps ........................................................................................................................................ 35
Piston rings - Fitting sequence ............................................................................................................................ 35
Piston weight ........................................................................................................................................................ 35
Precombustion chamber ...................................................................................................................................... 32
Rocker arm assemly ........................................................................................................................................... 29
Rocker arm cover for engines with recirculating vent ......................................................................................... 28
Rocker arm cover with vent into the air .............................................................................................................. 28
Speed governor ................................................................................................................................................... 44
Speed governor counter springs .......................................................................................................................... 45
Spring for extra fuel supply at starting ................................................................................................................. 46
Summary tables of the governor equipment according to the speed variation ................................................... 46
Tank ..................................................................................................................................................................... 27
Thrust bearing, oversizes .................................................................................................................................... 41
Thrust bearings .................................................................................................................................................... 40
Timing angles for checking puposes ................................................................................................................... 49
Timing belt operating angles ............................................................................................................................... 49
V belt .................................................................................................................................................................... 27
Valve guide insertion, after driving ...................................................................................................................... 31
Valve guides and cylinder head ........................................................................................................................... 30
Valve material ...................................................................................................................................................... 30
Valve recess and sealing surfaces ...................................................................................................................... 31
Valve removal ...................................................................................................................................................... 29
Valve seats and bore ........................................................................................................................................... 31
Valve spring - Check ............................................................................................................................................ 30
Valve spring - check under load .......................................................................................................................... 30
Valve timing check.............................................................................................................................................. 49
Valve timing without considering timing marks ................................................................................................... 48

IX TURBOCHARGER ...................................................................................................................................... 51

Checking actuator setting - “Waste gate” valve control rod stroke adjustment .................................................. 51
Turbocharger ........................................................................................................................................................ 51
Turbocharger components ................................................................................................................................... 51
Turbocharger Testing .......................................................................................................................................... 51

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 INDEX
X LUBRICATION SYSTEM ............................................................................................................................ 52-54

Oil filter cartridge ................................................................................................................................................. 53

Oil pressure adjusting valve ................................................................................................................................ 53
Oil pressure check ............................................................................................................................................... 54
Oil pressure curve for LDW 1503 - 1603 ........................................................................................................... 54
Oil pressure curve for LDW 2004 - 2204 ............................................................................................................ 54
Oil pressure curve for LDW 2004/T - 2204/T ..................................................................................................... 54
Oil pump .............................................................................................................................................................. 53
Oil pump rotor clearance ..................................................................................................................................... 53

XI COOLING SYSTEM .................................................................................................................................. 55- 56

Checking for cooling system leaks ...................................................................................................................... 56

Coolant circulating pump ..................................................................................................................................... 56
Expansion tank and cap ....................................................................................................................................... 56
Thermostat .......................................................................................................................................................... 56

XII FUEL SYSTEM ........................................................................................................................................ 57- 63

Checking injection pump delivery ....................................................................................................................... 61

Checking low pressure injection timing for engines with hydraulic tappets ........................................................ 62
Checking low pressure injection timing for engines with mechanical tappets ..................................................... 62
Electric fuel pump (24V) ...................................................................................................................................... 58
Fuel feeding pump ............................................................................................................................................... 57
Fuel feeding pump drive rod protrusion ............................................................................................................... 57
Fuel feeding/injection circuit ............................................................................................................................... 57
Fuel filter ............................................................................................................................................................. 57
How to reassemble injection pump components ................................................................................................ 59
How to reassemble injection pump feeding tubes ............................................................................................... 60
How to remove injection pump feeding tubes ..................................................................................................... 59
Injection pump .................................................................................................................................................... 58
Injection pump components ................................................................................................................................. 58
Injection pump control rod .................................................................................................................................. 59
njection pump delivery equalization .................................................................................................................... 60
Injection pump disassembly ................................................................................................................................. 58
njection pump non-return valve ........................................................................................................................... 59
Injection pump P. No. 6590-249 - Plunger and barrel assembly ........................................................................ 61
Injection timing correction by changing the pad thickness .................................................................................. 63
Injector setting ..................................................................................................................................................... 63
Injector (pin type) ................................................................................................................................................. 63
Instrument for equalizing injection pump delivery .............................................................................................. 60
Test data of injection pump ................................................................................................................................ 61

XIII ELECTRIC SYSTEM ............................................................................................................................... 64-73

Alternator type Iskra, AAK3139 14V 80A .......................................................................................................... 66

Alternator type Iskra, type AAK3570 28V 35A (for 24 V outfits) ........................................................................ 68
Alternator type Marelli AA 125 R 14V 45A ......................................................................................................... 64
Alternator type Marelli AA 125 R 14V 65A ......................................................................................................... 65
Characteristic curves for alternator type AAK3570 28V 35A (for 24 V outfits) .................................................. 68
Characteristic curves for alternator type Iskra, AAK3139 14V 80A ................................................................. 66
Characteristic curves for alternator type Marelli AA 125 R 14V 45A .................................................................. 64
Characteristic curves for alternator type Marelli AA 125 R 14V 65A .................................................................. 65
Characteristic curves for starting motor Iskra type AZE 4598 24V 3 kW ........................................................... 71
Characteristic curves for starting motor type Bosch EV 12V 2.2 kW ................................................................. 70
Characteristic voltage curve for regulator type AER 1528 ............................................................................ 66, 68
Characteristic voltage curve for regulator type RTT 119 AC ........................................................................ 64, 65
Connection diagram for preheating control unit ............................................................................................ 67, 69
Coolant high temperature lamp switch .......................................................................................................... 72, 73
Glow plug controller relay with coolant temperature sensor ................................................................................ 72
Key switch electrical layout ............................................................................................................................ 70, 71
Pre-heating glow plug .......................................................................................................................................... 72
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 INDEX

Spacer flange for starter motor ............................................................................................................................ 71

Starting Motor 12V ............................................................................................................................................... 70
Starting Motor 24V ............................................................................................................................................... 71
Temperature sensor ( Thermistor) ....................................................................................................................... 72
Thermistor for electric thermometer .................................................................................................................... 73
Thermistor for preheating water temperature – Thermal contact for water temperature indicator light ............. 73
Wiring diagram 24 V with alternator 35A ............................................................................................................. 69
Wiring diagram with alternator 45A / 65A ............................................................................................................ 67

XIV SETTINGS ............................................................................................................................................. 74 - 75

Application diagram for tampering system adjustment screw and torque gearing device for EPA-approved
engines ................................................................................................................................................................. 75
Fuel limiting device .............................................................................................................................................. 75
Fuel limiting device adjustment ........................................................................................................................... 75
Full speed setting in no-load conditions (standard) ............................................................................................. 74
Injection pump delivery limiting and torque adjusting device .............................................................................. 74
Settings ................................................................................................................................................................ 74
Standard injection pump delivery setting without torque dynamometer .............................................................. 74
Stop setting ......................................................................................................................................................... 75

XV STOCKAGE ................................................................................................................................................... 76

XVI TORQUE SPECIFICATIONS .................................................................................................................. 78- 80

XVII SPECIAL TOOLS ........................................................................................................................................ 81

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 I TROUBLE SHOOTING

THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:

1) - The engine rpms suddenly increase and decrease

2) - A sudden and unusual noise is heard
3) - The colour of the exhaust fumes suddenly darkens
4) - The oil pressure indicator light turns on while running

TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS

The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before
removing or replacing any part.

TROUBLE

No acceleration

Excessive oil
Non-uniform
Engine does

Engine starts

consumption
Inadequate
performance
Too low oil
White smoke
Black smoke
POSSIBLE CAUSE

High noise
Overheats
but stops

pressure
not start

speed

level
Obstructed fuel line

Fuel filter clogged

CIRCUIT
FUEL

Air or water leaks in fuel system

The tank cap vent hole is clogged

No fuel

Discharged battery
Cable connection uncertain or
incorrect
Faulty starting switch
ELECTRIC
SYSTEM

Faulty starting motor

Faulty glow plugs

Faulty glow plug control relay

Burnt fuse on preheating spark plugs

Clogged air filter

MAINTENANCE

Excessive idle operation

Incomplete run-in

Overloaded engine

Incorrect governor linkage adjustment

Governor spring broken or unhooked

Low idle speed

SETTINGS REPAIRS

Rings worn or sticking

Worn cylinder

Worn main con rod-rocker arm bearings

Badly sealed intake valve

Damaged cylinder head gasket

Defective timing system

Bent rods

Faulty hydraulic tappets

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 TROUBLE SHOOTING I

TROUBLE

Non-uniform
Engine does

No acceleration

Excessive oil
Engine starts

White smoke

Too low oil

consumption
Inadequate
performance
Black smoke
POSSIBLE CAUSE

High noise
Overheats
but stops

pressure
not start

speed

level
Damaged injector

Injection pump valve damaged

Injector not adjusted

Faulty fuel feeding pump

INJECTION

Hardened pump control rod

Broken or loose supplementary start-up
spring

Worn or damaged pumping element

Incorrect tuning of injection components

(delivery balancing advance)

Cracked or broken precombustion

chamber

Oil level too high

Oil level low

Oil pressure valve blocked or dirty

LUBRICATION

Worm oil pump

CIRCUIT

Oil sump suction line clogged

Faulty pressure gauge or pressure

switch
Blocked draining pipe

Faulty spray nozzles (Turbo engines

only).

Blocked draining pipe

Alternator fan belt loose or torn

Clogged radiator exchange surface

Insufficient coolant
COOLING

Fault fan, radiator or radiator plug

CIRCUIT

Faulty thermostatic valve

Blockage inside the radiator or the

coolant ducts

Coolant leaking from radiator, hoses,

the crankcase or from the water pump

Faulty or worn water pump

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 II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS

SAFETY AND WARNING DECALS

Failure to comply with the instructions Failure to comply with the

could result in damage to persons instructions could lead to technical
and property damage to the machine and/or
system

SAFETY INSTRUCTIONS

• Lombardini Engines are built to supply their performances in a safe and long-lasting way. To obtain these results,
it is essential for users to comply with the servicing instructions given in the relative manual along with the safety
recommendations listed below.
• The engine has been made according to a machine manufacturer's specifications and all actions required to meet
the essential safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit.
All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use
defined by Lombardini which thus declines all liability for any accidents deriving from such operations.
• The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning
engine operation in particular, along with the relative routine maintenance work.
• The user must read these instructions carefully and become familiar with the operations described. Failure to do this
could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity
of the machine.
• The engine may only be used or assembled on a machine by technicians who are adequately trained about its
operation and the deriving dangers. This condition is also essential when it comes to routine and, above all,
extraordinary maintenance operations which, in the latter case, must only be carried out by persons specifically
trained by Lombardini and who work in compliance with the existing documentation.
• Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal
of seals, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized
personnel shall relieve Lombardini from all and every liability for deriving accidents or for failure to comply with the
laws in merit.
• On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the
case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or
dangerous objects, also considering the movements made by the operator. Pull-starting with a free cord (thus
excluding self-winding starting only), is not permitted even in an emergency.
• Make sure that the machine is stable to prevent the risk of overturning.
• Become familiar with how to adjust the rotation speed and stop the engine.
• Never start the engine in a closed place or where there is insufficient ventilation. Combustion creates carbon
monoxide, an odourless and highly poisonous gas. Lengthy stays in places where the engine freely exhausts this gas
can lead to unconsciousness and death.
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 SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS II

• The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is
dust that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have
been certified for the machine.
• To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.
• Children and animals must be kept at a due distance from operating machines in order to prevent hazards
deriving from their operation.
• Fuel is inflammable. The tank must only be filled when the engine is off. Thoroughly dry any spilt fuel and move
the fuel container away along with any rags soaked in fuel or oil. Make sure that no soundproofing panels made
of porous material are soaked in fuel or oil. Make sure that the ground or floor on which the machine is standing
has not soaked up any fuel or oil.
• Fully tighten the tank plug each time after refuelling. Do not fill the tank right to the top but leave an adequate
space for the fuel to expand.
• Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place.
• Do not smoke or use naked flames when refuelling.
• The engine must be started in compliance with the specific instructions in the operation manual of the engine
and/or machine itself. Do not use auxiliary starting aids that were not installed on the original machine (e.g.
Startpilot’).
• Before starting, remove any tools that were used to service the engine and/or machine. Make sure that all guards
have been refitted.
• During operation, the surface of the engine can become dangerously hot. Avoid touching the exhaust system in
particular.
• Before proceeding with any operation on the engine, stop it and allow it to cool. Never 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 start operating when the engine is at a standstill. Only clean the coolant system when the engine is at a
standstill.
• When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to
safeguard the environment. The spongy filtering material in oil-cooled air filters must not be soaked in oil. The
reservoir of the separator pre-filter must not be filled with oil.
• The oil must be drained whilst the engine is hot (oil T ~ 80°C). Particular care is required to prevent burns. Do
not allow the oil to come into contact with the skin.
• Make sure that the drained oil, the oil filter and the oil it contains are disposed of in the correct way in order to
safeguard the environment.
• Pay attention to the temperature of the oil filter when the filter itself is replaced.
• Only check, top up and change the coolant fluid when the engine is off and cold. Take care to prevent fluids
containing nitrites from being mixed with others that do not contain these substances since "Nitrosamine",
dangerous for the health, can form. The coolant fluid is polluting and must therefore be disposed of in the correct
way to safeguard the environment.
• During operations that involve access to moving parts of the engine and/or removal of rotating guards,
disconnect and insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter
motor from being energized.
• Only check belt tension when the engine is off.
• In order to move the engine simultaneously use the eyebolts fitted for this purpose by Lombardini. These lifting points
are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer.

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III ENGINE TYPE

Engine type r.p.m

Serial number Customer code

(‘K’ No.)

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 ENGINE TYPE III

EC-directives certification references punched on the engine plate.

Name plate for EPA rules applied on rocker-arm cap.

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 IV TECHNICAL DATA

ENGINE TYPE CHD LDW 1503 LDW 2004 LDW 2004/T

Cylindres N. 3 4 4
Bore mm 88 88 88
Stroke mm 85 85 85
Displacement Cm³ 1551 2068 2068
Compression ratio 22:1 22:1 22:1
R.P.M. 3000 3000 3000
N 80/1269/CEE-ISO 1585-DIN 70020 26.4 35 44.1
Power KW NB ISO 3046 - 1 IFN - DIN 6270 24.6 33 42
NA ISO 3046 - 1 ICXN - DIN 6270 22.2 29.6 37.8
Max. torque * Nm @ RPM 95.4 128 165.7
@ 2100 @ 2100 @ 2000
Max. torque 3rd + 4th p.t.o. Nm @ RPM 39.2 39.2 39.2
@ 3000 @ 3000 @ 3000
Oil consumption ** Kg/h 0.024 0.032 0.04
Dry weight Kg 155 190 195
Combustion air volume at 3000 r.p.m. l/min 2326 3100 3900
Cooling air volume at 3000 r.p.m. m3/min 108.3 128 180
Max. permissible driving shaft axial load in both directions Kg 300 300 300
Max. 60 seconds 35° 35° 35°
Max inclination Lasting up to 30 seconds 25° 25° 25°
Permanent *** *** ***
Firing Order 1-3-2 1-3-4-2 1-3-4-2

* Referred to max. N power

** At NA power
*** Depending on the application

LDW 1503 LDW 2004/T

LDW 2004

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 TECHNICAL DATA IV

ENGINE TYPE CHD PLUS LDW 1603 LDW 2204 LDW 2204/T
Cylindres N. 3 4 4
Bore mm 88 88 88
Stroke mm 90.4 90,4 90,4
Displacement Cm³ 1649 2199 2199
Compression ratio 22:1 22:1 22:1
R.P.M. 3000 3000 3000
N 80/1269/CEE-ISO 1585-DIN 70020 30 38 49,2
Power KW NB ISO 3046 - 1 IFN - DIN 6270 27.6 34,5 47
NA ISO 3046 - 1 ICXN - DIN 6270 25,4 32 42,3
Max. torque * Nm @ RPM 113 144 190
@ 1600 @ 2200 @ 1800
Max. torque 3rd + 4th p.t.o. Nm @ RPM 39.2 39.2 39.2
@ 3000 @ 3000 @ 3000
Oil consumption ** kg/h 0.019 0.025 0.04
Dry weight kg 156 192 197
Combustion air volume at 3000 r.p.m. l/min 2475 3300 4200
Cooling air volume at 3000 r.p.m. m3/min 96 128 180
Max. permissible driving shaft axial load in both directions kg 300 300 300
Max. 60 seconds 35° 35° 35°
Max inclination Lasting up to 30 seconds 25° 25° 25°
Permanent *** *** ***
Firing Order 1-3-2 1-3-4-2 1-3-4-2

* Referred to max. N power

** At NA power
*** Depending on the application

LDW 1603 LDW 2204/T

LDW 2204

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CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES

LDW 1503 LDW 2004

LDW 2004/T

N (80/1269/CEE - ISO 1585) AUTOMOTIVE RATING: intermittent operation with variable speed and variable load.
NB (ISO 3046 - 1 IFN) RATING WITH NO OVERLOAD CAPABILITY: Continuous light duty operation with constand speed and variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOUS RATING WITH OVERLOAD CAPABILITY: continuous heavy duty with constant speed and constant load.
MN Torque curve (N curve) - MB (NB curve) - MA (NA curve).
C: Specific fuel consumption curve (NB curve)
Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m altitude and by 2% every 5°C above 25°C.
Engine power can be influenced by the type of coupling used with the cooling fan.

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 CHARACTERISTICS V

CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES

LDW 1603 LDW 2204

LDW 2204/T

N (80/1269/CEE - ISO 1585) AUTOMOTIVE RATING: intermittent operation with variable speed and variable load.
NB (ISO 3046 - 1 IFN) RATING WITH NO OVERLOAD CAPABILITY: Continuous light duty operation with constand speed and variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOUS RATING WITH OVERLOAD CAPABILITY: continuous heavy duty with constant speed and constant load.
MN Torque curve (N curve) - MB (NB curve) - MA (NA curve).
C: Specific fuel consumption curve (NB curve)
Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m altitude and by 2% every 5°C above 25°C.
Engine power can be influenced by the type of coupling used with the cooling fan.

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OVERALL DIMENSIONS LDW 1503-1603

Note : Dimensions shown in mm

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OVERALL DIMENSIONS LDW 2004 - 2204

Note : Dimensions shown in mm

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OVERALL DIMENSIONS LDW 2004/T - 2204/T

Note : Dimensions shown in mm

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 MAINTENANCE - PRESCRIBED LUBRICANT - COOLANT - REFILLING VII

Failure to carry out the operations described in the table may lead to technical damage to the machine
and/or system

EXTRAORDINARY MAINTENANCE

AFTER THE FIRST 50 WORKING Engine oilreplacement. Oil filter replacement.

HOURS

ORDINARY MAINTENANCE
FREQUENCY x HOURS
OPERATION DESCRIPTION
1234567
1234567
1234567
10 200 1234567
300
1234567 600 1200 5000 10000
LEVEL ENGINE LUBRICANT
COOLANT LEVEL
DRY AIR CLEANER (***)
OIL BATH AIR CLEANER
RADIATOR EXCHANGE SURFACE 1234567
1234567
BELT FAN/ALTERNATOR STRETCH (*) 1234567
1234567
1234567
CHECK
1234567
1234567
SLEEVES (*)
SETTING AND INJECTORS CLEANING (**)
FUEL PIPES 1234567
1234567
RUBBER INTAKE HOSE (AIR FILTER – 1234567
1234567
INTAKE MANIFOLD) 1234567
INTERIOR RADIATOR CLEANING
ALTERNATOR AND STARTER MOTOR
12345678
12345678
ENGINE LUBRICANT (*) 12345678
OIL FILTER (*)
12345678
12345678
12345678
12345678
FUEL FILTER (*)
ALTERNATOR FAN BELT (**)
COOLANT LEVEL (**)
PARTIAL OVERHAUL
TOTAL OVERHAUL
REPLACEMENT FUEL PIPES
RUBBER INTAKE HOSE (AIR FILTER – (**)
INTAKE MANIFOLD) (**)
SLEEVES (**)
DRY AIR CLEANER EXTERNAL (***)
AFTER 6 CHECKS WITH CLEANING
CARTRIDGE
DRY AIR CLEANER INTERNAL (***)
AFTER 3 CHECKS WITH CLEANING
CARTRIDGE

200 STANDARD OIL SUMP (*) - In case of low use: every year.
(**) - In case of low use: every 2 years.
123456
123456 (***) - The period of time that must elapse before cleaning or replacing the filter element depends
123456
123456
300 ENHANCED OIL SUMP on the environment in which the engine operates. The air filter must be cleaned and replaced
more frequently in very dusty conditions.

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LUBRICANT

SAE Classification

In the SAE classification, oils differ on the basis of their

viscosity, and no other qualitative characteristic is taken
into account.
The first number refers to the viscosity when the engine is
cold (symbol W = winter), while the second considers
viscosity with the engine at régime.
The criteria for choosing must consider, during winter, the
lowest outside temperature to which the engine will be
subject and the highest functioning temperature during
summer.
Single-degree oils are normally used when the running
temperature varies scarcely.
Multi-degree oil is less sensitive to temperature
changes.

* Mineral base
SAE- Grade ** Semi-synthetic base
*** Synthetic base

International specifications
They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing
and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.
A.P.I : ( American Petroleum Institute )
MIL : Engine oil U.S. military specifications released for logistic reasons
ACEA : European Automobile Manufacturers Association
Tables shown on page 53 are of useful reference when buying a kind of oil.
Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different brands
and choosing the kind with the right characteristics.
Usually a specification showing a following letter or number is preferable to one with a preceding letter or number.
An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.

ACEA REGULATIONS - ACEA SEQUENCES

PETROL HEAVY DUTY DIESEL ENGINES

12345678901
12345678901
A1 =Low-viscosity, for frictions reduction E1 =12345678901
OBSOLETE
A2 =Standard
A3 =High performances E2 = Standard
E3 = Heavy conditions (Euro 1 - Euro 2 engines )
LIGHT DUTY DIESEL ENGINES E4 = Heavy conditions (Euro 1 - Euro 2 - Euro 3 engines )
E5 =High performances in heavy conditions (Euro 1 - Euro 2 -
B1 =Low-viscosity, for frictions reduction Euro 3 engines )
B2 =Standard
B3 =High performances (indirect injection)
B4 =High quality (direct injection)
API / MIL SEQUENCES

DIESEL PETROL
123456789012345678
12345678901234567890123456789
123456789012345678
12345678901234567890123456789
API CH-4 CG-4 CF-4 CF-2 123456789012345678
CE CD CC CB CA12345678901234567890123456789
CF 123456789012345678
12345678901234567890123456789
SA SB SC SD SE SF SG SH SJ SL

L - 2104 D / E
MIL L - 46152 B / C / D / E
12345678
12345678
12345678
OBSOLETE
CURRENT

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AGIP SINT 2000 API CF - SH

specifications
PRESCRIBED LUBRICANT TURBODIESEL ACEA B3-B4
10W40 MIL - L-2104 C/46152 D

In the countries where AGIP products are not available, use oil API CF/SH for Diesel engines or oil corresponding to the
military specification MIL-L-2104 C/46152 D.
For a temperature of -10°C an oil with a 5W40 viscosity is recommended. For a temperature of -15°C an oil with a 0W30 viscosity
is recommended.

CHD ENGINES OIL CAPACITY LDW 2004 - 2004/T

LDW 1503-1603
2204 - 2204/T

OIL VOLUME AT MAX LEVEL Sheet STD oil sump. 4,4 6,4 - 5,3*
Litres
(OIL FILTER INCLUDED)
ENHANCED aluminium oil sump. 7,1 9,5
OIL VOLUME AT MAX LEVEL Sheet STD oil sump. 3,8 5,7 - 4,5*
(WITHOUT OIL FILTER) Litres
ENHANCED aluminium oil sump. 6,4 8,8

* With dynamic balancer

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 . Use the chart
when chosing your engine oil.

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.

COOLANT

The fluid coolant circuit is pressurized. Inspections must only be made when the engine has cooled and even in this
case, the radiator or expansion chamber plug must be unscrewed with the utmost caution.
If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the engine is at
a standstill.
Coolant fluid is polluting, it must therefore be disposed of in the correct way. Do not litter.

The use of anti-freeze protection liquid (e.g. AGIP ANTIFREEZE) is recommended mixed with water, preferably decalcified.
The freezing point of the cooling mixture depends on the product concentration in water:
at -15°C (30%), at -20°C (35%), at -25°C (40%), at -30°C (45%), at -35°C (50%).
It is therefore recommended to use a 50% diluted mixture which guarantees a certain degree of overall protection. As well as
lowering the freezing point, the permanent liquid also raises the boiling point.

Coolant refueling

LDW LDW LDW

ENGINE TYPE 2004/T - 2204/T
1503 - 1603 2004 - 2204

CAPACITY (Litres)
Without radiator 4,00 5,50 5,70

For information concerning the capacity of Lombardini radiators, please contact Lombardini directly.
The total volume for refilling the cooling liquid varies according to the type of engine and radiator.

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FUEL SPECIFICATIONS

To achieve optimum performance of the engine, use good quality fuel with certain characteristics:

Cetane number (minimum 51): indicates the ignition quality. A fuel with a low cetane number may cause problems when starting
from cold and have a negative effect on combustion.
Viscosity (2.0/4.5 centistokes at 40°C): this is the resistance to flow and performance may decline if not within the limits.
Density (0.835/0.855 Kg/litre): a low density reduces the power of the engine, and density that is too high increases performance
and opacity of the exhaust
Distillation (85% at 350°): this is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light
hydrocarbons may have a negative effect on combustion.
Sulphur (maximum 0.05% of the weight): high sulphur content may cause engine wear. In those countries where diesel has a high
sulphur content, it is advisable to lubricate the engine with a high alkaline oil or alternatively to
replace the lubricating oil recommended by the manufacturer more frequently.

PRESCRIBED LUBRICANT

Fuel with low sulphur content API CF4 - CG4

Fuel with high sulphur content API CF - CD - CE

The countries in which diesel normally has a low sulphur content are: Europe, North America and Australia.

FUELS FOR LOW TEMPERATURES

It is possible to run the engine at temperatures below 0°C using special winter fuels. These fuels reduce the formation of paraffin
in diesel at low temperatures. If paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.

Fuel can be: - Summer up to 0°C

- Winter up to -10°C
- Alpine up to -20°C
- Arctic up to -30°C

For all fuel types, the cetane number cannot be lower than 51.

AVIATION KEROSENE AND RME FUELS (BIOFUELS)

The use of these fuels is allowed. However they may condition the performance of the engine. The only Aviation fuels that may
be used in this engine are: JP5, JP4, JP8 and JET-A if 5% oil is added. For more information on Aviation fuels and Biofuels (RME,
RSME) please contact the Lombardini applications department.

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 DISASSEMBLY/REASSEMBLY VIII
DISASSEMBLY AND REASSEMBLY

During repair operations, when using compressed Besides disassembly and reassembly operations this chapter also
air, wear eye protection. includes checking and setting specifications, dimensions, repair and
operating instructions. Always use original LOMBARDINI spare parts
for repair operations.

Oil-bath air cleaner

Never clean the filtering element 6 using solvents with a

highly flash point. This could cause an explosion !

During repair operations, when using compressed air, wear eye

protection.

Check gaskets and replace if necessary.

Check that flange welds are free of porosity or defective spots.
Carefully clean bowl and filtering element with Diesel fuel and dry
with compressed air.
Top up engine oil to the mark (see below).
1 When refitting tighten nuts to 25 Nm
See page 21 for periodic cleaning and oil replacement.

Oil-bath air cleaner components

1 Bowl
2 Outer seal ring
3 Lower filtering element
4 Inner seal ring
5 Gasket
6 Cover
7 Cap clamp
8 Cap
9 Centrifugal pre-filter
10 Centrifugal pre-filter clamp
11 Oil level mark
2 12 Upper filtering element (polyurethan sponge)

Note: Centrifugal pre-filter 9 is fitted upon request.

Dry air cleaner

Never clean the filtering element 6 using solvents with a low

flash point. This could cause an explosion !

A = Fitting to accomodate clogging indicator

See page 21 for periodic dry air cleaner check and replacement and
the rubber intake hose (air filter - intake manifold).

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Dry air components

1 Main cartridge
2 Safety cartridge
3 Axial cover
4 Vacuator valve
5 Cap complete with clamp

Scavenging valve 4 must be positioned as in figure 4.

The cartridge can be cleaned by blowing compressed air breadthways
outside and inside the cartridge, at a pressure not greater than 5
atmospheres, or in necessity case by knocking the front of the cartridge
several times against a flat surface.
Use a lamp to check that the filter element is not damaged or inspect it
4
against the light while slanted. In case of doubt, install a new cartridge.

Air filter restriction switch

Components:

1 Reset button
2 Connection

Note: There are two types: one for an aspirated engine and one for
a supercharged engine.
Setting for aspirated engine(LDW 1503 - 1603 - 2004 -2204)
= 600/650 mm column of water.
Setting for supercharged engine (LDW 2004/T - 2204/T) =
370/420 mm column of water.
5

Intake manifold

The sealing surface should be clean, smooth and free of any strains
and scoring.
When reassembly replace gasket A.
Tighten the fastening screws to 25 Nm.

Exhaust manifold

Allow the exhaust manifold to cool before demounting it in

order to prevent scorching and burns.

Verify that the seal surfaces are free of distortions and scratches and
that the manifold is not broken in any way.
When refitting, replace gaskets B.
Tighten nuts to 25 Nm.

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 DISASSEMBLY/REASSEMBLY VIII
"V" belt

Check the belt tension only when the engine is not running

Tension adjustment:
Loosen alternator fixing bolts C.
Stretch belt so that a 100 Nm load located half-way between the two
pulleys causes a 10÷15 mm flexure.
Pull strongly alternator externally and tighten fixing bolts C.
The final torque must be 40 Nm.
If you use the belt tension gauge type DENSO BTG-2, the correct value
of tension must be from 20 to 25 kg.
8

Cooling fan

Before disassembling the cooling fan, isolate the positive

battery cable to prevent accidental short-circuiting and,
consequently, activation of the starter motor

Take off the fan and check that all blades are not damaged; if any
are damaged, replace the entire fan.
Depending on the type of application the cooling fans can be suction or
blower fans and can differ in diameter..

Driving pulley (2a P.T.O.)

The maximum torque that can be drawn from the second power take-
off must be at maximum 70 Nm.
The driving pulley drives the alternator and the water pump and
consequently the cooling fan.
Bolt D can be loosened by turning clockwise. When refitting
lubricate the bolt with Molyslip and tighten it at 360 Nm.

10

Tank

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
vapours from being inhaled. Dispose of fuel in the correct way
and do not litter as it is highly polluting.

Remove fuel line and loosen clamp screws.

Completely empty the tank and check that no impurities are found
inside.
11 Check that cap breather hole is not clogged.

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Flywheel

During the demounting phases, pay particular attention to

prevent the flywheel from dropping as this could seriously
injure the operator.
Wear protective goggles when removing the flywheel ring.
Remove the bolts which attach the flywheel to the crankshaft; when refitting
tighten to 140 Nm after checking that the locating pin is in its seat.
To remove the starter ring gear, it is recommended to cut it into
several portions with an iron hacksaw and then use a chisel.
To remove the starter rim, it is advisable to cut it into several parts
with a hacksaw and to then use a chisel. To replace, slowly heat for
15-20 minutes to a temperature of 300°C max.
Fit the rim into the flywheel housing. make sure that it rests evenly
12
against the support of the housing itself. Allow it to slowly cool.

Rocker arm cover with vent into the air

Components:

1 - Decanting device
2 - Oil fill cap
3 - Gasket

Inside the decanting device 1 there is a small metal skein that separates
the oil from the bled vapours; before reassembling it, clean it and verify
its intactness.
Every time the rocker arm cap is removed it is advisable to replace the
gasket 3.
13

Rocker arm cover for engines with recirculating vent

Components:

1 - Recirculating vent system

2 - Oil refilling plug
3 - Rubber hose for the passage of the oil vapours
4 - Intake manifold

In the rocker arm cap we find most of the recirculating vent system 1.
This device is used to separate the oil vapours and to convey them, via
a rubber hose 3, into the intake manifold 4.
The vapours are then recirculated inside the engine and not released
into the air as they can be polluting.
14

A clogged up air filter and a consequent increase in suction vacuum

could cause the oil to be sucked into the combustion chamber and the
engine over-revving.
This is in any case avoided as the diaphragm valve 7 by winning the
resistance of spring 6 - properly calibrated - closes duct 5 and stops the
oil from reaching manifold 4 via hose 3.

15

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 DISASSEMBLY/REASSEMBLY VIII
Rocker arm assemly

Loosen the screws which fasten the assembly to the head; when
refitting tighten to 50 Nm.
Inside the rocker arm pin flows the oil that lubricates the rocker arms and
feeds the hydraulic tappets.
To clean the rocker-arm pin inside, remove the two tightening screws C
at the ends (fig. 17).
When refitting apply a drop of Loctite 270 onto the threads.

16

To check the pin and the rocker-arm pin bearings for wear compare the
measured values with the parameters in the table below.

Table of pin-rocker arm dimensions

Dimensions Clearance Limit value

Ref.
(mm) (mm) (mm)

Ø A* 14,032 ÷ 14,050
Ø A -Ø B =
0.014
ØB 13,989 ÷ 14,000 0,043 ÷ 0,050

17
* With bushing fitted to the rocker arm and reamed.

Cylinder head

Do not demount when hot or the part could become

deformed.

Do not remove when hot to avoid deformation.

Check cylinder head plane using a metal straight edge and thickness
gauge; if warpage exceeds 0.10 mm, level off by removing a
maximum 0.20 mm.
See fig.56- 59 for cylinder head tightening.

18

Valve removal

Components:

1 - Valve
2 - Lower spring seat
3 - Valve guide seal (for intake only)
4 - Spring
5 - Spring cap
6 - Cotters

To remove the cotters firmly press down as shown in the figure 20.

19 20

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Valve spring - Check

Check the overall state of the valve springs. Replace if damaged or if

they have lost their original elasticity.
First of all, use a gauge to check that the free length matches the
measurements given below.

A = 52 mm

21

Valve spring - check under load

Verify (with a dynamometer) that the length under load matches the
nominal length. If it is shorter than that quoted in figure 22, replace the
spring.

22

Valve material

Ref. Dimensions

A 6,985 ÷ 7,00 mm

B 35,30 ÷ 35,50 mm

C 40,30 ÷ 40,50 mm

α 45°30' ÷ 45°45'
VALVOLA DI SCARICO VALVOLA DI ASPIRAZIONE
α1 60°30' ÷ 60°45'
23

Valve guides and cylinder head

Intake and exhaust valve guides are both made of gray cast iron with
pearlitic and phosphoric matirx.

Ref. Dimensions (mm)

D 38,00

E 12,020 ÷ 12,038

F 12,048 ÷ 12,058

24 Valve guides with outside diameter F increased by 0.5 mm are

available; in such case valve guide bore E should also be increased
by 0.5

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 DISASSEMBLY/REASSEMBLY VIII
Valve guide insertion, after driving

Press guides considering the N distance from the head plane X.

Dimensions Ref. Clearance Limit value

Ref. (mm)
(mm) (mm)
X 7,020 ÷ 7,035 Y-A
0,020 ÷ 0,050 0,100
Y 7,020 ÷ 7,035 X-A
L 36,8 ÷ 37,2

A 6,985 ÷ 7,00

25

Oil seal in the valves guides, (intake and exhaust)

To prevent the seal 1 warping when mountig the valve guide 3 put it
into the tool 2 part no. 7107-1460-047 and proceed as shown in the
figure 27, making sure the seal 1 reaches its stop.

26 27

Valve seats and bore

Ref. Dimensions

A 41,500 ÷ 41,520 mm

B 41,575 ÷ 41,590 mm

C 36,500 ÷ 36,520 mm

D 36,575 ÷ 36,590

α 44° 53' ÷ 45°

28 α1 59° 53' ÷ 60°

Valve recess and sealing surfaces

Ss* = Sealing surface width on exhaust side

Sa* = Sealing surface width on intake side
H = Valve recess with reference to the head plane

Dimensions Limit value

Ref. (mm)
(mm)

S s* 1,27 ÷ 1,55
2,00
S a* 1,20 ÷ 1,60

29 30 H 0,75 ÷ 1,00 1,30

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Precombustion chamber

The precombustion chamber can be extracted from the head banging

with a punch into the hole from the injector housing. This procedure
implies irreversible damages to the precombustion chamber which will
have to be replaced. In the assembly stage line up the dowel 1 with the
reference notch 2 located in the head. Driving must be carried out evenly
The clearance allowance between the precombustion chamber and
its bore on the cylinder head is equal to 0.05 mm. Using a depth
gauge check that the precombustion chamber plane protrusion does
not exceed 0.04 and does not receed over 0.02 mm from the head
plane level.
The precombustion chamber plugs of the CHD PLUS series engines
31 32 have a different internal volume from the CHD series; therefore, they are
not interchangeable

Hydraulic tappet valve control

Dimensions Clearance Limit value

Ref. (mm)
(mm) (mm)

A 23,000 ÷ 23,021
0,040 ÷ 0,046 0,10
B 22,960 ÷ 22,975

Nota: If tappet is worn out along diameter B replace it. No oversize

tappets are available. If tappet/camshaft surface is worn -
replace

33 34

Hydraulic diagram for feeding the tappets

1 Rocker-arm pin
2 Rocker arm
3 Push rod
4 Oil drainage
5 Hydraulic tappet

35

Hydraulic tappet components:

a) Tappet body
b) Plunger
c) Non-return valve
d) Spring
e) Push rod
f) Low-pressure chamber
g) High-pressure chamber
The hydraulic tappet is a device that enables elimination of
clearance between timing system components and provides the
following advantages:
- Reduces noise levels during operation.
- Reduces wear of the timing system components, thanks
36 to there being no collisions at the opening with consequent
breaking of the oil film.
- No maintenance.

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 DISASSEMBLY/REASSEMBLY VIII
Hydraulic tappet operation

The operating principle of the hydraulic tappet is based on the

incompressibility of the liquids and on controlled leakage.
Through push rod 1, the pressurised oil gets into the tappet in chamber
A (low-pressure chamber), maintaining a constant flow of oil in the
above chamber as well as in the high-pressure chamber B.
The oil can only enter chamber B through the non-return valve 2 and
leave through the clearance between the plunger 3 and the tappet body
4 (controlled leakage).
Chamber B is refilled when the tappet is on the bottom of the cam base
and spring 5 keeps plunger 3 pressed, thus eliminating the clearance in
the entire valve-rocker arm-push rod-tappet-cam system.
37 The tappet body moves away from the plunger creating a slight vacuum
in chamber B and causing the valve 2 to open, thus allowing the oil in
chamber A to flow into chamber B, re-establishing the quantity of oil
required for optimal running conditions.

Difficult operating conditions:

For correct functioning of the hydraulic tappets the pressure chamber of plunger 3 must always be filled with oil.
However, this is not possible in some conditions in that, when the engine is not running, oil leakages may cause partial
emptying of the tappets. This situation will cause excessive clearance which will make itself apparent through an unusual
ticking sound that is not to be confused with the normal ticking of the injectors.

1- Starting from cold: the engine has not been used for some time and oil may have leaked out of the pressure
chamber of the tappets. Moreover, lubricant flows with greater difficulty at low temperatures, and hence several
seconds may go by before the tappets are once again supplied with oil.

2- Engine very hot: at minimum speed, the oil pressure is low and tiny air bubbles may form inside it (more than 5%
of its volume). This causes the lubricant to become compressible and the tappet is squeezed slightly creating
clearance and, thus making a noise.

3- Starting and stopping the engine repeatedly (very rare): in this situation the tappets may empty temporarily.

In all three cases the ticking should not last too long. If this is not the case, the problem is definitely due to a manufacturing fault,
wear and tear or dirt, which can be drawn in by the oil and get between the non-return valve and its seat inside the plunger, thus
compromising the functioning of the tappets. In this case the hydraulic tappets must be replaced.

Injection pump follower

Introduce the follower into its housing and manually turn screw 3
until it matches with notch 2.
Before locking screw 3 use your finger to check that the follower is
allowed to move upwards freely.
Space 1 should be introduced into the pushrod with the flat surface
facing upwards

Note: The screws 3a can be fitted without distinction in each

cylinder. Screw 3b however, which is shorter than the others,
has to be fitted on the timing side of the cylinder (inside the
stop lever cover).
38 39

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Cylinders

Reset dial gauge with a calibrated ring. Check diameter size D at 1, 2

and 3; repeat the same operation at the same places after turning the
dial gauge by 90°. Check for wear in the X area where piston rings
are located.

Limit value
D (m m ) (mm)
88,00÷88,01 88,100

To check clearance with the matching piston measure the diameter

40 41 size at Z along the axis which runs at right angles to the driving shaft.

Cylinder roughness

Do not manually hone the cylinder bore surfaces with emery

cloth or other means.

The inclination of the cross-hatched marks left by machining should

range between 115°-140°; they should be uniform and clearly visible
in both directions.
Average roughness should range between 0.5 and 1 mm .
The cylinder surface which comes into contact with the piston rings
should be machine honed with the plateau system.

42

Piston

Remove circlips and piston pin.

Remove piston rings and clean grooves.
Measure diameter Q at the A distance from the bottom of the skirt (A
= 12 mm)
In case of diameter wear exceeding 0.05 mm of the minimum given
value replace piston and rings.

Nota : The oversizes are 0.50 and 1.00 mm. The LDW TURBO
piston differs from that of the NATURALLY ASPIRATED
LDW in its cooling sprayer passage niche and an insert in
the slot of the first ring.
43 44

Piston availability

The pistons oversized by 0.5 and 1.0 mm have the uprating reference
on the crown, fig. 45-46.

Class Ø Cylinder Ø Piston Clearance

A 88.00 ÷ 88.01 87.960 ÷ 87.967 0.033÷0.050

45 46

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Piston weight

Weigh the pistons when replacing them in order to avoid unbalance.

The difference in weight should not exceed 6 g.

47

Piston rings - End gaps

Place piston rings into the cylinder and measure end gap A.

1st ring A = 0,30 ÷ 0,50 mm

2nd ring A = 0,30 ÷ 0,50 mm

3rd ring A = 0,20 ÷ 0,50 mm

48

Piston rings - Clearance between grooves

Ref. NATURALLY LDW TURBO

ASPIRATED LDW
A 0,07 ÷ 0,12 mm A*
B 0,02 ÷ 0,08 mm 0,06 ÷ 0,95 mm
C 0,05 ÷ 0,08 mm 0,05 ÷ 0,08 mm

49 50

Piston rings - Fitting sequence

A* = 1st chrome plated compression ring *

B = 2nd tapered compression ring *
C = 3rd spiral spring oil scraper ring

* The first ring in the LDW TURBO engine is different from the
NATURALLY ASPIRATED version, it has a trapezoidal cross-section.

Assemble the segments with the TOP marking facing the piston crown.

51

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Piston - Refitting

Connect piston to connecting rod after lubricating piston pin and

introducing it by exerting pressure with your thumb.
Position the two piston pin circlips and check that they are well inside
their seats. Using a ring compressor introduce the piston into the
cylinder with combustion chamber facing the injection pump side.

52 53

Piston position and clearance

To obtain a clearance of 0.67÷0.90 mm measure protrusion A of all

pistons from the cylinder plane and consider the A value of the most
protruding piston.
Perform this measurement along the engine axis.

54

Cylinder head gasket

Remove the head gasket from its protective wrapping only

when ready for fitting.

At B the gasket shows small semi-circular notches indicating

thickness.
Choose the proper head gasket considering that for each value of A
(maximum projection of the piston from the cylinder surface) there is a
matching gasket among the three available (with no notch, one notch or
two notches) to achieve a clearance volume between 0.66 and 0.90 mm.
In the LDW 1503 / 1603 engines the head gasket is made of fibre, while
in the LDW 2004 / 2204-T / 2204 / 2204-T engines the head gasket is
55 metal.

No.of notches Resulting Note: The notches shown above protrude from
Engine type A (mm)
clearance (mm) the cylinder head plane; you can thus determine
the gasket thickness before taking down the
LDW 1503/1603 0,68 ÷ 0,083 0,67 ÷ 0,82 head.
LDW 2004 / 2004-T
2204 / 2204-T 0,68 ÷ 0,081 0,72 ÷ 0,85

LDW 1503/1603
0,83 ÷ 0,98 0,67 ÷ 0,82
LDW 2004 / 2004-T
0,81 ÷ 0,94 0,69 ÷ 0,82
2204 / 2204-T

LDW 1503/1603
0,98 ÷ 1,10 0,67 ÷ 0,82
LDW 2004 / 2004-T
0,94 ÷ 1,07 0,66 ÷ 0,79
2204 / 2204-T

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Cylinder head tightening for engines without hydraulic tappets

Use a torque wrench (fitted with tool for angular tightening).

It is recommended to replace the screws whenever the head is
disassembled.

The cylinder head must never be retightened.

It is advisable to lubricate the lower part of the screws with
anti-seize of the type MOLYSLIP AS COMPOUND 40.

56

Cylinder head tightening steps

Following the number sequence shown in the figure 57 bolts should

LDW 1503 be tightened in four susequent steps with the following torque
1603 values:
1st step = 40 Nm
2nd step = 70 Nm
3rd step = 100 Nm
4th steps = For bolts 10 R: Rotate wrench by 180° (in two steps
LDW 2004 90°+90°)
2004/T For bolts 12 R (present only in the TURBO engines):
2204 perform a rotation of the key of 270° (in three steps,
2204/T 90° + 90°+ 90°)
57

Assembling and tightening the cylinder head on engines with

hydraulic tappets

Before re-assembling the cylinder head the tappets must be

removed from their housing and released.
This operation must be carried out using a pin 1.
Insert pin 1 inside the tappet and open the non-return valve.
The excess oil is released by turning the tappet upside down.
Rotate the crankshaft so as to position the pistons at half stroke for
three-cylinder engines.
For four-cylinder engines, place the piston of cylinder number one at
150° after the top dead centre (in crossover stage).
Fit the head, insert the fastening screws and tighten them in the order
58 shown in figure 57 and to their respective torques (see “Cylinder Head
Tightening Stage).
Reassemble the complete pin inserting the seats of the rocker-arms on
their respective rods and screw up the fastening screws of the supports
by hand.
To avoid bending the push rods or damaging the tappets, the fastening
screws of the rocker-arm pin supports must be tightened gradually
before reaching the final torque.
This procedure will give time for the excess oil in the tappets to drain
away.
Each time you start to tighten up the fastening screws of the supports,
you can use the upper spring support cup of the valve spring as an
indicator to know how far to screw them up.
The cup must never be compressed so much that it touches the valve
stem oil sealing ring fitted on the guide.

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Tightening must be carried out as shown in figure 59.
Once the final torque 50 Nm is reached, wait ten minutes (with
environmental temperatures that are not harsh) before manually rotating
LDW 1503
the engine to verify that the pistons do not collide with the valves.
1603
At first start-up the engine may run irregularly until all the air contained
in the tappets has been drained.

LDW 2004
2004/T
2204
2204/T
59

Connecting rod

When remounting the big-end bearings, remember to

thoroughly clean the parts and generously lubricate them to
prevent seizure when the engine is started up for the first time

Remove oil pan and oil pump suction pipe.

Dsconnect the connecting rod from the engine shaft and perform the
following checks:
When refitting both centering notches A and B should be located on
the same side.
Tghten the connecting rod big end bolts to 70 Nm.
60 61

Connecting rod weights

WeighConnecting rod, piston and piston pin can also be weighed in a

preassembled state but the difference in weigt should not exceed 14
g in order to avoid unbalance.

62 63

LDW LDW LDW Connecting rod and piston pin

1503-2004-2004/T 1603-2204-2204/T 2004/T-2204/T The connecting rod big end shell bearings
Dimensions are supplied in either standard or with this
Ref.
(mm) value decreased by 0.25 and 0.50 mm
A 144,98 ÷ 145,02 respectively.
The fastening screws must be tightened
LDW F 147,98 ÷ 148,02 by hand until the beginning of the
1503-1603 tightening stage and then pre-tightened to
2004-2204 B* 28,02 ÷ 28,03
10-15 Nm.
C** 53,689 ÷ 53,708 Final tightening is to 70 Nm.

D 27,995 ÷ 28,000
Clearance Limit value
Ref.
E 62,1 ÷ 62,3 (mm) (mm)
64
G 65,6 ÷ 65,8 B-D 0,02 ÷ 0,03 0,06
* With driven and bored bearing.
** With cap fitted and screws tightened to a torque of 70 Nm.

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 DISASSEMBLY/REASSEMBLY VIII
Connecting rod alignment

Use a surface plate and a dial gauge as shown in the figure 65.
Check the alignment of the axes using the wrist pin of the piston;
deviation A = 0.02 mm; limit = 0.05 mm
Moderate warpage may be corrected by gradually working with a
press.

65

Piston cooling sprayer

This is assembled on turbo engines LDW 2004/T -2204/T.

Blow on it with compressed air and check that there are no
impurities inside.
Reassemble it back into place making sure you maintain axis
alignment A of the spray with respect to axis B shown in the fugure
67.
Anyway the correct position is ensured by the fixing screw.
Ref. Dimensions

α 3°

α
α11 28°
66 67
D 28 m m

Connecting rod/piston assemblies

The three connecting rod/piston assemblies should be fitted back

into their original cylinders. Mark them with references to avoid
mistake.

Note: The custom at LOMBARDINI is to consider the cylinder on the

flywheel side as the first cylinder.

68 69

Center main bearings

The main bearing caps and the crankcase have reference holes marked
on them (one, two or three).
In the assembly stage make sure that the number of holes on the
bearings matches those on the crankcase and that they are on the same
side.
The main bearing, the crankshaft bearing and the thrust washers have
been unified as from engine serial number 7306062 for LDW1503, from
serial number 7303552 for LDW 2004 and from serial number 7305782
for LDW 2004/T.
Pre- and post-modification single parts are not interchangeable.

70

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Main bearing caps timing side - flywheel side

When refitting rear flywheel side main bearing cap 1, replace the
rubber gaskets 2 considering that A and B should protrude 0.5÷1.0
mm from the crankase; cut any excess portion.
Follow the same procedure for the timing side main bearing cap.
To introduce the supports complete with silicone rubber seals 2 into the
crankcase place two plates C and D measuring 0.1 mm in thickness
between the surfaces.
Tighten the screws to 120 Nm.
The main bearing, the crankshaft bearing and the thrust washers have
been unified as from engine serial number 7306062 for LDW1503, from
serial number 7303552 for LDW 2004 and from serial number 7305782
71 72 for LDW 2004/T.
Pre- and post-modification single parts are not interchangeable.

Check clearance between main bearings and journals

Use "Perfect Circle Plastigage" A and position it with a few drops of

oil at the center of the half bearing; tighten bolts to 120 Nm.
Determine clearance by measuring the squeezed portion of the
plastigage with the indexed scale supplied.
For clearance between main journals, connecting rod big end
journals and the corresponding bearings fig 89.

Note: When replacing bearings make sure that the lower half is kept
separate from the upper one.

73 74

LDW Thrust bearings

LDW
1503/2004 1603/2204
2004-T/2204-T The main bearing, the crankshaft bearing and the thrust washers have
been unified as from engine serial number 7306062 for LDW1503, from
serial number 7303552 for LDW 2004 and from serial number 7305782
for LDW 2004/T.
Pre- and post-modification single parts are not interchangeable.

75 76

Grease the shoulder half-rings so that they will remain in their seats
during assembly.
Halves should be fitted with grooves A as shown in the figure77-78.
Thrust bearing thickness = 2.31÷2.36 mm; oversize halves with
thickness increased by 0.1 and 0.2 mm are available as spares.

77 78

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 DISASSEMBLY/REASSEMBLY VIII
Thrust bearing, oversizes
C B (fig. 82) A (fig. 81)

Standard 27.77 ÷ 27.92 28.00 ÷ 28.05

1st Oversize 27.97 ÷ 28.12 28.20 ÷ 28.25

0.08 ÷ 0.28
2nd Oversize 28.07 ÷ 28.22 28.30 ÷ 28.35

3rd Oversize 28.17 ÷ 28.32 28.40 ÷ 28.45

Grinding B according to the above table, following half-rings can be

assembled:
1st Oversize. Half-rings 1 and 2, on both the support sides +0.10 mm.
2nd Oversize. Half-rings 1 and 2 , on one support side +0.10 mm
79 80 and on the other side +0.20 mm.
3rd Oversize. Half-rings 1 and 2, on both the support sides +0.20 mm.

Crankshaft end play

After tightening main bearings measure the end play A between the
crankshaft shoulder on the flywheel side and main bearing halves.

Clearance
Ref.
(mm)
A 0.08 ÷ 0.28

B 28.00 ÷ 28.05

If the end play does not fall within the given values check B and
possibly fit the oversize thrust bearings.
81 82

Crankshaft front and rear oil seal

The front oil seal A is located in the oil pump cover while the rear oil
seal ring B, is positioned in the flange on the flywheel side.
Replace seals if warped, hardened or damaged.
In case of replacement:
· Carefully clean the seat.
· Soak the seal in engine oil for approximately half an hour.
· Fill the inside with grease and lubricate and sealing lip with thick oil.
· Drive the seal into its seal exerting a uniform pressure over the
entire front area.

Warning: in case of room temperature below -35°C seals could

83 84 become damaged.

Crankshaft timing gear

If gear A has to be replaced, use a bearing puller to remove it.

To reassemble it, you need to heat it up to a temperature of 180° ÷ 200°C
and then fit it snugly.

85

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Crankshaft lubrication ducts

During repair operations, when using compressed air, wear eye

protection.

Dip crankshaft into a bath (use a cleaning product).

Remove plugs and clean ducts A, B and C with a pointed tool.
Finally blow with compressed air.
Re-place plugs using a calking tool and check for sealing.

86

Checking main journals and crank pins

Use an outside micrometer gauge.

The main bearing, the crankshaft bearing and the thrust washers have
been unified as from engine serial number 7306062 for LDW1503, from
serial number 7303552 for LDW 2004 and from serial number 7305782
for LDW 2004/T.
Pre- and post-modification single parts are not interchangeable.

87

Main journal and connecting rod big end journal diameter

LD W
1503/2004/2004-T LD W
Ref.
1603/2204/2204-T
Pre-modification Post-modification Dimensions (mm)
A 57,980 ÷ 58,000 59,981 ÷ 60,000 59,981 ÷ 60,000

B 49,989 ÷ 50,000 49,984 ÷ 50,000 49,984 ÷ 50,000

The crakshaft is made of spheroidal graphite cast iron hardened at

the level of the oil seal rings 1 and 2. Hardness 55 hrc, hardening
depth 0.5÷1.5 mm.
88

Main bearing and connecting rod big bearing inside diameter

LD W
1503 - 2004 - 2004/T LD W
Ref. 1603 - 2204 - 2204/T
Pre-modification Post-modification
Dimensions (mm)
E 50,035 ÷ 50,066

F 58,041 ÷ 58,091 59,04 ÷ 59,969 59,04 ÷ 59,969

Clearance Limit Clearance Limit value Clearance Limit value
Ref. (mm) value (mm) (mm) (mm) (mm) (mm)
E-B 0,035 ÷ 0,077 0,150 0,035 ÷ 0,077 0,150 0,035 ÷ 0,077 0,150

F-A 0,041 ÷ 0,111 0,200 0,031 ÷ 0,096 0,200 0,031 ÷ 0,096 0,200
89
See fig. 73 and 74 for checking procedures.
Note: Both main bearing and connecting rod big end bearings are
available with inside diameter measuring 0.25 and 0.50 mm.

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 DISASSEMBLY/REASSEMBLY VIII
Crankshaft for engines with dynamic equalizer (only four-cylinder
engines).
The crankshaft comes with seat for the control gear of the counter-
rotating shaft dynamic balancer.
Components:
1 Control gear for counter-rotating shafts
2 Seat for the control gear of counter-rotating shafts

Ref. Dimensions (mm)

L 132.00 ÷ 132.03

M 132.07 ÷ 132.09

90 To replace the gear heat it up to 180°÷200°C.

Locate it into its seat so that the timing reference marks on the teeth
are found on the flyweel side.

Dynamic balancer (on request) - Adjustment of clearance

between teeth D and ring gear A

Follow figures 91 and 92.

Screw the screw B into support C taking care to centre the hole in
the mass of the gear D to lock it.
Fit the mass assembly under the crankcase so that the tooth with
reference E goes between the teeth with references F.
Fix the mass assembly with the four M10 screws to the crankcase,
provisionally tightening it to 40 Nm. Remove screw B.
By making the driving shaft turn, check the clearance between the
ring gear A and the gear of mass D; set a comparator with the feeler
91 on one tooth of the timing system control gear G; by turning the
driving shaft a little way check the clearance which must be
0.026÷0.067.
If the clearance measured does not come within the values given,
repeat the operation placing the 0.05 mm shims provided for
adjustment between the support C and the crankcase.
When mounting the balancer, lubricate the bushings with Molikote
then couple the two masses, taking into account the references H
and I.
Permanently fix the support C to the crankcase by tightening the
screws to 50 Nm plus one turn of the wrench clockwise through 45°.
The four screws will have to be mounted with a few drops of Loctite
242.

92

Front cover

To remove front cover 1 bring the 1st cylinder to the top dead center,
remove throttle cover 2 and release spring 3.
When refiting replace gasket 4 and 5; tighten front cover 1 to 25
Nm.

93 94

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 VIII DISASSEMBLY/REASSEMBLY
Idler gear and hub

Components:

1 Idle wheel 2 Hub

3 Thrust washer 4 Fitting
5 Oil seal ring 6 Bushing lubrication hole

Dimensions
Clearance Worn limit Ref. (mm)
(A-B) mm (A-B) mm
A 36,00 ÷ 36,02
0,025 ÷ 0,061 0,120
B 35,959 ÷ 35,975
End play Worn limit
95 96 (mm) (A-B) mm C 1,95 ÷ 2,05
0,10 ÷ 0,30 0,60
D 0,96 ÷ 1,00

Note: Unscew fitting 4 clockwise and when refitting it to 150 Nm.

Speed governor

During reassembly, make sure the components are

undamaged and verify they work properly.
Malfunctioning of the speed governor can cause serious damage
to the engine and to people in the vicinity of it.

Components:

1 Gear
2 Bell
3 Counterweights
4 Bolt
5 Throttle control rod
97 98
6 Governor spring
7 Injection pump delivery rod
8 Yoke 9adjustement eccentric
9 Control yoke for injection pump delivery rod
10 Bushing
11 Lever
12 Adjusting screw

Yoke 9 is pre-set through screw 12 and eccentric 8. Do not unscrew.

When refitting camshat gear 1 tighten bolt 4 to 80 Nm

Dimensions for injection pump delivery control yoke

adjustement

Components:
9 Control yoke for injection pump delivery rod
10 Bushing
11 Lever
12 Adjusting screw
13 Reference and mounting plane for support 14
14 Lever Support
Dimensions Note: If, when adjusting, screw 12 is
Ref.
(mm) unintentionally loosened adjust
99
A 10,8 mm yoke 9 considering the
dimensions A, C and D.
C 13,4 mm In case of replacement lever 11
is supplied complete with preset
D 88 mm
yoke 9.

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Camshaft gear - Speed governor counter weights

Components:

1 Camshaft gear
2 Governor weights
3 Governor weight support
4 Governor weight pin

The governor weights 2 are housed inside the camshaft gear 1.

The weights 2 can be of two types: light or heavy, depending on the
speed rate and the type of application.
Heavy weights for engines set to run at low rpm (1500 - 1800 rpm and
100 agricultural applications), light weights for engines set to run at high rpm
(2200 - 3000 rpm).

Speed governor counter springs

Besides the weights used according to the speed rate and application
type, different types of springs with different features are used as well.

Components:

1 Camshaft gear
6 Speed governor springs

101

Components:

1 Limiting device / torque gearing device

2 Maximum rpm adjustment screw
3 Minimum rpm adjustment screw
4 Camshaft gear
5 Governor weight
6 Speed governor spring

For engines used on generating sets it is preferable to fit a single spring

6 to act against the heavy governor weights to avoid hunting with
variations in the load and to achieve a more constant frequency over
time.
102

Frame with idling speed governor spring

Engines for applications requiring a certain power capacity at low

speeds are fitted with the frame 2 complete with the idling speed
spring which allows satsifying the above described requirements
without the engine tending to stop.

Components:
1 Rocker arm with speed governor springs.
2 Frame for idling speed spring

103

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Summary tables of the governor equipment according to the speed variation.

LDW 1503-1603 LDW 2004-2204-2004/T-2204/T

rpm Weight type N.Spring Spring serial number rpm Weight type N.Spring Spring serial number

1500 Duty 1 5655370 1500 Duty 1 5655370

1500 Duty 2 5655154/5655156 **
Duty
1500 2 5655154/5655156 **
1800 Duty 1 5655370
1800 Duty 1 5655370
1800 Duty 2 5655154 **
1800 Duty 2 5655154 **
2000 Light 2 5655135
2000 Light 2 5655135
2200-2900 Light 2 5655135
2200 Light 2 5655129/5655135
2800 Duty 2 5655405
2500 Duty 2 5655129 *
3000 Light 2 5655129/5655135
2800 Duty 2 5655405
* Idle frame
** Anti-hunting 3000 Light 2 5655129/5655135

* Idle frame
** Anti-hunting

Spring for extra fuel supply at starting

The device is operated automatically: when the engine is stopped

spring 1 acts on the injection pump control lever 2 providing
maximum fuel delivery until the governor starts operating.

104

Camshaft removal

To remove camshaft first remove valve tappets 1, injection pump

follower 2, bearing stop plate 3 and fuel pump control rod 5.

Note: To remove follower 2 loosen screw 4 by three or four turns.

105

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Checking camshaft bushing internal diameter

Use a bore gauge.

If the diameter size does not correspond to the given value remove
the bushings using the special tool (fig 109 et 110)and replace.

106

Camshaft journals and bushings in model LDW 1503

Clearance Worn limit

Dimensions
Ref. (mm) (mm)
(mm)
(A-B) (C-D) (A-B) (C-D)
A 43.000 ÷ 43.025

B 42.940 ÷ 42.960
0.040 ÷ 0.085 0,16
C 42.000 ÷ 42.025

D 41.940 ÷ 41.960

Note: A and C values refer to driven in and bored bushings.

107

Camshaft journals and bushings in models LDW 2004-2004/T

Dimensions Clearance (mm) Worn limit (mm)

Ref.
(mm) (A-B) (C-D) (E-F) (A-B) (C-D) (E-F)

A 44.000 ÷ 44.025
B 43.940 ÷ 43.960
C 43.000 ÷ 43.025
0.040 ÷ 0.085 0,16
D 42.940 ÷ 42.960
E 42.000 ÷ 42.025

108 F 41.940 ÷ 41.960

Camshaft bushing replacement

Tool part No.7104-1460-021

Components:

1 Mandrel
2 Centering bushing
3 Bushing diam. 44 mm
4 Bushing diam. 43 mm
5 Bushing diam. 42 mm

Note: Before driving in the bushing, position it in such a way that the
lubricating hole maiches with the hole in the crankcase.
109 110

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 VIII DISASSEMBLY/REASSEMBLY

Intake, exhaust and injecton cam height for model LDW 1503

A (mm) S (mm) I (mm)

L D W 1503
36.058 ÷ 36.120 35.62 ÷ 35.68 33.85 ÷ 33.90
L D W 2004

LDW 2004/T 35.54 ÷ 35.60 35.24 ÷ 35.30 33.85 ÷ 33.90

Limit value
(mm) 0,4

A1 =1st cylinder intake cam S1 = 1st cylinder exhaust cam I1 = 1st cylinder injection cam
A2 = 2nd cylinder intake cam S2 =2nd cylinder exhaust cam I2 = 2nd cylinder injection cam
111 A3 = 3rd cylinder intake cam S3 = 3rd cylinder exhaust cam I3 = 3rd cylinder injection cam
A4 = 4th cylinder intake cam S4 = 4th cylinder exhaust cam I4 = 4th cylinder injection cam

Intake, exhaust and injection cam height for models LDW

2004- 2004/T

A (mm) S (mm) I (mm)

35.44 ÷ 35.50 35.14 ÷ 35.20 33.95 ÷ 34.00

A1 =1st cylinder intake cam S1 = 1st cylinder exhaust cam I1 = 1st cylinder injection cam
A2 = 2nd cylinder intake cam S2 =2nd cylinder exhaust cam I2 = 2nd cylinder injection cam
A3 = 3rd cylinder intake cam S3 = 3rd cylinder exhaust cam I3 = 3rd cylinder injection cam
A4 = 4th cylinder intake cam S4 = 4th cylinder exhaust cam I4 = 4th cylinder injection cam
112

Camshaft timing

Fit idler gear B by making timing mark 2 coincide with timing mark 1
on the camshaft control gear A and mark 3 with 4 on the timing gear
C.

113

Valve timing without considering timing marks

Locate piston 1 (on flywheel) at the top dead center. Position two
small rods A of the same length onto the tappets.
Rotate camshaft stopping when cylinder 1 tappets are in overlap
position (intake open exhaust closed).
Using the straight edge B check that rods A are at the same length.
Mark the idler gear with camshaft and timing gear.

114

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 DISASSEMBLY/REASSEMBLY VIII
Valve timing check

Check valve timing at the crankshaft.

The values shown are checked at the flywheel circumference (with
flywheel diameter of 290 each degree corresponds to 2.53 mm).
Set valve clearance at 0.65-0.70 mm (after checking reset the value
to 0.15 mm).
Set dial gauge on intake valve to a zero value; by rotating the
crankshaft according to its direction of rotation you can measure α
(intake valve opening advance referred to top dead center S) and β
(intake valve closing delay referred to bottom dead center I).
Follow the same procedure for exhaust valves checking γ (exhaust
valve opening advance )and δ ( exhaust valve closing delay).
115

Timing angles for checking puposes

(valve clearance = 2 mm)
α = 14° after S (corresponding to 35 mm on the flywheel)
β = 6° after I (corresponding to 15 mm on the flywheel)
γ = 17° before I (corresponding to 43 mm on the flywheel)
δ = 15° before S (corresponding to 38 mm on the flywheel)

Timing angles for operating purposes

(valve clearance 0.15 mm)
α = 14° before S (corresponding to 35 mm on the flywheel)
β = 34° after I (corresponding to 85 mm on the flywheel)
γ = 46° before I (corresponding to115 mm on the flywheel)
δ = 14° after S (corresponding to 35 mm on the flywheel)

Timing angles for checking purposes LDW 2004/T

(valve clearance 2 mm)
α = 15° after S (corresponding to 38 mm on the flywheel)
β = 21° after I (corresponding to 52 mm on the flywheel)
γ = 31° before I (corresponding to 77 mm on the flywheel)
δ = 13° before S (corresponding to 32 mm on the flywheel)

Timing angles for operating purposes LDW 2004/T (valve

clearance 0.15 mm)
α = 12° before S (corresponding to 30 mm on the flywheel)
β = 48° after I (corresponding to 120 mm on the flywheel)
γ = 58° before I (corresponding to 145 mm on the flywheel)
δ = 14° after S (corresponding to 35 mm on the flywheel)
116

Engines with hydraulic tappets

Timing belt operating angles (with valve clearance set to zero)

r.p.m. Engine type Intake Exhaust

L D W 1503
down L D W 1603 α = 8° before S γ = 36° before I
2400 r.p.m. LDW 2004 β = 28° after I δ = 8° after S
L D W 2204

L D W 1503
up L D W 1603 α = 12° before S γ = 48° before I
2400 r.p.m. LDW 2004 β = 36° after I δ = 12° after S
L D W 2204
down/up LDW 2004/T α = 12° before S γ = 58° before I
2400 r.p.m. LDW 2204/T β = 48° after I δ = 14° after S

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 VIII DISASSEMBLY/REASSEMBLY
Camshaft end play

Check camshaft end play after removing the cylinder head, the
injection and the fuel pumps from the engine. Check that plate 1 is
tightened.
Position the dial gauge on the camshaft front surface; push and pull
the camshaft.
Maximum end play should be 0,008 mm (ball bearing end play).

117

Hydraulic pump p.t.o.

A = 3rd p.t.o. with hydraulic pump Gr 2.

B = 4th p.t.o. with hydraulic pump Gr 1

Hydraulic pumps of either GR 1 or GR 2 type can be fitted, even

simultaneously, on the erd and 4th p.t.o. provided the resulting
torque does not exceed 40 Nm.
The gear ratio between engine r.p.m. and 3rd and 4th p.t.o. is 1:1.

118

GR 1 and GR 2 hydraulic pump 3rd p.t.o.

1 O-R
2 O-R
3 Center ring
4 Circlip
5 Thrust washer
6 GR 2 hydraulic pump flange
7 GR 1 hydraulic pump flange
8 Bushing
9 Trust washer
10 GR 2 hydraulic pump drive gear
11 GR 1 hydraulic pump drive gear
12 Control gear
119

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 TURBOCHARGER IX
Turbocharger
It is installed on the engine in two versions: with air intake on the
flywheel side and with air intake on the fan side.
To control the supercharge air pressure, screw the pressure gauge
into the M8 holes A and B both for the version with air intake on
flywheel side (fig. 120) and for air intake on fan side (fig.121)

120 121

Turbocharger components

1 Flexible hose 14 Snap ring

2 Actuator 15 Thickness
3 Collar 16 Segment
4 Turbine body 17 Oil deflector
5 Snap ring 18 Thrust block sleeve
6 Compressor volute 19 O-ring
7 Thickness 20 Thrust block bearing
8 Nut 21 Thrust block ring
9 Lock nut 22 Bearing
10 Shaft with turbine 23 Snap ring
11 Segment 24 Snap ring
12 Flame shield 25 Bearing support
122
13 Bearing

Turbocharger Testing

Get a pressure gauge with scale from zero to 2 bar, connect it

according to fig, 120 and 121.
Start up the engine, warm it up for a few minutes, then take it to
3000 rpm at the power NB.
The supercharge air pressure value to be measured is 89÷93 KPa
(0.89÷0.93 bar).
If the setting pressure does not come within the required value it is
necessary to adjust the stroke of the valve control rod C (Waste
gate).

123

Checking actuator setting - "Waste gate" valve control rod

stroke adjustment
This test must be done with the engine stationary.Disconnect pipe 7
from the compressor side.Using a T coupling, connect up with a
pressure gauge 4 (scale from zero to 2 bar) and with the
compressed air mains pipe complete with reduction unit 5.The mains
air pressure must be 1.5÷2.0 bar. Make a hole B diameter 1.5 mm in
the pressure gauge pipe where part of the air will escape which has
the purpose of stabilizing the pressure in the pressure gauge.
Use the reduction unit 5 to send air to the actuator so as to make
terminal 2 of A move forward (A = 1 mm).Position a comparator 6
so that the feeler rests on the terminal 2.The pressure read on the
pressure gauge must be 830÷890 mm Hg (1.11÷1.19 bar). If the
pressure is lower than the given value, proceed as follows.
124
Unscrew the lock nut 1.Remove the split pin 9 and disconnect the
rod 8. Keeping the rod stationary, screw the terminal 2 to reach the
setting pressure. While the terminal is rotating the rod must undergo
no twisting.
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 X LUBRICATION SYSTEM

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 . Use the chart
when chosing your engine oil.

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.

LUBRICATION SYSTEM LAYOUT

8 1
16
2

3
10

15
4

11 5

12 6

13

7
14
125

Components:
1) Oil fill cap 6) Oil dipstick 11) Oil pump
2) Rocker arm shaft 7) Drain plug 12) Crankshaft
3) Oil filter 8) Breather 13) Oil pressure adjusting valve
4) Main journal 9) Camshaft 14) Oil pick-up screen
5) Connecting rod journal 10) Oil pressure switch 15) Hydraulic tappet
16) Turbocharger (LDW 2004/T-2204/T)

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 LUBRICATION SYSTEM X
Oil pump

Components:

1 Suction port 5 External rotor

2 Delivery port 6 Internal rotor
3 Oil pressure adjusting Valve port 7 Key
4 Gasket

The oil pump is driven by the crankshaft via key 7. Rotor 6 is locked
in the circumferential but not in the axial direction. This allows the
shaft to move axially while rotors 5 and 6 are prevented from
damaging the pump sealing surfaces.
126 127 Oil pump capacity = 24.5 litres/min. at a pressure of 4.5÷4.75 bar
(engine speed 3000 rpm, oil temperature 38÷42°C).

Oil pump rotor clearance

Measure clearance A between the teeth located along the axis of the
keyway as shown in the figure 129; its value is 0.150 mm; worn limit
clearance 0.280 mm.

128 129

Oil pressure adjusting valve

Components:
1 Valve
2 Spring
3 Gasket
4 Plug

Length of spring A = 45.5 ÷ 46.0 mm.

Blow compressed air into the valve seat and carefully clean all
components; using a caliper measure the length of spring A.

130 131

Oil filter cartridge

Components:
1 Gasket 4 Blade
2 Plate 5 Filtering material
3 Gasket 6 By-pass valve

Specifications:
Max. working pressure ................... 7 bar
Max. explosion pressure ................ 20 bar
Low temperature limit .................... -35°C
By-pass valve setting ..................... 2.1/2.8 bar
Total filtering surface ..................... 2000 cm2
Degree of filtration ......................... 15 µm
132

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 X LUBRICATION SYSTEM
Oil pressure check

On completing assembly, fill with engine oil and fuel; connect a 10

bar pressure gauge to the pressure switch fitting.
Start the engine and check pressure as a function of the oil
temperature.

133

Oil pressure curve for LDW 1503 - 1603

Fig. 134 - The curve is obtained at the oil filter level constant engine
speed of 850 rpm in no-load conditions.

Fig. 135 - The curve is obtained at the oil filter level with engine
working at 3000 rpm at the N power.

134 135

Oil pressure curve for LDW 2004 - 2204

Fig. 136 - The curve is obtained at the oil filter level constant engine
epeed of 850 rpm in no-load conditions.

Fig. 137 - The curve is obtained at the oil filter level with engine
working at 3000 rpm at the N power.

136 137

Oil pressure curve for LDW 2004/T - 2204/T

Fig. 138 - The curve is obtained at the oil filter level constant engine
epeed of 850 rpm in no-load conditions.

Fig. 139 - The curve is obtained at the oil filter level with engine
working at 3000 rpm at the N power.

Note:
The max lubrication oil temperature must be lower than the sum:
ambient temperature + 95°C.

138 139

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 COOLING SYSTEM XI

The fluid coolant circuit is pressurized. Inspections must only be made when the engine has cooled and even in this
case, the radiator or expansion chamber plug must be unscrewed with the utmost caution.
If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the engine is at
a standstill.
Coolant fluid is polluting, it must therefore be disposed of in the correct way. Do not litter.

COOLING SYSTEM

1
5
9

6 3

10

4
8

140

Components:
1) Coolant fill cap 6) Thermostat
2) Expansion tank 7) Fan
3) Cylinder block 8) Radiator
4) Circulating pump 9) Temperature sensor
5) Coolant temperature warning lamp 10) Heat exchanger (LDW 2004/T - 2204T).

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 XI COOLING SYSTEM
Expansion tank and cap

The expansion tank is separated from the radiator and is fitted with a
coolant fill cap. The cap comes with vacuum valve 1 and pressure
relief valve 2.
The pressure relief valve opens at a pressure of 0.7 bar.

141

Checking for cooling system leaks

Remove the cap from the expansion tank and check coolant level.
Replace the cap with one fitted with portable hand air pump coupling
as shown in the figure 142.
Compress air at a pressure of 1 bar for approximately 2 minutes.
Check that no leaks occur.

Note: In very dusty working conditions verify and clean

the outside of the radiator frequently.
Replace coolant as specified on page 21.

142

Coolant circulating pump

Impeller 3 and hub 5 are fitted to the shaft by press fit.

To remove the impeller, screw the M 18x1.5 bolt into bore 2.
To remove that shaft take 4 which locks the bearing to the pump
body.
A seal is located on the shaft between the bearing and the impeller.
In case of worn-out seal, coolant leaks from hole 1.

LDW 1503 - 1603 - 2004 - 2204:

The ratio between the pump and engine rpm = 1:1.2
Pump delivery at 3000 rpm is 70 liters/min.
LDW 2004/T - 2204/T:
143 144 The ratio between the pump and engine rpm = 1:1.5
Pump delivery at 3000 rpm is 116 liters/min.

Thermostat

1 - Air valve

Specifications:
Opening temperature: 77°/81°C
Max. stroke at 94°C = 7.5 mm
Coolant flow rate with thermostat and valve in closed position = 15
Liters/h.

145 146

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 FUEL SYSTEM XII
Fuel feeding/injection circuit

Components:

1 - Tank
2 - Fuel feeding pump
3 - Fuel filter
4 - Fuel delivery tube
5 - Injector pumps overflow tube
6 - Injection pump
7 - High-pressure tube between pump and injector
8 - Injector
9 - Injector return tube
147 10 - Solenoid valve

Fuel filter

Components:
1 - Drain screw
2 - Cover
3 - Seal
4 - Fitting
5 - Cartridge

Cartridge specifications
Filtering paper: ................... PF 904
Filtering area: ..................... 5000 cm2
Filtering degree: ................. 2/3 m
148 Max. working pressure: ...... 4 bar
See page 21 for maintenance details.

Fuel feeding pump

Components:

1 - Feeding pump
2 - Push rod
3 - Seal ring

The fuel feeding pump is of the diaphragm type operated by a

camshaft eccentric through a push rod.
If features an external lever for manual operation.

149

Fuel feeding pump drive rod protrusion

Push rod 2 shows a protrusion A of 1.5÷1.9 mm from the crankcase

plane. Check this value with eccentric 1 at the lowest point (on the
bottom of the cam base of the camshaft).

Push rod length = 32.5÷32.7 mm.

Check push rod length and replace push rod if size is inadequate.

150

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 XII FUEL SYSTEM
Intake Electric fuel pump (24V)
side The use of the electric pump is foreseen for certain applications (where
the engine has to be started at very low temperatures).
Assembly notes:
When the electric fuel pump is installed in a diesel engine, it is
necessary to:
Support
clump
1) Remove the filter fitted at the pump intake (intake side).
2) Insert the prefilter upstream of the pump (intake side).
3) The electric pump on the application must be at such a height from
the minimum tank level that it generates a maximum pressure drop
equal to a column of 500 mm of water.
4) Avoid running dry due to emptying of the intake pipeline, inserting
a non-return valve.
151 Features: Pressure: 0.44 / 0.56 bars
Max capacity: 100 l/h

Injection pump
The injection pump of a simplified Q type has been designed by
LOMBARDINI for installation on engines of the CHD series.
The injection system includes three or four separate pumps each of
which feeds a cylinder.
Located on the crankcase at the level of the corresponding cylinder,
pumps are directly operated by the camshaft. All high pressure tubes
between injector and pump A feature the same shape and
dimensions.
Features LDW 1503 - 2004 LDW 1603 - 2204 LDW 2004/T - 2204/T

Pumping Ø 6 mm Ø 7 mm Ø 7 mm

152 Sealing Volume 25 mm3 Volume 25 mm3 Volume 25 mm3

valve 1 hole Ø 0,81 1 hole Ø 0,81 3 holes Ø 1,5

Injection pump disassembly

Release the spring from the cap and remove the plunger.
Two pins keep the upper cap connected to the pump body; pry with a
tool between the pump body and the cap.

Injection pump components

1 Delivery union
2 Spacer
3 Spring
4 Gasket
5 Delivery valve
6 Gasket
7 Cap
8 Spring
9 Upper cap
10 Plunger pumping
11 Lever
12 Pin
13 Body

A Fuel feed union

B Fuel dischrge union
C Pump flange
D Barrel pumping
E Fuel control helix

153 Note: Union A and B, flange C and barrel D form an integral part
of the pump body.

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 FUEL SYSTEM XII
How to reassemble injection pump components

Fit the plunger with helix E directed towards the discharge union B; if
it is erroneously fitted with spiral facing the fuel feed union A the
injection pump will not operate (thus the possibility of the engine
overspeeding is completely ruled out); complete reassembly
following fig. 154
Tighten delivery union to 35 Nm; it is essential to use a torque wrench.

154

Tool serial number Injection pump non-return valve

7107.1460.212
The discharge union is fitted with a non-return valve A; this valve
improves injection by bleeding the air inside the fuel and stops the
engine immediately after the stop device is operated.
To replace the outlet union with non-return ball valve on QLC type
injection pumps (having inlet and outlet unions pressure-fitted on the
pump case) use the special tool serial number 7107.1460.212.
Tool B is required for removal of valve A, tool C for driving.

155 156

Injection pump control rod

Control rod 1, operated by the throttle and governed by the speed

governor, controls the injection pump.
Ring nut 2 keeps rod 1 in the required position by means of groove
3.

Note: Do not unscrew ring nut 2 before removing rod 1.

157 158

How to remove injection pump feeding tubes

Cut the nylon tube at A.

Remove the portion left inside the union using pliers. Remove the
nylon tube without damaging the union seals as shown in the figure
159.

Warning:

Cutting the pipe in the opposite direction to the arrow A (horizontally)

damages the pump coupling with consequent leakage of fuel.

159 160

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 XII FUEL SYSTEM
How to reassemble injection pump feeding tubes

1 Pliers for 6 mm diam. tubes (intake) - Part No. 7104-1460-022

2 Pliers for 8 mm diam. tubes (discharge) - Part No. 7104-1460-
023

Feeding and discharge tubes are made of nylon; they fit into the
injection pump unions by exerting pressure and using special pliers
and a plastic hammer.
The nylon tubes can no longer be used after disassembly.
Replace them every time they are removed.

161 162

Instrument for equalizing injection pump delivery

Part No. 7104-1460-090
Components:
1 Tank 4 Switching lever
2 Test tube 5 Injection pump discharge tube cut-off valve
3 Support 6 Injection pump intake tube-off valve

A Tube for connection to injection pump intake union

B Tube for connection to injection pump discharge union
Remove feed tubes from all injection pumps and fit the i n s t r u m e n t
tubes making sure that each pump has its own intake and discharge
tubes.
Connect the instrument A with the engine A and the instrument
B with the engine B. Proceed in a similar manner with the other
163
pumps.

Injection pump delivery equalization.

Connect delivery tube A of the tool to the inlet union A of the pump and
the return tube B of the tool to the overflow union B of the pump.
Proceed in a similar way for the other pumps.
After checking the injection advance go ahead with the delivery
balancing of the pumps. Before connecting the tool serial number
7104-1460-090 to the pumps and refilling tank 1 with fuel, set it to a
higher level of at least 200 mm than that of the pumps themselves.
Open taps 5 and 6 and start the engine, set the engine to an idling
speed of 2000 rpm. Switch the engine feed from tank 1 to the tubes 2
using the switching lever 4 fig. 163. After the first minute (minimum
testing time), verify that the level between the highest and lowest levels
in the tubes is not more than 2 cm³. At this point, it is possible to either
164 reduce the delivery of the pump that consumes most (tube with the
lowest level) or increase the delivery of the pump that consumes the
least (tube with the highest level). To vary the delivery of the pumps,
rotate slightly in one direction or the other at the injection pumps.
Unscrew the fastening screws of the pump to be adjusted by a quarter
of a turn. Rotating clockwise the delivery is increased, anti-clockwise
the delivery is reduced. Once adjustment is finished, tighten the
fastening screws to 25 Nm. Whenever an injection pump is disassembled
or replaced, delivery balancing must be carried out.
Note: A reference notch is located between the pump flange and its
mounting on the crankcase. If one or more pumps are
disassembled and reassembled do as follows:
- Make a reference marking on the fastening flanges of the injection
pumps and on the base planes of the crankcase.
- Leave the shims for injection timing setting under each pump
unchanged.
- Each pump should be reassembled in its own housing. Align the
delivery reference notches located on the pump flange with those
on the crankcase.

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 FUEL SYSTEM XII
Injection pump P. No. 6590-249 - Plunger and barrel assembly

Components:

1 Pump body
2 Barrel
3 Plunger
4 Plunging blade

Note: Barrel 2 forms an integral part of the pump body 1. For this
reason both the barrel and plunger 3 should not be replaced.

165

Checking injection pump delivery

Components:

1 Delivery adjustment rod

2 Rod 1 stop position
3 Rod 1 max. delivery position
A =18.5÷19.5 mm (rod max. stroke)
α = 66° (rod max. rotation)

166

Test data of injection pump

Control rod Rod stroke from LDW

Camshaft LDW 1503-2004 LDW 1603-2204 2004/T-2204/T
max. force max. delivery rpm Delivery Delivery
Newton point (mm) Delivery
mm3/stroke mm3/stroke
mm3/stroke

1500 30 ÷ 40 31 ÷ 41 40 ÷ 48
9
0,35 500 25 ÷ 35 23 ÷ 33 20 ÷ 28

0 150 56 ÷ 66 56 ÷ 66 58 ÷ 64

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 XII FUEL SYSTEM
Checking low pressure injection timing for engines with
hydraulic tappets

To verify the delivery starting point, the first operation to carry out is to
disconnect the nylon tubes at the inlet 4 and outlet 3 of every injection
pump.
Then, disassemble the air filter, the intake manifold and the rocker arm
cap.
Now disassemble the whole rocker-arm pin and, after removing the
push rods, reassemble it.
Screw the special tool 1 serial number 7107-1460-075 (fig. 167) onto
the head, making sure the dial indicator tracer 5 sets against the upper
spring bearing ring of the intake valve.
167 Use a provisional fuel tank (e.g. delivery balancing tool) to gravity-feed
the injection pump connecting it to the inlet union 4; on the outlet union
3 fit the transparent nylon tube 6 by the means of which we measure
LD W LD W the overflow. Place the pump control rod in the stop position.T Operate
α 1503-2004-2004/T 1603-2204-2204/T the lever 2 of the tool to rotate the crankshaft until the valve touches
(mm) (mm) the piston crown. This procedure determines the exact TDC (top dead
centre of the piston) of the cylinder in question; reset the dial indicator
16° 2,12 2,27
in this position.
15° 1,86 2,00 Then rotate clockwise the crankshaft on the flywheel side until diesel
fuel begins to flow out of the small hose on the pump outlet. Now
14° 1,63 1,74
change the rotation direction to anticlockwise. The flow diminishes. As
13° 1,40 1,50 soon as it stops flowing, the delivery starting point is determined. Then,
lower the tool lever to make contact between the valve and the piston
12° 1,20 1,28 crown and, using the dial indicator 5, measure how much lower the
11° 1,01 1,08 piston is with respect to the TDC (top dead centre) in mm. Use the
transformation chart (mm to degrees) to find out the correspondence
10° 0,83 0,89 between mm measured with the dial indicator 5 and degrees. Example
9° 0,67 0,72 LDW 1503-2004-2004/T: an advance of α=15° corresponds to a
lowering of the piston with respect to the TDC (top dead centre) of 1.86
8° 0,53 0,57 mm. The same operation must be carried out on each pump. The
7°
difference in adjustment must be limited to about 1°. Disassemble the
0,41 0,43
various equipment, remove the rocker-arm pin and put back the push
6° 0,30 0,32 rods in their seats. Then re-assemble the rocker-arm pin.
5°
Rotate the crankshaft so as to position the pistons at half stroke for
0,21 0,22
three-cylinder engines.
4° 0,13 0,14 For four-cylinder engines, place the piston of cylinder number one at
150° after the top dead centre (in crossover stage).
3° 0,07 0,08
The rocker-arm pin must be fastened in different stages so as to allow
the oil inside the tappets to be drained, thus allowing them to position
themselves correctly.
Oil density and ambient temperature are important factors that will
affect the waiting time (about 10') between successive fastening
operations. Hurried fastening can cause serious damage to the engine.
As a guideline to each fastening operation, make sure that the cup of
the upper spring bearing ring does not touch the valve stem oil sealing
Engine Low pressure value Low pressure value ring fitted on the guide. The final torque of the rocker-arm pin is 50 Nm.
type for r.p.m. ≤ 2400 for r.p.m. ≥ 2400 Reassemble the rocker-arm cap and the intake manifold, tightening
the screws to the indicated torque.
L D W 1503
L D W 1603
13° ± 1° 11° ± 1°
L D W 2004 Checking low pressure injection timing for engines with
L D W 2204
mechanical tappets
LDW 2004/T
7° ± 1° 4° ± 1° The check of the advance on engines with mechanical tappets
LDW 2204/T
is carried out using the same procedure as that described for the
hydraulic tappets; the only difference is in the disassembly and
reassembly of the rocker-arm pin and of the push rods which is
not necessary.

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 FUEL SYSTEM XII

Injection timing correction by changing the pad thickness

Should it be necessary to correct the injection static advance, remove

the injection pump from the engine block and replace pad B inside the
injection tappets with one of a different thickness (to extract pad B use
a magnet C). Its value is printed on the lower part of the pad. Eight
spare pads are supplied for the advance variations and their thickness
can vary from 4 to 4.7 mm.
The gasket A, between the injection pump flange and the engine block,
is only one, with the only task of preventing any possible oil leaks.
Previously, to vary the injection advance, gaskets of different thicknesses
were used between the injection pump surface and the engine block
surface (in effect, gasket A without sealing rubber border).
168 169

Injector (pin type)

Components:

1 Fuel inlet 7 Delivery union

2 Filter 8 Backflow union
3 Body 9 Setting shims
4 Delivery duct 10 Pressure spring
5 Pad 11 Pressure pin
6 Clamping ring nut 12 Nozzle
13 Fireproof bulkhead

170

Whenever maintenance operations are carried out on the injector

replace the seal ring 1.
Introduce seal ring 1 into the injector housing with the sealing
surface facing upwards (see figure 171).
See page 21 for maintenance intervals.
Fix injector to the head tightening to 70 Nm.

171

Injector setting

Connect the injector to a injection test stand and check that the
pressure setting is 140 / 150 bar.
Adding the shims 9 increases the pressure setting, reducing their
number lowers it.
Eleven spare setting shims 9 are included, their measurements range
from 1 to 2 mm.
When spring 10 is replaced, calibration must be carried out at a
pressure 10 bars higher than the nominal pressure (160 bar) to
counterbalance bedding in the operation.

Check needle valve sealing by slowly moving the hand pump until
approximately 120 bar per 10 seconds.
172 Replace nozzle 12 in case of dripping.
The torque of the injector ring nut is 70 / 90 Nm.

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 XIII ELECTRIC SYSTEM
Alternator type Marelli AA 125 R 14V 45A

Characteristics:
Rated voltage ........................... 14V
Rated current ........................... 45A
Max. speed ............................... 14000 giri/1'
Peak speed (max 15 min) ........ 15000 rpm
Bearing on control side ............ 6203.2z
Bearing on manifold side ......... 6201-2z/C3
Voltage regulator ..................... RTT 119 AC
RH direction of rotation.

Note: Lube the two bearings with high temperature grease.

Tighten the nut 1 to 60 Nm.
173
The alternator has a W terminal for a speed indicator.

Characteristic curves for alternator type Marelli AA 125 R 14V

45A

The curves have been detected with electronic voltage regulator after
thermal stabilization at 25°C; test voltage 13.5 V.
P1 = Power in kW
I = Current in Ampere
η = Alternator efficiency

Note: The alternator rpm is equal to to the rpm shown in the table
multiplied by 1000.
Ratio between engine/alternator rpm = 1:1.8

174

Characteristic voltage curve for regulator type RTT 119 AC

The electronic voltage regulator is built into the alternator.

The curve changes depending on temperature.
A = Max. voltage curve
B = Min. voltage curve

175

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 ELECTRIC SYSTEM XIII
Alternator type Marelli AA 125 R 14V 65A

Characteristics:
Rated voltage ........................... 14V
Rated current ........................... 65A
Max. speed ............................... 14.000 giri/1'
Peak speed (max 15 min) ........ 15.000 rpm
Bearing on control side ............ 6203.2z
Bearing on manifold side ......... 6201-2z/C3
Voltage regulator ..................... RTT 119 AC
RH direction of rotation.

Note: Lube the two bearings with high temperature grease.

176 Tighten the nut 1 to 60 Nm.
The alternator has a W terminal for a speed indicator.

Characteristic curves for alternator type Marelli AA 125 R 14V

65A

The curves have been detected with electronic voltage regulator

after thermal stabilization at 25°C; test voltage 13.5 V.
P1 = Power in kW
I = Current in Ampere
η = Alternator efficiency

Note: The alternator rpm is equal to the rpm shown in the table
multiplied by 1000.
Ratio between engine/alternator rpm = 1:1.8

177

Characteristic voltage curve for regulator type RTT 119 AC

The electronic voltage regulator is built into the alternator.

The curve changes depending on temperature.

A = Max. voltage curve

B = Min. voltage curve

178

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 XIII ELECTRIC SYSTEM
Alternator type Iskra, AAK3139 14V 80A
Characteristics:
Rated voltage ........................... 14V
Rated current ........................... 80A
Speed of the load starting point ............... 1350 rpm
Maximum permanent - intermittent speed (max. 15') 13000 -15000 rpm
Front bearing ............................................ 6303 - 2RS - C3
Rear bearing ............................................. 6201 - 2RS - C3
Max. force on the bearing .................. 600 N
Voltage regulator ..................... AER 1528
RH direction of rotation.

Note: Lube the two bearings with high temperature grease.

179 Tighten the nut 1 to 60 Nm.
The alternator has a W terminal for a speed indicator.

Characteristic curves for alternator type Iskra, AAK3139 14V

80A

The curves have been detected with electronic voltage regulator

after thermal stabilization at23 ± 5°C; test voltage 13 V.

I = Current in Ampere

Note: The alternator rpm is equal to the rpm shown in the table
multiplied by 1000.
Ratio between engine/alternator rpm = 1:1.8

180

Characteristic voltage curve for regulator type AER 1528

The electronic voltage regulator is built into the alternator.

The curve changes depending on temperature.

A = Max. voltage curve

B = Min. voltage curve

181

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 ELECTRIC SYSTEM XIII
Wiring diagram with alternator 45A / 65A

1 Alternator
2 Starter Motor
3 Battery (See below for sizing details)
4 Glow Plugs
5 Thermistor (Glow Plug Controller Circuit)
6 Glow Plug Controller / Timer
7 Key Switch
8 System Fuse
9 Fuse (Accessory)
10 Fuel Valve
11 Glow Plug Indicator Lamp
12 Coolant High Temperature Lamp
13 Coolant High Temperature Switch (N.O.)
14 Oil Pressure (Low) Lamp
15 Oil Pressure Switch (N.C.)
16 Alternator Charging Lamp (Off if Charging)
17 Diode
18 Air Filter High Restriction Indicator
19 Air Filter Restriction Switch (N.O.)
20 Low Fuel Level Lamp
21 Low Fuel Level Switch (N.O.)
22 n. 2 100 ohm resistances in parallel

A Accessory
B Off Position
C On Position
D Starting Position

Note: This electric starting diagram holds for both 45A and 65A
alternators.
Battery 3 is not supplied by LOMBARDINI.
Anyhow, for installation we recommend a battery for all the
range of engines with the following particulars, see following
table.

182

Connection diagram for preheating control unit

Components:

1 Cable cross-section 2.5 mm2 at point “50” of the key panel

2 Cable cross-section 6 mm2 at the fuse holder box
3 Cable cross-section 1.5 mm2 at the earth
4 Cable cross-section 1 mm2 at the spark plug warning light (max. 2 W)
5 Cable cross-section 6 mm2 at point “30” of the key panel
6 Cable cross-section 1 mm2 at the water temperature sensor
7 Cable cross-section 1.5 mm2 at the fuse

183

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 XIII ELECTRIC SYSTEM
Alternator type Iskra, type AAK3570 28V 35A (for 24 V outfits)
Characteristics:
Rated voltage ........................... 28V
Rated current ........................... 35A
Speed of the load starting point ............... 1140 rpm
Maximum permanent - intermittent speed (max. 15') 13000 -15000 rpm
Front bearing ............................................ 6303 - 2RS - C3
Rear bearing ............................................. 6201 - 2RS - C3
Max. force on the bearing .................. 600 N
Voltage regulator ..................... AER 1528
RH direction of rotation.
Note: Lube the two bearings with high temperature grease.
Tighten the nut 1 to 60 Nm.
184 The alternator has a W terminal for a speed indicator.

Characteristic curves for alternator type AAK3570 28V 35A (for

24 V outfits)

The curves have been detected with electronic voltage regulator

after thermal stabilization at 23 ± 5°C;test voltage 13 V.

I = Current in Ampere

Note: The alternator rpm is equal to the rpm shown in the table
multiplied by 1000.
Ratio between engine/alternator rpm = 1:1.8

185

Characteristic voltage curve for regulator type AER 1528

The electronic voltage regulator is built into the alternator.

The curve changes depending on temperature.

A = Max. voltage curve

B = Min. voltage curve

186

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 ELECTRIC SYSTEM XIII
Wiring diagram 24 V with alternator 35A

1 Alternator
2 Starter Motor
3 Battery (See below for sizing details)
4 Glow Plugs
5 Thermistor (Glow Plug Controller Circuit)
6 Glow Plug Controller / Timer
7 Key Switch
8 System Fuse
9 Fuse (Accessory)
10 Fuel Valve
11 Glow Plug Indicator Lamp
12 Coolant High Temperature Lamp
13 Coolant High Temperature Switch (N.O.)
14 Oil Pressure (Low) Lamp
15 Oil Pressure Switch (N.C.)
16 Alternator Charging Lamp (Off if Charging)
17 Diode
18 Air Filter High Restriction Indicator
19 Air Filter Restriction Switch (N.O.)
20 Low Fuel Level Lamp
21 Low Fuel Level Switch (N.O.)

A Accessory
B Off Position
C On Position
D Starting Position

Note: This electric starting diagram holds for both 45A and 65A
alternators.
Battery 3 is not supplied by LOMBARDINI.
Anyhow, for installation we recommend a battery for all the
range of engines with the following particulars, see following
table.

187

Connection diagram for preheating control unit

Components:

1 Cable cross-section 2.5 mm2 at point “50” of the key panel

2 Cable cross-section 6 mm2 at the fuse holder box
3 Cable cross-section 1.5 mm2 at the earth
4 Cable cross-section 1 mm2 at the spark plug warning light (max. 2 W)
5 Cable cross-section 6 mm2 at point “30” of the key panel
6 Cable cross-section 1 mm2 at the water temperature sensor
7 Cable cross-section 1.5 mm2 at the fuse

188

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 XIII ELECTRIC SYSTEM
Starting Motor 12V

Bosch type EV 12V 2.2 Kw

RH direction of rotation.

Note: Apply to a Bosch service center for any tipe of repair.

189

Characteristic curves for starting motor type Bosch EV 12V 2.2

kW

The solid lines were obtained at a temperature of +20°C; the dotted

lines were obtained at a temperature of -20°C.Battery type 110 Ah
450A.

U = Motor terminal voltage in Volt

n = Motor speed in rpm.
A =Absorbed current in Ampere
P =Power in kW
M = Torque in Nm

190

Key switch electrical layout

A = Accessory
B = Off position
C = On position
D = Starting position

191

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 ELECTRIC SYSTEM XIII
Starting Motor 24V

Iskra type AZE 4598 24V 3 kW

RH direction of rotation.

192

Characteristic curves for starting motor Iskra type AZE 4598 24V
3 kW

The thick lines were obtained at a temperature of +20°C; the thin lines
were obtained at a temperature of -20°C. Battery type 55 Ah 300A.

U = Motor terminal voltage in Volt

n = Motor speed in rpm.
A =Absorbed current in Ampere
P =Power in kW
M = Torque in Nm

193

Key switch electrical layout

A = Accessory
B = Off position
C = On position
D = Starting position

194

Spacer flange for starter motor

The 24V starter motor requires the assembling of the spacer flange.

195

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 XIII ELECTRIC SYSTEM
Pre-heating glow plug
Components:
1 Sheath 2 Regulation filament
3 Heating filament
Installation torque 20 Nm.
Glow plug Type 12 V 24 V

Nominal voltage 12.5 V 25 V

Current 12 ÷ 14 A( after 5") 15 A ( after 60")

Sheath surface 850°C ( after 9")

850°C ( after 5")
temperature 1100°C ( after 1')

Note: The glow plug is not damaged in any way due to the prolonged
196 197 activation time.

Glow plug controller relay with coolant temperature sensor

To avoid white smoke generation at cold start-up, post-heating is
maintained for approximately 5 sec. after starting.

Trasducer Heating time in seconds

Resistance Temperature Pre-heating Pre-heating Starting control
Ω °C 12V 24V andPost-heating
- 30 11860 - ~ 30

- 20 7000 23.5 ÷ 29.5 19 ÷ 23

0 2400 13.5 ÷ 16.5 9.5 ÷ 12.5

4÷7
+ 20 1000 8.5 ÷ 10.5 5÷7

198 + 40 460 6.0 ÷ 8.0 2÷4

+ 50 ≤ 320 Stop

Temperature sensor (Thermistor)

The thermistor is located on the thermostat housing, adjacent to the

high coolant temperature switch. The thermistor must be installed in
the thermostat housing in the port located nearest to the cylinder
head. (See the figure to the left)
Characteristic:
Voltage ............................... 6/24 V
Max. installation torque ..... 30 Nm.

Features of standard sensor

Temperature °C Resistance Ω
199
-30 9790 ÷ 13940
Features of heavy-duty -20 6300 ÷ 7700
start sensor
Temperature Resistance Ω -10 4900 ÷ 3600
°C
+ 37.7 1125 -0 2160 ÷ 2640

+ 65.5 405 + 20 900 ÷ 1100

+ 37.7 448 ÷ 672

+ 93.3 170
+ 65.5 180 ÷ 270
+ 100 140
+ 93.3 80 ÷ 120
+ 121.1 80
+ 100 75 ÷ 95

+ 121.1 45 ÷ 55

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 ELECTRIC SYSTEM XIII
Coolant high temperature lamp switch

Characteristics:

Single-pole circuit, normally open

Supply voltage ......................... 6÷24V
Absorbed power ....................... 3W
Circuit closing temperature ...... 107÷113°C
When refitting tighten to 25 Nm.

200 201

Thermistor for electric thermometer

Thermistor features
Temperature °C Resistance Ω

-35 73806 ÷ 53983

-30 52941 ÷ 39229

-15 20825 ÷ 18006

0 8929 ÷ 7095

+ 30 2040 ÷ 1718

+ 60 589 ÷ 521

202 + 90 205 ÷ 189

+ 120 85 ÷ 77

Thermistor for preheating water temperature – Thermal contact

for water temperature indicator light

Thermal contact T1 features

Temperature °C Resistance Ω

-30 9971 ÷ 14199

-20 6045 ÷ 8445

-0 2457 ÷ 3333

+ 20 1169 ÷ 1541

+ 40 659 ÷ 849
203
+ 60 435 ÷ 547

+ 80 327 ÷ 405

+ 100 275 ÷ 335

+ 120 146 ÷ 296

Thermal contact T2 features

Circuit Unipolar
Closing temperature 107 ÷ 113 °C
Contactopeningtemperature > 85 °C
Supply voltage 12 ÷ 24 V
Maximum thermal contact power 3W

The max. torque is 30 Nm.

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XIV SETTINGS
Settings

Idling speed setting in no-load conditions (standard)

After filling with oil, fuel and coolant, start the engine and warm up
for 10 minutes.
Adjust idling speed at 850÷950 rpm by turning screw 1 then tighten
lock nut.

Note: Speed decreases when loosening scew 1 and increases when

tightening it.

204

Full speed setting in no-load conditions (standard)

Before carrying out this operation, make sure that the engine
adjustment is standard; i.e. corresponding to one of the power
curve diagrams shown on pages 16-17.

Example of adjustment of an engine at 3000 rpm:

After setting idle speed turn screw 2 and set full speed in no-load
conditions at 3200 rpm; then tighten lock nut.
When the engine reaches the pre-set power, full speed stabilizes at
3000 rpm.

Nota: Speed increases when loosening scew 2 and decreases when

205 tightening it.

Standard injection pump delivery setting without torque

dynamometer

This adjustment must only be carried if necessary and if there is no

dynamometric brake, since this type of adjustment is very approximate.

Loosen delivery limiting device C by 5 turns.

Bring engine to max. rpm in no-load conditions i.e. 3200 rpm.
Tighten limiting device C until the engine rpm decreases.
Unscrew limiting device C by 1 1/2 turn.
Tighten lock nut.

Note:If the engine, at full load, generates too much smoke tighten C;
loosen C if no smoke is observed at the exhaust and if the
206
engine cannot deliver its full power.

Injection pump delivery limiting and torque adjusting device

Limiting device C has the function of limiting the injection pump

maximum delivery
The same device acts as torque adjusting device since springs N act
on lever L and thus oppose the resistance of spring M contained in
the barrel.
The torque limiting device allows lever L to have a stroke H of
1.0÷1.1 mm: this increases the injection pump delivery while torque
reaches its peak.

Note: In application for generating sets and motor welding units the
torque adjusting device only acts as delivery limiting device
207 without spring M and stroke H.

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 SETTINGS XIV
Fuel limiting device (fig. 208-209)

When starting up the engine the fuel limiting device has the aim of
preventing excessive smoke at the exhaust.
Use the delivery adjustment rod of the injection pumps 5 Fig.209 in a
constant manner when ambient temperature is above 15°C.
As the temperature gradually falls, this device gradually lessens its
action to then exclude it at 0°C.

208

Fuel limiting device adjustment (fig208-209)

• Take the engine to the setting speed and power

• Loosen the lock nut 2.
• Unscrew the screw 1 (to bring lever 4 close up to rod 5) until the
engine speed tends to decrease.
• Screw the screw down by at most 1/2, 3/4 of a turn so as to
distance lever 4 from rod 5 by 1.2/1.8 mm.
Screw down the lock nut 2.
• When the temperature falls under 0°C, lever A turns (pin 6 of the
thermostat 3 comes back in) to go into position B thereby
allowing rod 5 to go into the supplement position.
209

Stop setting

• Unscrew the screw 2

• Move rod 1 fully to the left.
• Screw down screw 2 to touch rod 1.
• Continue screwing screw 2 by 1/2 turn.
• Lock nut 3.

Note: In these conditions the injection pump delivery control limit

stops cannot be damaged by violent impact caused by
operation of any electro-stops that may be fitted.

210 211

Application diagram for tampering system adjustment screw and

torque gearing device for EPA-approved engines

Components:

1 Breaking nut
2 STEI screw
3 Rivets (No.2)
4 TCEI screw
5 Special cover fixing screw
6 Lower plate
7 Upper plate

212

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 XV STOCKAGE
Storage

When the engines are not used for long periods they have to be protected performing the operations described :

Internal engine protection:

- Start the engine and heat it.
- Stop the engine.
- Remove the drain plug and let the oil flow completely.
- Replace the oil filter with a new one (screw manually the new filter).
- Clean the oil drain plug and after having assembled a new gasket, tighten it.
- Carry out the oil refilling to the upper level of the rod, using AGIP RUSTIA C (for Countries in which this product is not available
find an equivalent product on the market).
- Start for about 10 minutes and verify any possible oil leakage, then stop the engine.

Injection systems protection:

- Empty the fuel tank.
- Replace the fuel filter with a new one.
- Carry out the filling of fuel using 10% of AGIP RUSTIA NT special additives.
- After having performed the air bleeding, start the engine, verify any possible fuel leakage, then stop the engine.

External engine protection:

- Carefully clean the radiator the exchange surface and the fan.
- Loosen the drive belt of the fan and of voltage alternator.
- Protect the external non-painted surfaces with AGIP RUSTIA 100/F.
- Seal with adhesive tape the intake and exhaust systems
- Coat the engine with a nylon or plastic sheet.
- Keep in a dry place. If possible not in direct contact with the ground and away from high voltage electric lines.

PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE

- Remove all protections and coverings.
- Remove the rust preventer from the external part of the engine by means of adequate products (solvent or degreaser).
- Tension the blower timing belt.
- Disassemble the injectors and introduce, by means of a bowl, motor oil on the piston crown ( no more than 2 cc for every cylinder).
- Remove valve covers and spray motor oil on the valves, then turn the crankshaft manually for a few revolutions.
- Start the engine and heat it for about 10 minutes.
- Remove the drain plug and let the protective oil flow completely.
- Reinsert the drain plug.
- Carry out motor oil refilling to the upper level of the rod using the oil recommended by the manufacturer for a normal engine
operation.

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 NOTE XV

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 XVI TORQUE SPECIFICATIONS

MAIN TORQUE SPECIFICATIONS

Diam.and pitch Torque Type of
POSITION Nm sealant
mm
Diesel fuel union bolts 14x1.5 40
Flywheel housing 10x1.5 50
Preheating glow plug 12x1.25 20
Roker arm cover 8x1.25 20
Main bearing cap 12x1.25 120
Cap vent 6x1 10
Intake manifold 8x1.25 25
Exhaust manifold 8x1.25 25
Throttle cover 6x1 10
Camshaft cover 6x1 10
Timing cover 8x1,25 25
1P hydraulic pump flange cover 6x1 10
Hydraulic pump gear support cover 8x1,25 25
Oil pump top cover 6x1 10 Loctite 270
Oil pump bottom cover 6x1 10 Loctite 518
Thermostat cover 8x1,25 25
Oil sump 8x1,25 25
Water pump case and pump support 8x1,25 25
Flange for flywheel control oil sealing ring 6x1 10
Nozzle clamping ring nut 24x2 70 ÷ 90
Rod support ring nut 18x1,5 40
Equalizer unit 10x1,5 60 Loctite 242
Oil pressure indicator 12x1.5 35
Camshaft gear 10x1 100
Injector 24x2 70
Starting motor 10x1.5 45
Intermediate pin 8x1,25 25
Front engine foot 16x1.5 200
Engine foot on bell 10x1.5 40
Fuel pump 8x1,25 25 Loctite 270
Injection pump 8x1,25 25
Feed pump stud bolts 8x1.25 10
Drive puly 16x1.5 360
Oil filter nipple UNF 3/4 - Loctite 270
Fuel pump and solenoid valve union 10x1 12
Injection pump union 12x1.5 35
Intermediate thrust block union 22x1.5 150 Loctite 270
Injection pump union 12x1.5 25
Water recirculation unions in brass 14x1.5 - Loctite 554
Revolution counter driving gear 5x0,8 5
Alternator bracket 8x1,25 25
Engine mounting bracket 12x1.75 50
Bracket of the oil suction hose with equalizer 6x1 10
Bracket of the oil suction hose without equalizer 8x1 25 Loctite 242
Alternator support 8x1,25 25
Injection pump control rod support 6x1 10
Rocker arm assembly 10x1.5 50 Loctite 270
Governor lever support 6x1 10
Tank bracket 8x1.25 30
Thermostat support 8x1,25 25 Loctite 242
Crankcase lubrication port plug 14x1.25 - Loctite 554
Plug for oil pressure regulating valve 16x1,5 50
Water drain plug 14x1.5 40 Loctite 242
Oil drain plug 18x1.5 50
Air bleed plug under oil sump 12x1.5 35 Loctite 242
Head (see fig. 55 - 56 )
Connecting rod big end 10x1,5 70

COMPILER TECO/ATLO REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

78 REVISION 04 09.05.2006
1-5302-345 50534 31.12.1989
 TORQUE SPECIFICATIONS XVI

MAIN TORQUE SPECIFICATIONS

Diam.and pitch Torque Type of
POSITION Nm sealant
mm
Oil suction hose 6x1 10
Air bleed tube under oil sump 12x1.5 35 Loctite 518
Water pump control fan and pulley 6x1 10
Alternator fixing screw 10x1,5 40
Flywheel 12x1.25 140 Loctite 270

COMPILER TECO/ATLO REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

1-5302-345 31.12.1989
REVISION 04 09.05.2006 79
50534
 XVI TORQUE SPECIFICATIONS

TIGHTENING TORQUE TABLES

The tables show the tightening torques for standard screws and the main components.
Tightening torques are provided again, along with method and sequence, in the instructions for assembling
components and/or assemblies
Table of tightening torques for standard screws (coarse thread)
Resistance class (R)

4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9

Quality/
Dimensions

R>400N/mm2 R>500N/mm2 R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2

Diameter
Nm Nm Nm Nm Nm Nm Nm Nm
M3 0,5 0,7 0,6 0,9 1 1,4 1,9 2,3
M4 1,1 1,5 1,4 1,8 2,2 2,9 4,1 4,9
M5 2,3 3 2,8 3,8 4,5 6 8,5 10
M6 3,8 5 4,7 6,3 7,5 10 14 17
M8 9,4 13 12 16 19 25 35 41
M10 18 25 23 31 37 49 69 83
M12 32 43 40 54 65 86 120 145
M14 51 68 63 84 101 135 190 230
M16 79 105 98 131 158 210 295 355
M18 109 145 135 181 218 290 405 485
M20 154 205 193 256 308 410 580 690
M22 206 275 260 344 413 550 780 930
M24 266 355 333 444 533 710 1000 1200
M27 394 525 500 656 788 1050 1500 1800
M30 544 725 680 906 1088 1450 2000 2400

Table of tightening torques for standard screws (fine thread)

Resistance class (R)

4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9

Quality/
Dimensions

R>400N/mm2 R>500N/mm2 R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2

Diameter
Nm Nm Nm Nm Nm Nm Nm Nm
M 8x1 10 14 13 17 20 27 38 45
M 10x1 21 28 26 35 42 56 79 95
M 10x1,25 20 26 24 33 39 52 73 88
M 12x1,25 36 48 45 59 71 95 135 160
M 12x1,5 38 45 42 56 68 90 125 150
M 14x1,5 56 75 70 94 113 150 210 250
M 16x1,5 84 113 105 141 169 225 315 380
M 18x1,5 122 163 153 203 244 325 460 550
M 18x2 117 157 147 196 235 313 440 530
M 20x1,5 173 230 213 288 345 460 640 770
M 20x2 164 218 204 273 327 436 615 740
M 22x1,5 229 305 287 381 458 610 860 1050
M 24x2 293 390 367 488 585 780 1100 1300
M 27x2 431 575 533 719 863 1150 1600 1950
M 30x2 600 800 750 1000 1200 1600 2250 2700

COMPILER TECO/ATLO REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

80 REVISION 04 09.05.2006
1-5302-345 50534 31.12.1989
 SPECIAL TOOLS XVII

SPECIAL TOOLS DESCIPTION Part No.

Fuel delivery equalization tool. Allows the

adjustment of individual unit injector fuel 7104-1460-090
delivery.

Glass column for fuel delivery

equalization tool. 7104-1460-072

Camshaft bushing replacement

tool 7104-1460-021

Static timing tool 7271-1460-024

T.D.C. determination fixture. 7107-1460-075

Pliers for injection pump feeding tubes

1 For tube diam. 6 mm 1 7104-1460-022

2 For tube diam. 8 mm 2 7104-1460-023

Tool for replacement of injection pump outlet

union:
7107-1460-212
1 For extraction
2 For driving

COMPILER TECO/ATLO REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

1-5302-345 31.12.1989
REVISION 04 09.05.2006 81
50534
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COMPILER TECO/ATLO REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

82 REVISION 04 09.05.2006
1-5302-345 50534 31.12.1989