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Lombardini LDW 1003 Repair Manual

Lombardini LDW 1003
88 pages
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WORKSHOP
MANUAL
Focs series engines, code 1-5302-351
SERVICE
1
LDW 502
LDW 602
LDW 903
LDW 1204
LDW 1204/T
LDW 702
LDW 1003
LDW 1404
5st Edition
COMPILER TECO/ATL
REG. CODE
1-5302-351
MODEL N°
50563
DATE OF ISSUE
04.90
REVISION 04
ENDORSED
DATE
10.06.99

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Lombardini LDW 1003 Specifications

General IconGeneral
Number of Cylinders3
Cooling SystemWater-cooled
Power Output18.5 kW (25 hp) at 3000 rpm
Fuel SystemIndirect injection
Fuel TypeDiesel
Engine TypeDiesel, 4-stroke
Starting SystemElectric
Displacement1028 cm³ (62.7 in³)
Bore x Stroke75 x 77.6 mm (2.95 x 3.06 in)

Summary

FOREWORD

GENERAL SERVICE NOTES

General guidelines for servicing Lombardini engines, including safety and tool usage.

TROUBLESHOOTING CHART - LDW FOCS SERIES

SAFETY AND WARNING DECALS

Essential safety advice for operating and maintaining Lombardini engines to prevent risks.

I GENERAL

POWER RATINGS FOR LDW-FOCS GENSET SPEC DIESEL ENGINES

Continuous and intermittent power ratings (kW) for various LDW-FOCS diesel engine models.

LDW FOCS SERIES- TECHNICAL SPECIFICATIONS AND CAPACITIES

Technical data including bore, stroke, displacement, compression ratio, torque, and fluid capacities.

POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES

Performance graphs showing power, torque, and fuel consumption for specific LDW engine models.

LDW-FOCS SERIES MAINTENANCE SCHEDULE

A schedule outlining recommended maintenance operations and their intervals for LDW-FOCS engines.

RECOMMENDED OIL

Specifies recommended engine oil types, grades, and API/ACEA specifications.

DIESEL FUEL SPECIFICATIONS

Details on diesel fuel quality, storage, and EPA specifications required for Lombardini engines.

ANTI-FREEZE / COOLANT SPECIFICATIONS/DETAILS- FOCS SERIES

Guidelines for selecting and using anti-freeze/coolant mixtures, including concentration and water quality.

CRITICAL TORQUE SPECIFICATIONS

A table listing critical torque values for specific engine components and locations.

II DISASSEMBLY/REASSEMBLY

TIMING BELT INSTALLATION- TIMING PROCEDURE

Step-by-step guide for installing the timing belt, routing it correctly, and aligning marks.

TIMING BELT TENSION PROCEDURE

Details the procedure for tensioning the timing belt using a torque wrench and rotating the engine.

VALVE ADJUSTMENT

Procedure for adjusting valve clearances on a cold engine, including locknut tightening.

UNIT INJECTOR REMOVAL / INSTALLATION

Procedure for removing and reinstalling unit injectors, emphasizing not loosening adjustment screws.

CAMSHAFT REMOVAL/ REPLACEMENT

Procedure for removing and installing the camshaft, including inspection and torque for eccentric bolt.

CYLINDER INSPECTION / DIMENSIONAL SPECIFICATIONS

Procedure for inspecting cylinders, measuring bore dimensions, and determining piston clearance.

PISTON / CONNECTING ROD INSTALLATION

Procedure for installing the piston/connecting rod assembly into the cylinder, noting orientation and lubrication.

CYLINDER HEAD INSTALLATION

Procedure for installing the cylinder head, including cleaning, bolt stretching, and torque sequence.

CRANKSHAFT JOURNAL INSPECTION / MEASUREMENT

Steps for inspecting and measuring crankshaft journals for wear and dimensions.

CRANKSHAFT JOURNAL SPECIFICATIONS

Provides main and rod journal diameter specifications and wear limits for LDW engines.

III TURBOCHARGER

TURBOCHARGER PRESSURE TESTING

Procedure for testing turbocharger pressure, including gauge installation and expected readings.

TURBOCHARGER WASTE GATE ADJUSTMENT- BENCH METHOD

Detailed steps for bench testing and adjusting the turbocharger wastegate.

IV LUBRICATION SYSTEM

OIL PRESSURE TESTING

Procedure for measuring engine oil pressure using a calibrated gauge.

VI FUEL SYSTEM

UNIT INJECTOR POPPING PRESSURE TESTING AND ADJUSTMENT- HIGH PRESSURE PROCEDURE

Procedure for testing and adjusting popping pressure for early unit injectors using high pressure.

UNIT INJECTOR POPPING PRESSURE TESTING AND ADJUSTMENT- LOW PRESSURE PROCEDURE

Procedure for testing and adjusting popping pressure for current/intermediate injectors using low pressure.

STATIC INJECTION TEST INSTRUMENTATION- EARLY UNIT INJECTORS

Details on test instrumentation for static injection timing of early unit injectors.

TDC DETERMINATION and STATIC INJECTION TIMING CHECKING

Procedure for determining TDC and checking static injection timing using a fixture.

STATIC TIMING ADJUSTMENT

Steps for adjusting static injection timing using the timing adjustment screw.

VII ELECTRICAL SYSTEM

ELECTRICAL SYSTEM SERVICE PRECAUTIONS / WARNING

Safety precautions and warnings for working with electrical system components.

GLOW PLUG CONTROLLER / RELAY WITH COOLANT TEMP. SENSOR

Details on the glow plug controller, its functions, and temperature sensor data.

VIII TESTING-OPERATIONAL-ADJUSTMENTS

IDLE SPEED ADJUSTMENT

Procedure for adjusting the engine's idle speed using the adjustment screw.

HIGH (MAXIMUM) SPEED ADJUSTMENT

Steps for adjusting the engine's maximum speed, including throttle lever and locknut settings.

GOVERNOR / UNIT INJECTOR RACK ADJUSTMENT

Steps for adjusting the governor and unit injector rack for proper fuel delivery.

POWER, TORQUE DEVICE and SPEED ADJUSTMENTS- DYNAMOMETER METHOD.

Procedure for adjusting engine parameters using a dynamometer, with warnings.

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