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Lombardini LDW 1204/T User Manual

Lombardini LDW 1204/T
106 pages
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cod. 1-5302-351
WORKSHOP MANUAL
FOCS Engine Series

Table of Contents

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Lombardini LDW 1204/T Specifications

General IconGeneral
Number of Cylinders4
Cooling SystemWater-cooled
AspirationNaturally aspirated
Fuel SystemIndirect injection
Starting SystemElectric starter
Engine TypeDiesel

Summary

GENERAL REMARKS AND SAFETY INFORMATION

GENERAL SAFETY DURING OPERATING PHASES

Safety precautions for engine operation, including warnings and guidelines.

GENERAL SERVICE MANUAL NOTES

Guidelines for using the manual and performing service operations.

GLOSSARY AND TERMINOLOGY

Definitions of terms used throughout the manual for clarity.

SAFETY AND ENVIRONMENTAL IMPACT

Procedures to assess and monitor the engine's environmental impact.

SAFETY AND WARNING DECALS

Explanation of symbols and decals used to highlight risks.

SAFETY REGULATIONS

Rules and regulations to ensure safe engine operation and maintenance.

WARRANTY CERTIFICATE

Details on the warranty period, terms, and conditions for Lombardini engines.

TECHNICAL INFORMATION

MANUFACTURER AND ENGINE IDENTIFICATION

Information on identifying engine type, serial number, and manufacturer details.

OVERALL DIMENSION

Technical drawings showing engine dimensions and layout for various models.

PERFORMANCE DIAGRAMS

Graphs illustrating engine power, torque, and fuel consumption curves.

TECHINICAL SPECIFICATIONS

Detailed specifications for different engine models, including bore, stroke, and power.

TROUBLE SHOOTING

Table listing possible engine anomalies, their symptoms, and causes.

MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

ROUTINE ENGINE MAINTENANCE

Schedule for ordinary maintenance checks and replacements based on operating hours.

LUBRICANT

Guidelines on SAE classification, international specifications, and oil types.

PRESCRIBED LUBRICANT

Recommended lubricants and oil capacities for different engine models.

COOLANT

Information on coolant type, freezing point, and disposal, with safety warnings.

FUEL SPECIFICATIONS

Requirements for fuel quality, cetane number, and low-temperature performance.

DISASSEMBLY / REASSEMBLY

RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING

General advice and safety precautions before starting disassembly and reassembly.

RECOMMENDATIONS FOR OVERHAULS AND TUNING

Guidelines for performing engine overhauls and tuning operations safely.

Dry type air filter

Procedure for cleaning and maintaining the dry type air filter element.

E.G.R. Circuit

Explanation of the EGR system and its components, with disassembly steps.

Crankshaft, disassembly

Steps for removing the camshaft, including checking the gasket and drive rod.

Camshaft journals and housings - Dimensions (mm)

Specifications for camshaft journal and cylinder head bore dimensions.

CYLINDER HEAD, removal

Procedure for removing the cylinder head, with warnings about deformation.

Piston, assembly

Steps for assembling pistons, including lubrication and fitting to the connecting rod.

Main bearings and connecting rod big ends diameters

Dimensions for main bearings and connecting rod big ends, including tolerances.

Crankshaft front and back oil seal rings

Procedure for replacing crankshaft oil seal rings, with important warnings.

TURBOCHARGER

TURBO CHARGER

Overview of turbocharger availability for specific engine models.

Turbocharger components

Illustrated list of turbocharger parts and their designations.

Turbocharger pressure testing

Procedure for testing turbocharger pressure using a gauge.

Turbocharger west gate adjustment

Instructions for adjusting the turbocharger waste gate for proper operation.

LUBRIFICATION CIRCUIT

LUBRIFICATION CIRCUIT

Diagram and components of the engine's lubrication system.

Internal oil filter and oil sump return pipe

Steps for cleaning the internal oil filter and return pipe.

Oil pump

Information on oil pump delivery rates and pressure tests for different models.

Oil pump, clearance between rotors

Procedure for measuring rotor clearance in the oil pump and wear limits.

Oil pressure regulating valve

Components and function of the oil pressure regulating valve.

Oil filter cartridge

Specifications and characteristics of the oil filter cartridge.

Oil pressure check

Method for checking oil pressure after engine reassembly.

COOLANT CIRCUIT

COOLANT CIRCUIT

Diagram illustrating the engine's coolant circulation system and its components.

Radiator and compensation, check and seal tank cap

Procedures for checking coolant level, radiator, and tank cap integrity.

Coolant circulation pump, components

Identification of parts within the coolant circulation pump assembly.

Thermostatic valve

Characteristics and operating parameters of the thermostatic valve.

FUEL SYSTEM

Fuel feeding / injection circuit

Diagram of the fuel supply and injection system components.

Fuel filter detached from the tank (on request)

Characteristics and specifications of the external fuel filter.

Fuel lift pump

Information on the fuel lift pump, its drive, and operating characteristics.

Pump/injector unit

Overview of the pump/injector system exclusive to FOCS engines.

Pump/injector unit, components

Detailed list and illustration of pump/injector unit components.

Injection pump assembly/disassembly

Step-by-step instructions for the assembly and disassembly of the injection pump unit.

Injector, setting (old type)

Procedure for setting the injection pressure for old-type injectors.

Setting of injector according to current pump/injector unit

Method for setting injectors with current pump/injector units.

Injection advance control and regulation

Steps for controlling and regulating injection advance using specific tools.

Static injection advance tuning

Procedure for tuning static injection advance by adjusting a screw.

TDC (Top Dead Center) references

References on the timing belt protector for identifying TDC on various engine series.

Static injection advance regulation

Steps for regulating static injection advance by setting pump delivery control rod.

Injection pumps delivery balancing

Steps for balancing injection pump deliveries if errors are detected.

ELECTRIC SYSTEM

ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP (UPON REQUEST)

Diagram and explanation of the electric control panel and auxiliary terminals.

Alternator, Iskra 14V 33A

Specifications and performance curve for the Iskra 14V 33A alternator.

Electric starting layout (12V) with Iskra alternator 14V 33A

Wiring diagram for the 12V electric starting system with Iskra alternator.

Alternator, Marelli type AA 125 R 14V 45A

Specifications and performance curve for the Marelli AA 125 R 14V 45A alternator.

Electric starting layout (12V) with Marelli type AA 125 R 14V 45A alternator

Wiring diagram for the 12V electric starting system with Marelli alternator.

Flywheel Alternator

Information on flywheel alternators available in 12V 20A and 30A versions.

Alternator battery charger curve 12V 20A

Charging curve for the 12V 20A flywheel alternator.

Alternator battery charger curve 12V 30A

Charging curve for the 12V 30A flywheel alternator.

Electric starting layout (12V) with flywheel alternator

Wiring diagram for the 12V electric starting system using a flywheel alternator.

STARTER MOTOR - Bosch DW 12V 1,1 KW

Specifications and performance curve for the Bosch DW 12V 1.1 KW starter motor.

Pre-heating glow plug

Characteristics and components of the pre-heating glow plug.

Pre-heating plug control unit with coolant temperature sensor

Functionality of the pre-heating control unit based on coolant temperature.

Temperature sensor for control unit

Function and characteristics of the temperature sensor for the control unit.

Oil pressure switch

Characteristics and tightening torque for the oil pressure switch.

SETTINGS

SPEED SETTINGS

Procedures for setting minimum and maximum engine idle speeds.

Setting the idle minimum (standard)

Adjusting the engine idle speed to the specified minimum rpm.

Setting the idle maximum (standard)

Regulating the engine's maximum idle speed to the specified rpm.

Pump injection delivery standard setting without dynamometric brake

Approximate adjustment of pump injection delivery without a dynamometer.

Pump/injector unit delivery setting with braked engine

Procedure for setting pump/injector unit delivery with a dynamometer.

Required settings (as most commonly applies)

Table of required engine settings for various models and operating conditions.

E.G.R. calibration

Procedure for calibrating the EGR valve position based on vacuum pressure.

STORAGE

ENGINE STORAGE (NOT INSTALLED)

Guidelines for storing the engine properly when not in use.

PROTECTIVE TREATMENT

Measures to protect the engine during extended periods of inactivity.

PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT

Steps to take before operating an engine that has undergone protective treatment.

TORQUE SPECIFICATIONS AND USE OF SEALANT

Table of tightening torques for the main components

Torque values for major engine components and their specifications.

Table of tightening torques for standard screws (coarse thread)

Torque specifications for standard screws with coarse threads based on size and class.

Table of tightening torques for standard screws (fine thread)

Torque specifications for standard screws with fine threads based on size and class.

SPECIAL TOOLS

Injection pumps delivery balancing instrument

Tool for balancing injection pump deliveries.

Precombustion chamber extractor

Tool used to extract the precombustion chamber.

Injection pump static injection advance tester(old type)

Tester for checking static injection advance on old-type pumps.

Tool for injection advance control and setting of injector for pump/injector unit: se.no. 6590-272

Tool for controlling and setting injectors on specific pump/injector units.

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