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Lombardini LDW 903 User Manual

Lombardini LDW 903
106 pages
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cod. 1-5302-351
WORKSHOP MANUAL
FOCS Engine Series

Table of Contents

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Lombardini LDW 903 Specifications

General IconGeneral
Engine TypeDiesel
Number of Cylinders3
Cooling SystemLiquid-cooled
Fuel TypeDiesel
AspirationNaturally Aspirated
Fuel SystemIndirect injection
Starting SystemElectric
Displacement0.903 L
Bore x Stroke72 mm x 73 mm
Maximum Torque52 Nm @ 2200 RPM

Summary

Preface

General Service Manual Notes

Notes for using the service manual, including data format and terminology.

Glossary and Terminology

Definitions of terms used in the manual for clarity.

Safety and Warning Decals

Explanation of symbols used for warnings and important information.

Safety Regulations

Rules and precautions for safe engine operation and maintenance.

General Safety During Operating Phases

Specific safety measures for operating the engine safely.

Safety and Environmental Impact

Procedures for assessing and minimizing environmental impact.

Technical Information

Trouble Shooting

Table of common engine anomalies, symptoms, and possible causes.

Manufacturer and Engine Identification

Information on identifying the engine type and serial number via its nameplate.

Technical Specifications

Detailed specifications for various LOMBARDINI engine models.

Performance Diagrams

Graphical representation of engine performance curves (power, torque).

Overall Dimension

Technical drawings showing engine dimensions for different models.

Maintenance - Recommended Oil Type - Refilling

Routine Engine Maintenance

Maintenance schedule based on operating hours.

Lubricant

Guidelines for selecting appropriate engine oil based on SAE and ACEA classifications.

Prescribed Lubricant

Recommended oil types and capacities for different engine models.

Coolant

Information on coolant type, mixture, and handling precautions.

Disassembly / Reassembly

Recommendations for Disassembling and Assembling

General guidelines and safety precautions for disassembly and reassembly.

Recommendations for Overhauls and Tuning

General guidelines for engine overhauling and tuning procedures.

Dry type air filter

Details on the dry type air filter, its specifications and maintenance.

E.G.R. Circuit

Explanation and components of the Exhaust Gas Recirculation system.

Exhaust manifold

Instructions for removing and installing the exhaust manifold.

Cooling fan

Procedure for cooling fan disassembly and checks.

Alternator/Cooling fan belt drive

Instructions for adjusting alternator and cooling fan belt tension.

Flywheel

Procedure for flywheel disassembly and ring gear replacement.

Ringfeder-type rings on LDW 1204-1204/T-1404

Mounting of Ringfeder rings for power transmission.

Timing belt / Timing pulley arrangement

Diagram showing the timing belt and pulley setup.

Camshaft timing - Belt Reassembly

Steps for correctly reassembling the timing belt.

Camshaft timing - Belt Tightening and Fastening

Procedure for setting and tightening the timing belt tension.

Valve timing - Angles

Timing angles for valve opening and closing relative to piston position.

Speed governor

Description of the mechanical speed governor and its components.

Speed governor - Limiting speed governor

Specific governor type for automotive applications.

Oil pump - disassembly

Procedure for disassembling the engine oil pump.

Rocker arm cover

Description of the rocker arm cover and its functions.

Crankcase vacuum regulator valve

Explanation of the crankcase vacuum regulator valve's function.

Valve / Rocker arm clearance

Procedure for checking and setting valve and rocker arm clearance.

Fuel rail

Instructions for removing and refitting the fuel rail.

Pump/injector unit - non-return valve

Details on the pump/injector unit's non-return valve function.

Pump/injector unit - Disassembly

Procedure for disassembling a pump/injector unit.

Camshaft, disassembly

Step-by-step guide for camshaft removal.

Camshaft journals and housings - Dimensions

Dimensional data for camshaft journals and cylinder head housings.

Cylinder head, removal

Procedure for removing the cylinder head.

Valves

Instructions for removing and installing engine valves.

Valve, specifications

Specifications for intake and exhaust valves.

Valve guides and valve guide housings

Information on valve guides and their housings.

Valve seats and housings - Dimensions

Dimensional data for valve seats and housings.

Pre-combustion chamber

Information on the pre-combustion chamber and its components.

Oil pan, removal

Procedure for removing the engine oil pan.

Piston, disassembly and inspection

Steps for disassembling and inspecting pistons.

Piston, class

Classification of pistons based on diameter.

Piston, weight

Procedure for weighing pistons to ensure balance.

Piston rings - End gaps (mm)

Measurement of piston ring end gaps.

Piston, assembly

Procedure for assembling pistons into cylinders.

Head gasket

Instructions for selecting and installing the head gasket.

Cylinder head assembly

Procedure for tightening the cylinder head bolts.

Connecting rod

General information and checks for connecting rods.

Connecting rod with bearings and pin

Dimensional data for connecting rods, bearings, and pins.

Connecting rod alignment

Procedure for checking and adjusting connecting rod alignment.

Cylinders

Instructions for checking cylinder diameter and wear.

Central main bearing caps

Procedure for tightening central main bearing caps.

Check the clearances between the bearings and the journal

Method for measuring bearing and journal clearances.

Piston coolant nozzles

Details on piston coolant nozzles and their installation.

Crankshaft axial clearance

Procedure for measuring crankshaft axial clearance.

Crankshaft front and back oil seal rings

Instructions for replacing crankshaft oil seal rings.

Crankshaft, lubrication lines

Maintenance of lubrication lines within the crankshaft.

Crankshaft, check journals and crank

Procedure for checking crankshaft journals and crank.

Main bearings and connecting rod big ends diameters

Dimensional data for main bearings and big end diameters.

Clearances between the bearings and corresponding pins

Measurement of clearances for bearings and pins.

Hydraulic pump drive

Information on the hydraulic pump drive.

Turbocharger

Turbocharger components

List and diagram of turbocharger components.

Turbocharger pressure testing

Procedure for testing turbocharger pressure.

Turbocharger west gate adjustment

Procedure for adjusting the turbocharger waste gate.

Lubrication Circuit

Internal oil filter and oil sump return pipe

Procedure for cleaning and replacing parts of the oil filter and return pipe.

Oil pump

Information on oil pump delivery rates and testing.

Oil pressure regulating valve

Description and function of the oil pressure regulating valve.

Oil filter cartridge

Details and characteristics of the oil filter cartridge.

Oil pressure check

Procedure for checking engine oil pressure.

Coolant Circuit

Coolant filler plug

Procedure for checking and topping up coolant.

Coolant circulation pump, components

Components of the coolant circulation pump.

Thermostatic valve

Characteristics and function of the thermostatic valve.

Fuel System

Fuel feeding / injection circuit

Overview of the fuel feeding and injection system.

Fuel filter detached from the tank (on request)

Details of the fuel filter and its characteristics.

Fuel lift pump

Description and characteristics of the fuel lift pump.

Pump/injector unit

Introduction to the pump/injector unit system.

Pump/injector unit, components

List of components for the pump/injector unit.

Plunger barrel ring nut assembly/disassembly

Procedure for assembling/disassembling the plunger barrel ring nut.

Injection pump assembly/disassembly

Steps for assembling and disassembling the injection pump unit.

Pumping element (old-type injection pump)

Description of the old-type injection pump's pumping element.

Pump/injector unit se.no. 6590.285 control data

Control data for specific pump/injector units.

Old type injector pump

Description of the old type injector pump system.

Intermediate injector pump

Description of the intermediate injector pump system.

Current pump injector

Description of the current pump injector system.

Injector, setting (old type)

Procedure for setting old type injectors.

Setting of injector according to current pump/injector unit

Procedure for setting current pump/injector units.

Injection advance control and regulation

Procedure for controlling and regulating injection advance.

Static injection advance tuning

Method for tuning static injection advance.

TDC (Top Dead Center) references

References for identifying Top Dead Center on the engine.

Static injection advance regulation

Procedure for regulating static injection advance.

Injection pumps delivery balancing

Procedure for balancing injection pump deliveries.

Electric System

Electric Control Panel with Automatic Engine Stop

Diagram and terminals for the electric control panel.

Alternator, Iskra 14V 33A

Specifications for the Iskra 14V 33A alternator.

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

Wiring diagram for 12V electric starting with Iskra alternator.

Alternator, Marelli type AA 125 R 14V 45A

Specifications 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 12V electric starting with Marelli alternator.

Flywheel Alternator

Description of the flywheel alternator types.

Alternator battery charger curve 12V 20A

Performance curve for the 12V 20A alternator.

Electric starting layout (12V) with flywheel alternator

Wiring diagram for 12V electric starting with flywheel alternator.

Starter Motor - Bosch DW 12V 1,1 KW

Specifications for Bosch DW 12V 1.1 KW starter motor.

Starter motor, Bosch DW 12V 1,6 Kw

Specifications for Bosch 12V 1.6 KW starter motor.

Pre-heating glow plug

Characteristics of the pre-heating glow plug.

Pre-heating plug control unit with coolant temperature sensor

Function of the glow plug control unit with temperature sensor.

Temperature sensor for control unit

Details of the temperature sensor for the control unit.

Oil pressure switch

Characteristics of the oil pressure switch.

Settings

Speed Settings

Procedures for setting engine idle speed (minimum and maximum).

Injection pump flow limiter and engine torque gearing device

Function of the injection pump flow limiter and torque gearing device.

Setting the stop

Procedure for setting the engine stop mechanism.

Pump/injector unit delivery setting with braked engine

Procedure for setting pump/injector delivery using a dynamometer.

Required settings (as most commonly applies)

Table of required engine settings for optimal performance.

E.G.R. calibration

Procedure for calibrating the Exhaust Gas Recirculation system.

Storage

Engine Storage (Not Installed)

Guidelines for storing the engine when not installed.

Protective Treatment

Steps for applying protective treatment to the engine.

Preparing the Engine for Operation After Protective Treatment

Procedures for preparing a stored engine for operation.

Torque Specifications and Use of Sealant

Table of tightening torques for the main components

Table listing torque specifications for major engine components.

Table of tightening torques for standard screws (coarse thread)

Torque values for standard coarse thread screws based on size and class.

Table of tightening torques for standard screws (fine thread)

Torque values for standard fine thread screws based on size and class.

Special Tools

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