Professional Documents
Culture Documents
12LD 435-2
12LD 435-2/B1
12LD 475-2
12LD 475-2 EPA
Drafting
body
CUSE/ATLO
Document
code
Model
N
Edition
Revision
Issue date
Review
date
1-5302-460
50705
9-93
14.06.2007
Endorsed
PREFACE
- Every attempt has been made to present within this service manual, accurate and up to date technical
information.
However, development on the LOMBARDINI series is continuous.
Therefore, the information within this manual is subject to change without notice and without obligation.
- The information contained within this service manual is the sole property of LOMBARDINI.
As such, no reproduction or replication in whole or part is allowed without the express written permission of
LOMBARDINI.
This manual was written by the manufacturer to provide technical and operating information to authorised
LOMBARDINI after-sales service centres to carry out assembly, disassembly, overhauling, replacement and
tuning operations.
As well as employing good operating techniques and observing the right timing for operations, operators must read
the information very carefully and comply with it scrupulously.
Time spent reading this information will help to prevent health and safety risks and financial damage.
Written information is accompanied by illustrations in order to facilitate your understanding of every step of the
operating phases.
-2-
CHAPTER INDEX
This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled, direct injection
Diesel engines type 12 LD 435-2 - 435-2/B1 - 475-2 - 475-2 EPA, updated 05-03-2007.
TABLE OF CONTENTS
-3-
Chapter index
Flywheel .................................................................................................................................................................. page 21
Governor springs with rocker arm ................................................................................................................................... 31
How to measure intake/exhaust cam height ................................................................................................................... 30
Hydraulic pump p.t.o. (1P) .............................................................................................................................................. 31
Injector projection ............................................................................................................................................................ 22
Main bearing and connecting rod big end bearing internal diameter ............................................................................ 29
Main bearing housing ...................................................................................................................................................... 29
Main bearing support, PTO-Side ..................................................................................................................................... 27
Main bearing support, timing gear side .......................................................................................................................... 27
Main bearing supports ..................................................................................................................................................... 29
Mechanical speed governor ............................................................................................................................................. 31
Oil-bath air cleaner .......................................................................................................................................................... 20
Piston ............................................................................................................................................................................... 24
Piston - Refitting .............................................................................................................................................................. 26
Piston clearance .............................................................................................................................................................. 26
Piston rings - End gaps ................................................................................................................................................... 25
Piston rings - Fitting sequence ........................................................................................................................................ 25
Piston weight .................................................................................................................................................................... 25
Pistons ringis - Clearance between grooves ................................................................................................................... 25
RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING .......................................................................... 20
RECOMMENDATIONS FOR OVERHAULS AND TUNING ............................................................................................ 20
Rocker arm assembly ...................................................................................................................................................... 22
Spring for extra fuel supply at starting ............................................................................................................................ 31
Valve guide insertion ....................................................................................................................................................... 23
Valve guides and valve guide housings .......................................................................................................................... 23
Valve I Rocker arm clearance ......................................................................................................................................... 21
Valve seat grinding .......................................................................................................................................................... 24
Valve seats and housings ................................................................................................................................................ 23
Valve timing without considering timing marks .............................................................................................................. 30
Valves ............................................................................................................................................................................... 23
-4-
Chapter index
Characteristic curves for starting motor type Bosch DWL 12 V, 1.7 kW ............................................................ Page 42
Electrical starting layout with battery charging light ....................................................................................................... 40
How to check voltage regulator for proper operation ..................................................................................................... 42
OPTIONAL ELECTRIC EQUIPMENT ............................................................................................................................. 41
Starting motor type Bosch DWL 12 V, 1.7 kW ............................................................................................................... 42
Voltage regulator .............................................................................................................................................................. 41
SETTINGS ______________________________________________________________________ 43 - 44
Full speed setting in no-load conditions (standard) ....................................................................................................... 43
Idling speed setting in no-load conditions ...................................................................................................................... 43
Injection pump delivery limiting and extra fuel device .................................................................................................... 43
Injection pump delivery setting ........................................................................................................................................ 43
Injection pump delivery setting with engine at the torque dynamometer ...................................................................... 44
Stop setting ...................................................................................................................................................................... 44
STORAGE __________________________________________________________________________ 45
External engine protection ............................................................................................................................................... 45
Injection systems protection ............................................................................................................................................ 45
Internal engine protection ................................................................................................................................................ 45
PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE ..................................................................... 45
STORAGE ........................................................................................................................................................................ 45
10
11
-5-
Chapter index
Notes :
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-6-
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 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.
-7-
Danger Attention
This indicates situations of grave danger which, if ignored,
may seriously threaten the health and safety of individuals.
Caution Warning
This indicates that it is necessary to take proper precautions
to prevent any risk to the health and safety of individuals
and avoid financial damage.
Important
This indicates particularly important technical information
that should not be ignored.
SAFETY REGULATIONS
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.
-8-
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 ~ 80C).
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.
Only use the eyebolts installed by Lombardini to move the engine.
These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should
be used.
-9-
TECHNICAL INFORMATION
TROUBLE SHOOTING
THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:
1)
2)
3)
4)
SETTINGS / REPAIR
MAINTE- ELECTRIC
LUBRIFICATION
NANCE SYSTEM
FUEL CIRCUIT
Dripping oil
and fuel from
the exhaust
Excessive oil
consumption
Oil level
increase
Oil pressure
too low
White smoke
Black smoke
Non uniform
speed
No acceleration
Engine starts
but stops
POSSIBLE CAUSE
Engine does
not start
TROUBLE
- 10 -
Technical information
MANUFACTURER AND MOTOR IDENTIFICATION DATA
B A
The identification plate shown in the figure can be found directly on the
engine.
It contains the following information:
A) Manufacturers identity
B) Engine type
C) Engine serial number
D) Maximum operating speed
E) Number of the customer version (form K)
F) Approval data
Approval data
The approval reference directives EC are on the engine plate.
The data plate for EPA Standards is applied on the air shroud.
1
2
4
1)
2)
3)
4)
5)
6)
7)
Current year
Engine displacement
Rated power, measured in kW
EPA family ID
Injection timing
Injection opening preassure
Valve clearance
3
5
- 11 -
Technical information
TECHINICAL SPECIFICATIONS
435-2/B1
475-2
EPA
475-2
GENERAL DETAILS
Four-stroke diesel
Operating cycle
Cylinders
Bore x stroke
n
mm
cm 3
Displacements
Compression rate
Intake
Cooling
Crankshaft rotation
Combustion sequenc
2 in line
90x75
90x75
871
954
871
18.0:1
18.0:1
18.0:1
Oil bath air cleaner or dry air cleaner
Air (fan integral to the flywheel)
954
20.0:1
86x75
86x75
Timing system
Valves
Shaft
Tappets
Fuel injection
Dry weight of engine
Direct, on piston
kg
80
80
80
80
Momentary
Up to 1 hour
35
25
35
25
35
25
35
25
l/min
l/min
1050
13300
1250**
16200**
1150
15500
1150
15500
Max power
kW/CV
Nm/kgm
Nm/kgm
Kg
3000
3000
14.0/19.0 14.7/20.0 15.8/21.5
12.7/17.2 13.2/18.0 14.8/20.1 14.8/20.1
11.4/15.5 12.0/16.3 13.5/18.3 13.5/18.3
49.0/5.0 49.0/5.0 57.0/5.8 48.0/4.9
25.0/2.5 25.0/2.5 25.0/2.5 25.0/2.5
3000
3600
300
300
300
300
280-206
0,020
245-180
0,025
257-189
0,025
- 12 -
g/kWh - g/CVh
kg/h
260-191
0,020
2000 rpm for 435-2 e 435-2/B1 engines, 2100 rpm for 475-2 engines, 2200rpm for 475-2 EPA engines.
At 3600 rpm.
At NB power.
Technical information
435-2/B1
475-2
475-2
EPA
Fuel type
Fuel supply
Fuel filter, internal
Filtering surface
cm2
Filter capacity
bar
2400
23
4
Filtering surface
460
7
Filter capacity
LUBRICATION CIRCUIT
Type of lubrication
Completely forced
Gear pump
Circuit supply
Maximum oil quantity
Maximum oil quantity
Oil pressure at min. speed (oil temperature: 120C)
2.7
2.7
2.7
2.7
2.5
2.5
2.5
2.5
bar
0,6
0,6
0,6
0,6
bar
bar
20
bar
cm2
1.51.7
bar
4.5
Filter capacity
m
bar
0.600.75
Filter capacity
By-pass valve setting
Filtering surface
15
730
70
ELECTRICAL SYSTEM
Alternator, Internal Standard (nominal voltage)
Alternator, Internal Optional (nominal voltage)
Alternator, Internal Standard (nominal current) *
Alternator, Internal Optional (nominal current) *
Starter motor power (Bosh GF)
V
V
12,5
12
A
A
14
18
kW
1.7
- 13 -
Technical information
PERFORMANCE DIAGRAMS
12 LD 435-2
12 LD 435-2 B1
12 LD 475-2
12 LD 475-2 EPA
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: Continuos light duty operation with constant speed
and variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOUS RATING WITH NO OVERLOAD CAPABILITY: Continuos heavy duty with constant
speed and constant load.
MN Torque curve (N curve) - MB (NB curve) - MA (NA curve).
C Specific fuel consumption curve.
The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the
environmental conditions of 20 C and 1 bar.
Max. power tolerance is 5%.
Power decreases by approximately 1 % every 100 m altitude and by 2 % every 5C above 20 C.
Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.
- 14 -
Technical information
OVERALL DIMENSIONS
12LD 435-2 435-2/B1 475-2 EPA
- 15 -
EXTRAORDINARY MAINTENANCE
ORDINARY MAINTENANCE
FREQUENCY x HOURS
OPERATION DESCRIPTION
10
125
250
500
1000
2500
5000
(***)
(***)
FUEL PIPES
COOLING SYSTEM CLEANING
CHECK
AIR
(*)
(*)
FUEL FILTER
(*)
RUBBER
INTAKE
HOSE
(DRY
AIR
(**)
FUEL PIPES
DRY
AIR
CARTRIDGE
DRY
AIR
CARTRIDGE
CLEANER
INTERNAL
EXTERNAL (***)
()
EXTERNAL (***)
()
PARTIAL
OVERHAUL
TOTAL
(*)
(**)
(***)
()
The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates.
The air filter must be cleaned and replaced more frequently In very dusty conditions.
Alternately when the clogging indicator, if present, indicates its necessary to replace the filter.
- 16 -
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 rgime.
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.
- - - - - - - + + + + + + + + + +
40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50
SAE 10W*
SAE 20W*
SAE 30*
SAE 40*
SAE 10W-30**
SAE 10W-40**
SAE 10W-60**
SAE 15W-40 **
SAE 15W-40 **
SAE 20W-60 **
SAE 5W-30 ***
SAE 5W-40 ***
SAE 0W-30 ***
* Mineral base
** Semi-synthetic base
*** Synthetic base
SAE- Grade
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.
PETROL
1234567890
1234567890
1234567890
E1 =OBSOLETE
E2 = Standard
E3 = Heavy conditions (Euro 1 - Euro 2 engines )
E4 = Heavy conditions
(Euro 1 - Euro 2 - Euro 3 engines )
E5 = High performances in heavy conditions (Euro 1 - Euro 2 Euro 3 engines )
DIESEL
API
MIL
1234567890123456789
12345678901234567891234567890123456789012345678
1234567890123456789012345678
1234567890123456789
1234567890123456789012345678
CF1234567890123456789
CE CD CC CB CA 1234567890123456789012345678
SA SB SC SD SE SF SG SH
12345678901234567891234567890123456789012345678
SJ
SL
L - 2104 D / E
L - 46152 B / C / D / E
CURRENT
123456789
123456789
OBSOLETE
- 17 -
PRESCRIBED LUBRICANT
AGIP
SUPERDIESEL
MULTIGRADE
10W40
API CF4 / SG
ACEA B2 - E2
MIL - L-4165 D/E
specifications
In the countries where AGIP products are not available, use oil API SJ/CF for Diesel engines or oil corresponding to the
military specification MIL-L-4165 D/E.
For a temperature of -10C an oil with a 5W40 viscosity is recommended.
For a temperature of -15C an oil with a 0W30 viscosity is recommended.
435-2
435-2/B1
475
Litres
2.5
2.7
Litres
2.4
2.5
Danger - Attention
- 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.
Danger - Attention
- 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.
- 18 -
FUEL SPECIFICATIONS
Danger - Attention
-
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.
To achieve optimum performance of the engine, use good quality fuel with certain characteristics:
Cetane number (minimum 51):
PRESCRIBED LUBRICANT
Fuel with low sulphur content
API CF - CD - CE
The countries in which diesel normally has a low sulphur content are: Europe, North America and Australia.
Summer
Winter
Alpine
Arctic
up
up
up
up
to
to
to
to
0C
-10C
-20C
-30C
For all fuel types, the cetane number cannot be lower than 51.
Litres
15
As for filters, tanks and special crankcases please refer to LOMBARDINI instructions.
- 19 -
DISASSEMBLY / REASSEMBLY
Important
To locate specific topics, the reader should refer to the
index.
Danger - Attention
During repair operations, when using compressed air,
wear eye protection.
5
6
7
8
- 20 -
Disassembly / Reassembly
Hand wheel
Cover
Cartridge
Seal ring
Bracket
Clogging indicator
Important
Replace cartridge immediately when indicator shows that it's
clogged.
2
Flywheel
Remove flywheel with puller (part N. 7271-3595-048).
Check starter ring gear and tapered crankshatt mating surfaces.
Unscrew bolt 1 clockwise; when refitting tighten bolt to 180 Nm.
Note: To replace starter ring gear heat it up to 200 + 250C and rapidly
drive it onto the flywheel.
Alternator
Remove stator and place it inside the rotor to prevent metal particles
from being attracted by the magnets.
When refitting tighten rotor screws and stator bolts at 10 Nm.
See pages 40 and 41 for alternator characteristics.
Caution - Warning
Setting should be performed when the engine is cold.
- 21 -
Disassembly / Reassembly
Compression release (optional)
Bring piston to top dead center on the compression stroke.
Unscrew rocker arm cover side plug and measure clearance A, which
must be 0.300.40 mm.
For setting purposes remove rocker arm cover, unscrew lock nut C
and set clearance A by adjusting the screw B.
Injector projection
The end of nozzle A should project 3.0 3.5 mm (2,002,50mm for
EPA engines) from the cylinder head plane.
Adjust injector projection by means of copper shims B measuring 1.5
and 1.00 mm in thickness.
10
Cylinder Head
Important
Do not remove it when hot to avoid deformation.
If cylinder head is deformed level it hot by removing a maximum of 0.3
mm.
When refitting tighten only if sure that rocker arm lubrication tube is
well inside its holes and that both heads are in line by fitting the inlet
and exhaust manifolds before tightening the cylinder head nuts.
Always replace copper head gasket: see page 26 (picture 32) for
choosing the right thickness.
Progressively tighten nuts in the 1, 2, 3, 4 sequence at 50 Nm.
11
- 22 -
Disassembly / Reassembly
Valves
Components:
1
2
3
4
5
6
Intake valve
Spring seat
Valve stem seal
Spring
Retainer
Half collets
Important
Valve stem seal 3 must be fitted to the intake valve only.
12
13
Ref.
Dimensions (mm)
42,0
53,5
14,00014,018
14,05014,060
14
Dimensions (mm)
30,8031,20
24,8025,20
Note: If guides are seated with stop ring C, first locate the ring in place
and then position guides without considering A and B.
15
EXHAUST
VALVE
INTAKE
VALVE
Ref.
Dimensions (mm)
40,00040,016
40,12040,140
34,00034,016
34,12034,140
16
- 23 -
Disassembly / Reassembly
Valve seat grinding
After cutting grind valve seats with fine emery paste in oil suspension.
The sealing surface S should not exceed 2 mm.
Valve recess after grinding D = 0.751.25 mm; maximum worn limit
1.65 mm.
17
18
Cylinder
Measure diameter size between two diametrically opposed points at
three different heights.
Per 12 LD 435-2 / 435-2B1: ..................... = 86,00 86,02 mm;
Per 12 LD 475-2 / 475-2 EPA .................. = 90,00 90,02 mm.
In case wear exceeds 0.10 mm, bore the cylinder and fit oversize
piston and rings.
In case of less wear replace piston rings only.
19
20
Cylinder roughness
The cylinder should show no blowholes or porosities check for
leakage by sealing both ends of the cylinder and preassurizing with
compressed air at 4 bar and immerging it in water for 30 seconds.
Fins must be intact.
Cross hatch pattern polishing must range between 4555 and be
uniform and clear in both directions.
Average roughness should range between 0.5 and 1 .
21
Piston
Remove circlips and remove piston pin.
Remove piston rings and clean grooves.
Measure diameter at 2 mm from the bottom of the piston.
Per 12 LD 435-2 / 435-2B1: ..................... = 85,920 85,940 mm;
Per 12 LD 475-2 / 475-2 EPA .................. = 89,925 89,940 mm.
In case of diameter wear above 0.05 mm replace piston and piston
rings.
Note: Oversize pistons of 0.5 and 1.0 mm are available.
22
- 24 -
23
Disassembly / Reassembly
Piston weight
Weigh pistons when replacing them in order to avoid unbalance.
The difference in weight should not exceed 6 g.
24
Ref.
Dimensions
(mm)
0,0300,050
25
26
Ref.
Dimensions
(mm)
Limit value
(mm)
0,0600,065
0,12
0,0300,035
0,07
0,0200,025
0,05
27
Important
Before fitting the piston into the cylinder stagger the ring gaps at
120.
28
- 25 -
Disassembly / Reassembly
Piston - Refitting
Connect piston to connecting rod in a way that the combustion
chamber center b is at right angle under nozzle tip a.
Lubricate piston pin and introduce it into the piston by exerting
pressure with your thumb.
Check that both circlips are well inside their seats.
29
30
Piston clearance
A = Piston clearance = 0,650,70 mm
0,550,60 mm for EPA engines
B = Copper head gasket
A is determined by placing the piston at top dead center and
measuring, with a feeler gauge and straight edge, the distance the
piston is below or above the cylinder face.
A copper gasket B (available in various thicknesses) is then selected
to ensure the clearance is correct.
Gaskets are available in the following thicknesses:
0,45 - 0,50 - 0,55 - 0,60 - 0,65 - 0,70 - 0,75 - 0,80 - 0,85 - 0,90 - 0,95 - 1,00
31
32
117,95118,05
22,01522,025
21,99522,005
0,010,03
C-D
0,07
limit of wear
33
34
- 26 -
35
Disassembly / Reassembly
36
37
38
39
- 27 -
Disassembly / Reassembly
CRANKSHAFT
Center main bearing support, locating bolt
Straighten plate 1 and unscrew bolt 2 before removing crankshaft.
When refitting, tighten bolt 2 to 30 Nm.
40
41
42
Important
When grinding main journals or crank pins restore the R value to
original specification.
The radius R connecting journals to shoulders is 2.8 3.2 mm.
43
- 28 -
44
Disassembly / Reassembly
Main bearing and connecting rod big end bearing internal diameter
45
Ref.
Dimensions (mm)
Ref.
Dimensions (mm)
71.98172.000
72.07072.090
40.00440.020
40.04540.076
55.34055.350
55.40455.435
54.93154.950
55.00055.020
Dimensions (mm)
E-A
0,0700,109
0,195
F-B
0,0250,072
0,150
G-C
0,0510,095
0,190
H-D
0,0500,089
0,180
46
47
Ref.
Dimensions
(mm)
130.000130.020
76.98077.020
128.000128,018
59.07459.092
75.99076.010
60.00060.020
Ref.
Dimensions
(mm)
130,000130,020
128,000128,020
76,00076,020
48
- 29 -
Disassembly / Reassembly
Dimensions of camshaft journals and housings
Ref.
Dimensions
(mm)
41.94041.960
42.00042.025
27.94027.960
28.00028.020
Clearance
(mm)
Limit value
(mm)
0.0400.085
0.160
0.0400.080
0.150
49
50
51
Camshaft timing
Fit camshaft gear by making timing mark 1 coincide with timing mark
2 on the crankshaft timing gear.
Tighten camshaft bolt to 60 Nm.
Camshaft end play
End play should be 0.100.26 mm; check by means of a dial gauge
pushing or pulling camshaft as required.
52
53
- 30 -
Disassembly / Reassembly
Seal ring
Centering ring
Coupling
Half coupling
Flange
Gear
Bracket
Thrust washer
Stop ring
Cover
55
1 Gear
2 Fly weight
3 Sliding bell
4 Stop ring
5 Yoke
6 Lever
7 Drive rod
8 Governor spring
9 Rack control lever
Weights are moved to the periphery by the centrifugal force and thus
axially shift a mobile bell connected to the injection pump rack control
lever by a linkage.
A spring placed under tension by the accelerator control offsets the
weights centrifugal force.
Balance between the two forces keeps speed at an almost constant
level in spite of load variations.
See picture 52 for timing.
Governor springs with rocker arm
Components:
1
2
3
4
5
56
57
- 31 -
LUBRICATION SYSTEM
Danger - Attention
- Old engine oil can cause skin cancer if repeatedly left in
contact with the skin and for long periods of time.
Wear protective gloves to avoid touching used oil.
- If contact with the oil is unavoidable, you are advised to
wash your hands with soap and water as soon as possible.
Dispose of old oil in the correct way as it is highly polluting.
58
Components:
1)
2)
3)
4)
5)
6)
7)
8)
- 32 -
Lubrication system
Oil Pump
Check that gear teeth are intact and that clearance between gear edge
and pump body does not exceed 0.15 mm.
Further more check that control shaft is free to rotate with end float not
exceeding 0.15 mm.
Oil pump delivery at 3000 r.p.m. is 9 liters/min.
59
60
Plug
Seal ring
Spring
Cartridge
Features:
Filtering capacity: ..................................... 70 m
By-pass valve opening pressure: ............. 0.60+0.75 bar.
Max. working pressure: ............................. 4.5 bar.
61
Gasket
Steel shroud
Gommino
Spring
5 Filtering element
6 Bypass valve
7 Spring
Characteristics:
Maximum operating pressure: ..................... 7 bar
Maximum blast pressure: ............................ 20 bar
Filtering capacity: ........................................ 15
By-pass valve setting: .................................. 1,51,7 bar
Total filtering surface: .................................. 730 cm2.
62
3
63
Piston
Washer
Valve housing
Spring
Snap ring
64
- 33 -
Lubrication System
Oil pressure curve at idling speed
The curve is obtained at the oil filter level with constant engine speed
of 1200 r.p.m. in no-Ioad conditions and at a room temperature of
+25C.
Pressure is given in bar and temperature in centigrade.
65
66
- 34 -
FUEL SYSTEM
Tank
Filter
Fuel feeding tube
Fuel feeding pump
Injection pump
Injection line
Injector
Injector leak off line and self bleeding system
67
Spring
Disc
Ring
Cartridge
Gasket
Gasket
Cap
Ring
Bolt
68
- 35 -
Fuel system
Injection pump
Components:
1 Pump body
2 Fitting
3 Seal ring
4 Filler
5 Shim
6 Spring
7 Delivery valve
8 Seat
9 Gasket
10
11
12
13
14
15
16
17
18
Plunger
Barrel
Rack rod
Sector gear
Spring
Upper retainer
Lower retainer
Tappet
Tappet roller
71
Control rod
max. force
Rod stroke
from max.
deliv. point
Newton
mm
R.P.M.
Delivery
Max. plunger
difference
mm 3
stroke
mm 3
stroke
10
1500
2326
12
500
48
150
5765
10
500
1014
Control rod
max. force
Rod stroke
from max.
deliv. point
R.P.M.
Delivery
Max. plunger
difference
Newton
mm
mm 3
stroke
mm 3
stroke
0,50
72
10
1500
2932
12
500
1115
150
6472
10
500
2024
0,50
- 36 -
Fuel system
74
75
76
By pressing tool lever 1 (pic. 75) on the valve, turn the flywheel, using
a spanner, until it meets the piston and the top dead centre of the piston
is reached.
By holding down the valve on the piston, reset dial indicator 2 (pic.75).
77
- 37 -
Fuel system
Fasten capillary tube 4 on the delivery union of the cylinder on which
the valve lowering tool is installed.
Turn the flywheel and alternatively fill the capillary tube until the fuel
flows out.
Turn the flywheel clockwise (pic. 77) and, during the compression
phase, turn it slowly.
Stop as soon as the fuel starts moving inside the capillary tube.
78
Press the valve by turning lever 1 until it meets the piston and using
dial indicator 2 read the piston position in millimetres before the TDC.
Use the transformation chart to find out the correspondence between
the millimeters measured with dial indicator 2 and the degrees.
Piston lowering
value (mm)
Engine type
R.p.m.
Advance
degrees
12LD435/2
3000
23 1
22
23
24
3.570
3.894
4.232
12LD435/2-B1
3600
23 1
22
23
24
3.570
3.894
4.232
12LD475-2
3000
21 1
20
21
22
2.961
3.258
3.570
12LD475-2 EPA
3000
20 1
19
20
21
2.676
2.961
3.258
79
Components:
1 Intake fitting
2 Nozzle holder
3 Shim
4 Spring
5 Pressure rod
6 Intermediate flange
7 Nozzle
8 Needle valve
9 Fixing flange
10 Taper pin
11 Gasket
12 System duct
13 Sump
80
- 38 -
Fuel system
Injector housing
Intake fitting
Shim
Spring
Pressure rod
Taper pin
7
8
9
10
11
12
Nozzle
Cup
Needle valve
Sump
System duct
Overflow pipe
Injector setting
Connect injector to a hand pump and check that setting pressure is
210220 bar (258270 bar for EPA engines); make the required
adjustments, if any, by changing the shim over the spring.
When replacing the spring, setting should be performed at a 10 bar
greater pressure (220230 bar for standard engines, 268280 bar for
EPA engines) to allow for bedding during operation.
Check needle valve sealing by slowly moving hand pump until
approximately 180 bar.
Replace nozzle in case of dripping.
82
- 39 -
ELECTRIC SYSTEM
Electrical starting layout with battery charging light
Components:
1
2
3
4
5
6
7
8
Alternator.
Starting motor
Voltage regulator
Battery
Pressure switch
Oil pressure warning light
Key switch
Battery charging light
83
12.5 V, 14 A Alternator
Features a fixed armature winding mounted on the air shroud bracket.
The rotating permanent magnet inductor is located in the fan spindle.
Dimensions (mm):
A
158,80 159,20
27,50 27,90
85
- 40 -
Electric system
158159,20
27,5027,90
Voltage regulator
Type LOMBARDINI, supplied by SAPRISA and DUCA TI: Voltage 12
V, max. current 26A. References for SAPRISA connections with the
cor-responding DUCATI connections.
SAPRISA
~
R
+
LE
oo
DUCATI
G
R
B
L
C
87
DUCATI
Width
Thickness
G
6,25
0,8
R
9,50
1,2
+
B
9,50
1,2
Le
L
4,75
0,5
oo
C
6,25
0,8
The voltage regulator fits to both circuits with and without battery
charging light; in the latter case connections LE (SAPRISA) and L
(DUCA-TI) are not used.
R
88
- 41 -
Electric system
How to check voltage regulator for proper operation
Caution - Warning
When the engine is running do not disconnect battery cables or
remove the key from the control panel.
Keep regulator away from heat sources since temperatures
above 75C might damage it.
No electric welding on engine or application.
89
Important
Flywheel should not project from ring gear plane B.
A = 29.5 31.5 mm
B = Ring gear plane
C = Flange plane
90
91
- 42 -
SETTINGS
Settings
1) Idling speed setting in no-load conditions
After filling with oil and fuel, start the engine and let it warm up for 10
minutes.
Adjust idling speed at 12001300 r.p.m. by turning setscrew 1; then
tighten lock nut.
92
93
- 43 -
Settings
Injection pump delivery setting with engine at the torque
dynamometer
R.P.M.
12LD435-2
3000
Power
kW (HP)
Time (sec)
per 100 cm3
g/kWh
(g/HPh)
N 13,97 (19)
74-76
290-282 (213-208)
NB 13,72 (17,3)
91-93
259-254 (191-186)
N 14,7 (20)
66-68
309-300 (227-221)
NB 13,23 (18)
78-80
291-283 (214-208)
N 15,8 (21,5)
73-75
260-253 (191-186)
NB 14,85 (20,2)
82-84
246-240 (181-177)
96
12LD435-2/B1
12LD475-2
3600
3000
Stop setting
- 44 -
STORAGE
When the engines are not used for more than 3 months, they have to be protected by performing the operations described:
STORAGE
- 45 -
10
POSITION
Picture
N
Torque
( Nm )
Connecting rod
Injection pump union
Rocker arm cover
Central support collar
Intake manifold
Exhaust manifold
Air conveyor
Throttle cover
Oil sump
Oil filter
Oil filter, internal
Hydraulic pump coupling flange
Camshaft gear
Oil pump gear
Starting Motor
Rocker arm shaft
Air conveyor baffle
Engine foot
Fuel feeding pump
Injection pump
Oil pump
Injector nozzle holder
Crankshaft timing side support
Crankshaft P.T.O. side support
Crankshaft central side support
Hydraulic pump gear holder
R.p.m. counter holder
Fuel tank support
Cylinder head
Flywheel
35
7173
5
42
62
61
54, n5
52
59
90
9
70
73
59
8081
38
39
40
54, n7
11
3
8X1,25
18X1,5
8X1,25
8X1,25
8X1,25
8X1,25
6X1,0
6X1,0
8X1,25
6X1,0
6X1,0
8X1,25
10X1,5
10X1,5
10X1,5
8X1,25
8X1,25
10X1,5
8X1,25
8X1,25
8X1,25
6X1,0
8X1,25
8X1,25
10X1,5
8X1,25
8X1,25
8X1,25
10X1,5
16X1,5
40
40
20
25
25
20
6
10
28
12,5
10
25
60
35
45
25
25
40
25
25
20
10
25
25
30
25
25
40
50
180
Use of sealant
POSITION
Tank bracket vibration dampers
Oil pump nut or union
Oil pump gear threading
Oil filter cartridge nipple
Oil filter center plate nipple
Head stud
Main bearing support fixing stud bolt, flywheel side
Crankcase stud bolt
Fuel feeding pump stud bolt
Blower housing stud
Tank bracket gasket
- 46 -
Type of sealant
Loctite 270
Loctite 270
Loctite 270
Loctite 270
Loctite 270
Loctite 270
Loctite 270
Loctite 270
Loctite 270
Loctite 270
Loctite IS 495
10
4.6
4.8
R>400N/mm2
Diameter
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
5.6
5.8
R>500N/mm2
6.8
8.8
10.9
12.9
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
0,5
1,1
0,7
1,5
0,6
1,4
0,9
1,8
1
2,2
1,4
2,9
1,9
4,1
2,3
4,9
2,3
3,8
3
5
2,8
4,7
3,8
6,3
4,5
7,5
6
10
8,5
14
10
17
9,4
18
13
25
12
23
16
31
19
37
25
49
35
69
41
83
32
51
43
68
40
63
54
84
65
101
86
135
120
190
145
230
79
109
105
145
98
135
131
181
158
218
210
290
295
405
355
485
154
206
205
275
193
260
256
344
308
413
410
550
580
780
690
930
266
394
355
525
333
500
444
656
533
788
710
1050
1000
1500
1200
1800
544
725
680
906
1088
1450
2000
2400
8.8
10.9
12.9
Diameter
M 8x1
M 10x1
M 10x1,25
M 12x1,25
M 12x1,5
M 14x1,5
M 16x1,5
M 18x1,5
M 18x2
M 20x1,5
M 20x2
M 22x1,5
M 24x2
M 27x2
M 30x2
4.6
4.8
R>400N/mm2
Nm
Nm
10
14
21
20
36
38
56
84
122
117
173
164
229
293
431
600
5.6
5.8
R>500N/mm2
6.8
Nm
Nm
28
13
26
17
35
42
56
79
26
48
24
45
33
59
39
71
52
95
73
135
45
75
42
70
56
94
68
113
90
150
125
210
113
163
105
153
141
203
169
244
225
325
315
460
157
230
147
213
196
288
235
345
313
460
440
640
218
305
204
287
273
381
327
458
436
610
615
860
390
575
367
533
488
719
585
863
780
1150
1100
1600
800
750
1000
1200
1600
2250
95
88
160
150
250
380
550
530
770
740
1050
1300
1950
2700
- 47 -
11
SPECIAL TOOLS
DESCIPTION
Part N.
1460 - 285
High-preassure
timing check
- 48 -
pump
for
static
injection
1460 - 273
1460 - 024
1460 - 108
1460 - 009
1460 - 113
Flywheel puller
1460 - 119
1460 - 047
Notes :
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Workshop Manual 12 LD _ cod. 1.5302.460 - 3 ed_ rev. 02
- 49 -
La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione.
Lombardini se rserve le droit de modifier, n'importe quel moment, les donnes reportes dans cette publication.
Data reported in this issue can be modified at any time by Lombardini.
Lombardini behlt sich alle Rechte vor, diese Angaben jederzeit zu verndern.
La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicacin.