Lombardini 3LD 450, 3LD 510, 3LD 451-S, 3LD 510-S, 4LD 640 Workshop Manual

WORKSHOP MANUAL

Engine Series 3 - 4 LD

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modifications to this document must be registered by the drafting body, by completing the following table.

	Drafting	Document	Model	Edition	Revision	Issue date	Review	Endorsed
	body	code	N°				date
	DICOM/ATLO	ED0053025560	50839	4°	3	01-94	15.06.2014

Manual’s purpose

•This manual contains the instructions needed to carry out a proper maintenance of the engine, therefore it must always be available, for future reference when required.

•Safety pictograms can be found on the engine and it is the operator’s responsibility to keep them in a perfectly visible place and replace them when they are no longer legible.

•Information, description and pictures in this manual reflect the state of the art at the time of the marketing ofengine.

•However, development on the engines is continuous.Therefore, the information within this manual is subject to change without notice and without obligation.

•LOMBARDINI srl reserves the right to make, at any time, changes in the engines for technical or commercial reasons.

•These changes do not require LOMBARDINI srl to intervene on the marketed production up to that time and not to consider this manual as inappropriate.

•Any additional section that LOMBARDINI srl will deem necessary to supply some time after the main text shall be kept together with the manual and considered as an integral part of it.

•The information contained within this manual is the sole property of LOMBARDINI srl. As such, no reproduction or replication in whole or part is allowed without the express written permission of LOMBARDINI srl.

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PREFACE

Every attempt has been made to present within this use and maintenance, accurate and up to date technical information. However, development on the Lombardini series is continuos.

Therefore, the information within this manual is subject to change without notice and without obligation.

Carefully read and follow all instructions in this booklet as well as all those provided with the equipment on which this engine is used. 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.

Information presented within this manual assumes the following the person or persons performing service work on Lombardini series engines:

1 - is properly trained and equipped to safely and professionally perform the subject operation;

2 - possesses adequate hand and Lombardini special tools to safely and professionally perform the subject service operation; 3 - has read the pertinent information regarding the subject service operations and fully understands the operation at hand.

-For spare parts and after sale assistance contact authorized service centers.

-For any spare parts order please specify following details: ENGINE TYPE AND SERIAL NUMBER

-Version (K) - on the engine name plate

-Tel. No. appears on service booklet or on the website: www.lombardinigroup.it

-Pls contact Service Centers for special applications.

GENERAL SERVICE MANUAL NOTES

1- Use only genuine repair parts. Failure to use genuine parts could result in sub-standard performance and low longevity.

2- All data presented are in metric format:	. dimensions are presented in millimeters (mm),
	. torque is presented in Newton-meters (Nm),
	. weight is presented in kilograms (kg),
	. volume is presented in liters or cubic centimeters (cc)
	. pressure is presented in barometric units (bar).

3- To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer’s manual for other important safety information.

This manual contains safety precautions which are explained below.

WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.

IMPORTANT This indicates particularly important technical information that should not be ignored.

CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored.

GLOSSARY AND TERMINOLOGY

For clarity, here are the definitions of a number of terms used recurrently in the manual.

-Cylinder number one: is the timing belt side piston .

-Rotation direction: anticlockwise «viewed from the flywheel side of the engine».

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- INDEX

This handbook provides the main information concerning the repair of the following LOMBARDINI Diesel engines 3LD 450, 3LD 510, 3LD 451/S, 3LD 510/S, 4LD 640, 4LD 705, 4LD 820, which are air-cooled, provided with direct injection and revised on the 15-06-2014.

1	GENERAL REMARKS AND SAFETY INFORMATION.......................................................................................	Pag. 6 - 7
	California Proposition 65 ...................................................................................................................................................	7
	General safety during operating phases ...........................................................................................................................	8
	Regulations for lifting the engine .......................................................................................................................................	7
	Safety and enviromental impact ........................................................................................................................................	8
	Safety information ..........................................................................................................................................................	6-7
2	TECHNICAL INFORMATION ...................................................................................................................................	10 - 15
	Manufacturer and motor identification data .....................................................................................................................	10
	Capacities in litres - Air filter oil bowl ...............................................................................................................................	14
	Capacities in litres - Standard fuel tanks .........................................................................................................................	14
	Capacities in litres - Standard oil sump ...........................................................................................................................	14
	Lubricant - ACEA-Regulations sequences ......................................................................................................................	15
	Lubricant - API-MIL sequences .......................................................................................................................................	15
	Lubricant - International specifications ............................................................................................................................	15
	Lubricant - SAE classification ..........................................................................................................................................	15
	Performance diagrams ....................................................................................................................................................	12
	Possible causes and trouble shooting .............................................................................................................................	13
	Routine engine maintenance ..........................................................................................................................................	14
	Table of likely anomalies and their symptoms .................................................................................................................	13
	Technical data ..................................................................................................................................................................	11
3	DISASSEMBLY / REASSEMBLY..............................................................................................................................	16 - 29
	Camshaft ..........................................................................................................................................................................	27
	Camshaft axial clearance .................................................................................................................................................	25
	Camshaft intake and exhaust cam height. .......................................................................................................................	28
	Camshaft intake and exhaust cam timing ........................................................................................................................	27
	Camshaft pin and housing dimensions (mm) ...................................................................................................................	28
	Clearance volume ............................................................................................................................................................	23
	Connecting rod equipped with bearings and piston pin .................................................................................................	24
	Connecting rod, big end bearings ....................................................................................................................................	24
	Cylinder and piston ..........................................................................................................................................................	22
	Decompression (by request) ............................................................................................................................................	18
	Distance among segment ends (mm) .............................................................................................................................	22
	Distribution timing without following the references ........................................................................................................	28
	Distribution timing .............................................................................................................................................................	28
	Drive shaft ........................................................................................................................................................................	26
	Drive shaft axial clearance ...............................................................................................................................................	24
	Drive shaft connecting radius ...........................................................................................................................................	26
	Drive shaft internal diam. crankshaft bearing / connecting rod head
	and clearances regarding their respective pins (mm) .....................................................................................................	27
	Drive shaft lubrication ducts .............................................................................................................................................	26
	Drive shaft main journal and crank diametres (mm) ........................................................................................................	26
	Flywheel ...........................................................................................................................................................................	17
	Head .................................................................................................................................................................................	19
	Injector, projection ............................................................................................................................................................	19
	Main bearing on flywheel side ..........................................................................................................................................	24
	Oil-bath air filter (standard) ..............................................................................................................................................	16
	Piston reassembly ............................................................................................................................................................	23
	Piston ring - Clearances among slots (mm) .....................................................................................................................	22
	Piston ring assembly order ...............................................................................................................................................	23
	Recommendations for disassembling ..............................................................................................................................	16
	Rocker arm pin and hole .................................................................................................................................................	19
	Rocker arm pin, extraction ..............................................................................................................................................	18
	Side distributor port ..........................................................................................................................................................	25
	Silencer (standard) ...........................................................................................................................................................	16
	Speed governor ................................................................................................................................................................	29
	Starting pulley ..................................................................................................................................................................	17
	Timing of the speed governor ...........................................................................................................................................	29

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		Index	-
	Valve guide dimensions and clearances .........................................................................................................................		20
	Valve guides insertion .....................................................................................................................................................		20
	Valve housings and seats	...............................................................................................................................................	21
	Valve seat grinding ...........................................................................................................................................................		21
	Valve/rocker arm clearance ..............................................................................................................................................		19
	Valves ...............................................................................................................................................................................		19
	Valves guides and housings .............................................................................................................................................		20
	Vent plug ..........................................................................................................................................................................		17
5	LUBRICATION CIRCUIT...........................................................................................................................................		30 - 32
	Lubrication circuit ............................................................................................................................................................		30
	Oil filter cartridge .............................................................................................................................................................		31
	Oil pressure check ..........................................................................................................................................................		32
	Oil pressure curve with the engine at its maximum speed ..............................................................................................		32
	Oil pressure regulating valve ...........................................................................................................................................		32
	Oil pump ..........................................................................................................................................................................		31
	Oil pump, difference between clockwise rotation pump and anticlockwise pump ..........................................................		31
6	FUEL INJECTION CIRCUIT......................................................................................................................................		33 - 35
	Advanced injection (static) .............................................................................................................................................		34
	Advanced Injection references on the conveyor and flywheel protection disk ...............................................................		35
	Feeding pump (by request) .............................................................................................................................................		33
	Feeding pump rod projection ..........................................................................................................................................		33
	Fuel filter inside the tank	(standard) ..............................................................................................................................	33
	Injection pump .................................................................................................................................................................		34
	Injection pump assembly .................................................................................................................................................		34
	Injector ............................................................................................................................................................................		35
	Injector setting .................................................................................................................................................................		35
	Standard feeding/injection circuit ....................................................................................................................................		33
7	ELECTRIC CIRCUIT..................................................................................................................................................		36 - 38
	12 V 14 A electrical ignition, diagram with voltage regulator , battery recharge lamp and manostat .............................		36
	12,5 V, 14 A alternator battery recharge curve ................................................................................................................		36
	12.5 V 14 A alternator .....................................................................................................................................................		36
	Bosch DW (L) 12 V 1, 1 KW type, starting motor ...........................................................................................................		37
	Bosch JF(L) 12V 2.5 kW type, starting motor ................................................................................................................		38
	Characteristic curves for	Bosch DW(L) 12V 1.1 kW type, starting motor ....................................................................	38
	Characteristic curves for	Bosch JF(L) 12V 2,5 kW type starting motor ..........................................................................	38
	Voltage regulator .............................................................................................................................................................		37
	Voltage regulator, running check .....................................................................................................................................		37
8	ADJUSTMENT...........................................................................................................................................................		39 - 40
	Adjustment of injection pump delivery with braked engine .............................................................................................		40
	Injection pump delivery adjustment (standard) ..............................................................................................................		39
	Limiting device for injection pump delivery and torque gearing device ..........................................................................		40
	Minimum rpm adjustment at idle running (standard) .......................................................................................................		39
	Peak rpm adjustment at idle (standard) ........................................................................................................................		39
	Required adjustments (the most demanded) ..................................................................................................................		40
9	STORAGE ........................................................................................................................................................................		41
	Protective treatment ........................................................................................................................................................		41
	Preparing the engine for operation after protective treatment .........................................................................................		41
10	MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS ...............................................................................		42 - 44
	Tightening torques main ...................................................................................................................................................		42
	Table of tightening torques for standard screws (fine thread) ..........................................................................................		43
	Table of tightening torques for standard screws (fine thread) ..........................................................................................		43
	Use sealant.......................................................................................................................................................................		44

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	1
			General remarks and safety information
	This manual contains safety precautions which are explained
	below.				CAUTION
					Caution is used to indicate the presence of a hazard that will or
					can cause minor personal injury or property damage if the caution
		WARNING
					is ignored.
	Warning is used to indicate the presence of a hazard that can
	cause severe personal injury, death, or substantial property
	damage if the warning is ignored.				IMPORTANT
					This indicates particularly important technical information that
					should not be ignored.
	SAFETY INFORMATION
	GENERAL NOTES				environments. The internal combustion process generates
	. Lombardini engines are built to provide safe and				carbon monoxide, an odourless and highly toxic gas, so
					spending too long a time in an environment where the engine
	longlasting performances, but in order to obtain these				discharges its exhaust products freely can lead to loss of
	results it is essential that the maintenance requirements				consciousness and even death.
	described in the manual are observed along with the				. The engine may not	be used in			environments containing
	following safety recommendations.				flammable materials, explosive atmospheres or easily
	. The engine has been built to the specifications of a machine
					combustible powders, unless adequate and specific
	manufacturer, and it is his responsibility to ensure that all				precautions have been taken and are clearly stated and
	necessary action is taken to meet the essential and legally				certified for the machine.
	prescribed health and safety requirements. Any use of the				. To prevent the risk of fire, keep the machine at a distance of at
	machine other than that described cannot be considered				least one metre from buildings or other machines.
	as complying with its intended purpose as specified by				. Children and animals must be kept at a sufficient distance from
	Lombardini, which therefore declines all responsibility for				the machine to prevent any danger resulting from its operation.
	accidents caused by such operations.				. Fuel is flammable, so the tank must be filled only when the
	. The following instructions are intended for the user of the				engine is turned off.	Dry carefully			any	fuel	that may have
	machine in order to reduce or eliminate risks, especially				spilled, remove the fuel container				and	any	cloths soaked
	those concerning the operation and standard maintenance				in fuel or oil, check that any sound-absorbing panels made
	of the engine.				of porous material are not soaked with fuel or oil, and make
	. The user should read these instructions carefully and get to
					sure that the ground on which the machine is located has not
	know the operations described. By not doing so he may				absorbed fuel or oil.
	place at risk his own health and safety and that of anyone				. Before starting, remove any tools that have						been used for
	else in the vicinity of the machine.				carrying out maintenance work to the engine and/or the
	. The engine may be used or mounted on a machine only
					machine and check that any guards removed have been
	by personnel suitably trained in its operation and aware of				replaced. In cold climates it is possible to mix kerosene with
	the dangers involved. This is particularly true for standard				the diesel fuel to make the engine easier to start. The liquids
	and,	above all, special maintenance work. For special			must be mixed in the tank by pouring in first the kerosene and
	maintenance contact personnel trained specifically by				then the diesel fuel. Consult Lombardini technical office for
	Lombardini. This work should be carried out in accordance				mixture proportions. Petrol may not be used because of the
	with existing literature.				risk of it forming flammable vapours.
	. Lombardini declines all responsibility for accidents or for
					. During operation the surface of the engine reaches
	failure to comply with the requirements of law if changes				temperatures that may be dangerous. Avoid in particular all
	are made to the engine’s functional parameters or to the				contact with the exhaust system.
	fuel flow rate adjustments and speed of rotation, if seals				. The liquid cooling circuit is under pressure. Do not carry out
	are removed, or if parts not described in the operating and				any checks before the engine has cooled down, and even
	maintenance manual are removed and reassembled by				then open the radiator cap or the expansion tank cautiously.
	unauthorized personnel.				Wear protective clothing and glasses. lf there is an electric
					fan, do not approach the engine while it is still hot as the fan
		WARNING			may come on even when the engine is not running. Clean the
					cooling system with the engine turned off.
	. In addition to all other machine specifications, ensure that				. While cleaning the oil bath air filter, check that the oil is
	the engine is in a near horizontal position when starting.				disposed of in such a way as not to harm the environment.
	lf starting manually, ensure that the necessary operations				Any filtering sponges in the oil bath air filter should not be
	can be performed without any risk of striking against walls				soaked with oil. The cyclone pre-filter cup must not be filled
	or dangerous objects. Rope starting (except for recoil rope				with oil.
	starting) is not permitted even in emergencies.				. Since the oil must be emptied out while the engine is still hot
	. Check that the machine is stable so that there is no risk of it				(approx. 80°C), particular care should be taken in order to
	overturning.				avoid burns. In any case make sure that oil does not come into
	. Get to know the engine speed adjustment and machine stop				contact with your skin because of the health hazards involved.
	operations.				. Fuel vapours are highly toxic, so fill up only in the open air or in
	. Do not start the machine in closed or poorly ventilated				well ventilated environments.

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General remarks and safety information 1

.During operations which involve access to moving parts of the engine and/or removal of the rotary guards, disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter

motor.

. Check the belt tension only when the engine is turned 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.

IMPORTANT

.To start the engine follow the specific instructions provided in the engine and/or machine operating manual. Do not use auxiliary starting devices not originally installed on the

machine (e.g. Startpilot systems which utilise ether etc.)

.Before carrying out any work on the engine, turn it off and allow it to cool down. Do not perform any operation while the engine is running.

. Check that the discharged oil, the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment.

.Close the fuel tank filler cap carefully after each fílling operation. Do not fill the tank right up to the top, but leave sufficient space to allow for any expansion of the fuel.

. Do not smoke or use naked flames while filling.

.Take care when removing the oil filter as it may be hot.

.The operations of checking, filling up and replacing the cooling liquid must be carried out with the engine turned off and cold. Take particular care if liquids containing nitrites are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard. The cooling liquid is polluting, so dispose of in a manner that does not damage the environment.

Regulations for lifting the engine

-Before removing the engine from the vehicle on which it is installed, disconnect the power supply, detach the fuel and coolant supply, and all connections including the mechanical ones.

-Attach the engine to a suitable lifting device (lifting beam).

-To move the engine simultaneously use the eyebolts installed, these lifting points are not suitable for the entire machine, then use the eyebolts installed by the manufacturer.

-Before lifting, make sure the weight is correctly balanced by checking its barycentre.

-Close all engine openings accurately (exhaust, intake, etc.), then wash the outside and dry with a jet of compressed air.

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

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1 General remarks and safety information

GENERAL SAFETY DURING OPERATING PHASES

–The procedures contained in this manual have been tested and selected by the manufacturer’s technical experts, and hence are to be recognised as authorised operating methods.

–A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations.

–All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely.

It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual.

–Holes must be lined up methodically and with the aid of suitable equipment. Do not use your fingers to carry out this operation to avoid the risk of amputation.

–Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.

–Do not use flammable liquids (petrol, diesel, etc.) to degrease or wash components. Use special products.

–Use the oils and greases recommended by the manufacturer.

Do not mix different brands or combine oils with different characteristics.

–Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.

–Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.

SAFETY AND ENVIRONMENTAL IMPACT

Every organisation has a duty to implement procedures to identify, assess and monitor the influence of its own activities (products, services, etc.) on the environment.

Procedures for identifying the extent of the impact on the environment must consider the following factors:

-	Liquid waste	- Atmospheric emissions
-	Waste management	- Use of raw materials and natural resources
-	Soil contamination	- Regulations and directives regarding environmental impact

In order to minimise the impact on the environment, the manufacturer now provides a number of indications to be followed by all persons handling the engine, for any reason, during its expected lifetime.

-All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place.

-Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution.

-When discontinuing use of the engine, select all components according to their chemical characteristics and dispose of them separately.

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2 TECHNICAL INFORMATION

MANUFACTURER AND MOTOR IDENTIFICATION DATA

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Technical information 2

				ENGINE TYPE
	Cylinders
	Bore
	Stroke
	Displacement
	Compression ratio
	rpm	N DIN 70020 - 80/1269/CEE - iso 1585
	KW Power
		NB	DIN 6271 - ISO 3046 - 1 IFN
		NA	DIN 6271 - ISO 3046 - 1 ICXN
	Peak torque *
	Fuel specific consumption
	Oil consumption
	Dry weight
	Combustion air volume at 3000 rpm
	Cooling air volume at 3000 rpm
	Max. axial load permissible for drive shaft in two directions
	Max.inclination			instantaneous
				extended to 1 h.
				permanent

	3LD450	3LD510
N.	1	1
mm	85	85
mm	80	90
Cm³	454	510
	18,1:1	18,1:1
	3000	3000
	7,5	9,0
	6,6	7,3
Nm	6,0	6,6
	28,5	32,8
RPM	@ 1700	@ 1800
l/h	1,7	1,9
Kg/h	0.007	0.008
Kg.	57	60
l./1'	560	630
l./1'	9000	9000
Kg.	250	250
a	35°	35°
α	30°	30°
α	****	****

				ENGINE TYPE
	Cylinders
	Bore
	Stroke
	Displacement
	Compression ratio
	rpm	N DIN 70020 - 80/1269/CEE - iso 1585
	KW Power
		NB	DIN 6271 - ISO 3046 - 1 IFN
		NA	DIN 6271 - ISO 3046 - 1 ICXN
	Peak torque *
	Fuel specific consumption
	Oil consumption
	Dry weight
	Combustion air volume at 3000 rpm
	Cooling air volume at 3000 rpm
	Max. axial load permissible for drive shaft in two directions
	Max.inclination			instantaneous
				extended to 1 h.
				permanent

	4LD640	4LD705	4LD820
N.	1	1	1
mm	95	100	102
mm	90	90	100
Cm³	638	707	817
	17,0:1	17,0:1	17,0:1
	3000	3000	3000
	10,5	12,0	13
	8,8	9,9 D	11,4 D
	7,9	8,8 D	10,3 D
Nm	38,7	43,1	48
RPM	@ 1700	@ 2000	@ 1600
l/h	2,4	2,6***	3,0***
Kg/h	0.024	0,030***	0,035***
Kg.	100	100	105
l./1'	780	770 D	890 D
l./1'	12000	10400 D	10400 D
Kg.	300	300	300
a	35°	35°	35°
α	25°	25°	25°
α	****	****	****

*It stands for power

**It stands for NB power

***	It stands to NB power at 2600 rpm
**** According to the application D at 2600 rpm
Note: For LDA 450, LDA 510, LDA 96, LDA 97, LDA 820 out-of-production engines, the repair specifi-
	cations are equal to those of the engines specified in the table.	3 LD 451/S, 3LD 510/S engines,
	which are currently produced, not specified in the table, turn anticlockwise ( seen from the flywhe-
	el side), and are provided with the same feature as 3LD450 and	3LD510engines.

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2 Technical information

PERFORMANCE DIAGRAMS

N (80/1269/EU - ISO 1585)	AUTOMOTIVES POWER : Discontinuous services at variable rpm and load.
NB (ISO 3046 - 1 IFN)	NON-OVERLOADABLE POWER:Continuous light services at constant rpm and variable load.
NA (ISO 3046 - 1 ICXN)	CONTINUOUS OVERLOADABLE POWER: Continuous heavy-duty services at constant rpm and load.

The above mentioned power levels refer to the engine equipped with air filter, standard silencer, suction fan - which previously underwent a breaking-in period - at 20°C ambient conditions, at 1 bar.

The maximum power is guaranteed with a 5% tolerance.

These powers are reduced of abt. 1% every 100 m height and of 2% for every 5°C exceeding 25°C.

C (NB): Specific fuel consumption at NB power

MT : Torque at N power

a: Continuous service field of use. For any purpose out of this field of use, please contact company LOMBARDINI.

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Technical information 2

POSSIBLE CAUSES AND 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.

PROBABLE CAUSES

		Clogged pipings
		Clogged fuel filter
	<![if ! IE]> <![endif]>CIRCUIT	Presence of air in the fuel circuit
		Clogged tank breather
		Faulty fuel pump
		Blocked injector
	<![if ! IE]> <![endif]>FUEL	Blocked injection pump valve
		Wrong injector setting
		Plunger excessive leakage
		Stuck injection pump delivery control
		Wrong injection pump delivery setting
	<![if ! IE]> <![endif]>LUBRICATION	High oil level
		Blocked pressure relief valve
		Worn oil pump
		Presence of air inside the oil intake pipe
		Faulty pressure gauge or switch
	<![if ! IE]> <![endif]>EELECTRICAL-	Clogged oil intake duct
		Discharged battery
	<![if ! IE]> <![endif]>EQUIPMENT	Inefficient or wrong cable connection
		Faulty starting switch
		Faulty starting motor
	<![if ! IE]> <![endif]>T	Clogged air filter
		Excessive idle operation
	<![if ! IE]> <![endif]>M A I N NANCE
		Incomplete running-in
		Overloaded engine
		Advanced injection
	<![if ! IE]> <![endif]>REPAIRINGS	Delayed injection
		Incorrect governor tinkage adjustment
		Broken or loose govener spring
		Low idling setting
		Worn or stuck piston rings
	<![if ! IE]> <![endif]>AND	Worn or scored cylinders
		Worn valve guides
	<![if ! IE]> <![endif]>SETTINGS	Sticking valves
		Crank shaft not turning freely
		Worn crankshaft-connecting rod bearings
		Non-sliding speed governor leverage
		Cylinder head gasket

TROUBLE

<![if ! IE]> <![endif]>It does not start	<![if ! IE]> <![endif]>It starts but does not stop	<![if ! IE]> <![endif]>It does not accelerate		<![if ! IE]> <![endif]>I n c o n s i - stent rpm	<![if ! IE]> <![endif]>Black smoke	<![if ! IE]> <![endif]>White smoke	<![if ! IE]> <![endif]>Low oil pressure	<![if ! IE]> <![endif]>Oil level increase	<![if ! IE]> <![endif]>Excessive oil consumption	<![if ! IE]> <![endif]>Oil and fuel leakage from the exhaust

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2 Technical information

ROUTINE ENGINE MAINTENANCE

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

MAINTENANCE ENGINES 3LD 450 - 510 - 450/S - 510/S 4LD 640 - 705 - 820

OPERATION

DETAIL

INTERVALS (HOURS)

10

50

125

250

500

1000

2500

5000

CLEANING

AIR FILTER (OIL-BATH) (*)

HEAD AND CYLINDER FINS (*)

FUEL TANK

INJECTORS

CHECK

LEVEL

AIR FILTER OIL

SUMP OIL

BATTERY LIQUID

FUEL HOSE

COUPLING FASTENING

VALVE AND ROCKER ARM CLEARANCE

INJECTOR SETTING

CHANGE

AIR FILTER(**) (***)

SUMP (***)

OIL FILTER CARTRIDGE

FUEL FILTER CARTRIDGE

OVERHAUL

PARTIAL (****)

GENERAL

First replacement.

(*)

In particular running conditions even every day.

(**)

In particularly dusty environments every 4-5 hours.

(***)

See prescribed oil.

(****) It includes the check of cylinders, segments, guides, valve seat springs and grindings, head and cylinder descaling, injection pump and injector checks.

CAPACITIES IN LITERS

Standard fuel tank

3LD450, 3LD510, 3LD450/S, 3LD510/S = 5.3 4LD 640, 4LD705, 4 LD 820 = 7.2

Standard oil sump:

3LD450, 3LD510, 3LD450/S, 3LD510/S =1.75 4LD640, 4LD705, 4LD 820 = 2.60

Air filter oil bowl = 0.3

For special filters, tanks and oil sumps, please follow LOMBARDINI instructions.

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Technical information 2

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.

-	-	-	-	-	-	-	-	0	+	+	+	+	+	+	+	+	+	+
40	35	30	25	20	15	10	5		5	10	15	20	25	30	35	40	45	50

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

SAEGrade ** 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 this page 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 - SEQUENCES

LIGHT DUTY DIESEL ENGINES

B1 = Low-viscosity, for frictions reduction

B2 = Standard

B3 = High performances (indirect injection)

B4 = High quality (direct injection)

HEAVY DUTY DIESEL ENGINES

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 )

API / MIL SEQUENCES

API CH-4 CG-4 CF-4 CF-2 CF CE CD CC

MIL	L- 46152 D / E

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