Lombardini 9LD Engine Service & Repair Manual
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cod. 1-5302-286
9 LD Engine Series
WORKSHOP MANUAL
- 3 -
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.
Information presented within this manual assumes the following:
1- The person or people performing service work on LOMBARDINI series engines is properly trained and equipped
to safely and professionally perform the subject operation;
2- The person or people performing service work on LOMBARDINI series engines possesses adequate hand and
LOMBARDINI special tools to safely and professionally perform the subject service operation;
3 - The person or people performing service work on LOMBARDINI series engines has read the pertinent
information regarding the subject service operations and fully understands the operation at hand.
- 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.
9 LD Engine Series
9LD Workshop Manual _ cod. 1.5302.286 - 3° ed_rev. 02
- 4 - 9LD Workshop Manual _ cod. 1.5302.286 - 3° ed_rev. 02
3° 06-88 2 26.11.2008
-
CUSE/ATLO
1-5302-286 50494
Drafting
body
Document
code
Edition Issue date
Review
date
Model
N°
Revision
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the following table.
Endorsed
- 5 - 9LD Workshop Manual _ cod. 1.5302.286 - 3° ed_rev. 02
-
This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled, direct injection Diesel
engines type 9 LD 625-2 - 625-2 EPA - 626-2 - 626-2 NR: updated November 26
th
, 2008.
CHAPTER INDEX
TABLE OF CONTENTS
1 GENERAL REMARKS AND SAFETY INFORMATION ______________________________________ 9-11
General safety during operationg phases .......................................................................................................................... 11
General service manual notes ............................................................................................................................................ 9
Glossary and terminology ................................................................................................................................................... 9
Safety and environmental impact ...................................................................................................................................... 11
Safety and warning decals ................................................................................................................................................ 10
Safety regulations ............................................................................................................................................................. 10
Warranty certificate ............................................................................................................................................................. 9
2 TECHNICAL INFORMATION _________________________________________________________ 12-21
Approval data .................................................................................................................................................................... 14
Main components .............................................................................................................................................................. 15
Manufacturer and engine identification .............................................................................................................................. 14
Overall dimension ............................................................................................................................................................. 20
Performance diagram ....................................................................................................................................................... 18
Table of likely anomalies and their symptoms ................................................................................................................... 12
Technical specifications .................................................................................................................................................... 16
Trouble shooting ............................................................................................................................................................... 12
3 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING _______________________________ 22-25
ACEA Regulations - ACEA Sequences ............................................................................................................................. 23
API / MIL Sequences ......................................................................................................................................................... 23
Extraordinary maintenance ............................................................................................................................................... 22
Fuel recommendations ..................................................................................................................................................... 25
International specifications ................................................................................................................................................ 23
Lubricant ........................................................................................................................................................................... 23
Ordinary maintenance ....................................................................................................................................................... 22
Prescribed lubricant .......................................................................................................................................................... 24
Routine engine maintenance ............................................................................................................................................. 22
SAE Classification ............................................................................................................................................................ 23
4 DISASSEMBLY / REASSEMBLY ______________________________________________________ 26-51
Air cleaner ......................................................................................................................................................................... 26
Camshaft .......................................................................................................................................................................... 45
Camshaft end play ............................................................................................................................................................ 46
Camshaft timing ................................................................................................................................................................ 46
Center main bearing support, locating screw. ................................................................................................................... 42
Checking main journals and crank pins ............................................................................................................................. 43
Clearance between main journals/crank pins and connecting rod bearings ...................................................................... 44
Clogging indicator ............................................................................................................................................................. 28
Compression release ........................................................................................................................................................ 32
Connecting rod .................................................................................................................................................................. 39
Connecting rod alignment ................................................................................................................................................. 40
Connecting rod big end bearing ......................................................................................................................................... 40
Connecting rod small end bushing .................................................................................................................................... 40
Connecting rod weight ...................................................................................................................................................... 40
Cooling fan ........................................................................................................................................................................ 30
Crankshaft ........................................................................................................................................................................ 42
Crankshaft center main bearing support ........................................................................................................................... 42
Crankshaft end play .......................................................................................................................................................... 45
- 6 - 9LD Workshop Manual _ cod. 1.5302.286 - 3° ed_rev. 02
- Chapter index
Crankshaft journal radius .................................................................................................................................................. 43
Crankshaft lubrication ducts .............................................................................................................................................. 42
Crankshaft removal ........................................................................................................................................................... 42
Crankshaft timing gear ...................................................................................................................................................... 41
Cylinder ............................................................................................................................................................................. 36
Cylinder head .................................................................................................................................................................... 33
Dimensions and clearance between guides and valves .................................................................................................... 35
Dimensions of camshaft journals and housings ............................................................................................................... 45
Dry air cleaner .................................................................................................................................................................. 27
Dry air cleaner, Donaldson type ........................................................................................................................................ 27
Electronic speed governor ................................................................................................................................................ 49
Exhaust manifold .............................................................................................................................................................. 28
External alternator blower control belt - Disassembly ....................................................................................................... 29
External alternator blower control belt - Reassembly ........................................................................................................ 29
External alternator blower control belt – Tension check .................................................................................................... 29
External alternator control belt .......................................................................................................................................... 29
Flywheel ............................................................................................................................................................................ 31
Fuel tank ........................................................................................................................................................................... 29
Governor springs with rocker arm system ........................................................................................................................ 49
Governor springs with single-spring system ..................................................................................................................... 49
Head seal thickness .......................................................................................................................................................... 39
How to measure camshaft journals and housings ............................................................................................................ 45
How to measure intake/exhaust cam height ..................................................................................................................... 46
How to measure main bearing inside diameter ................................................................................................................. 43
Hub .................................................................................................................................................................................... 30
Hydraulic pump ................................................................................................................................................................. 47
Hydraulic pump components (1 P) .................................................................................................................................... 48
Hydraulic pump p.t.o ......................................................................................................................................................... 47
Injector .............................................................................................................................................................................. 32
Injector for EPA and 97/68 CE engines ............................................................................................................................. 33
Injector projection .............................................................................................................................................................. 33
Intake manifold .................................................................................................................................................................. 28
Internal alternator .............................................................................................................................................................. 30
Main bearing and connecting rod big end bearing inside diameter .................................................................................... 44
Main bearing housings ...................................................................................................................................................... 44
Main bearing support, flywheeI side ................................................................................................................................... 41
Main bearing support, gear side ........................................................................................................................................ 41
Main bearing supports ....................................................................................................................................................... 41
Main bearíng supports - Dimensions ................................................................................................................................. 44
Main journal and crank pin diameter .................................................................................................................................. 43
Manifolds, intake/exhaust .................................................................................................................................................. 28
Mechanical speed governor .............................................................................................................................................. 48
Mechanical speed governor components .......................................................................................................................... 48
Oil vapour separator ......................................................................................................................................................... 28
Oil-bath air cleaner ............................................................................................................................................................ 26
Piston ................................................................................................................................................................................ 37
Piston - Refitting ................................................................................................................................................................ 39
Piston clearance ............................................................................................................................................................... 39
Piston rings - End gaps (mm) ........................................................................................................................................... 38
Piston rings - Fitting sequence .......................................................................................................................................... 38
Piston weight ..................................................................................................................................................................... 38
Pistons ringis - Clearance between grooves (mm) ........................................................................................................... 38
Pulley guard - Shroud - Side plates ................................................................................................................................... 30
Pushrod tube ..................................................................................................................................................................... 36
Recommendations for disassembling and assembling .................................................................................................... 26
Recommendations for overhauls and tuning ..................................................................................................................... 26
Rocker arm assembly ....................................................................................................................................................... 32
Rocker arms ..................................................................................................................................................................... 31
Shroud support (Gear cover plate) .................................................................................................................................... 31
Speed governor wiring diagram ......................................................................................................................................... 50
Table “Clearance between main bearings and main bearing housings” ............................................................................ 45
Table “Piston and cylinder types and sizes" ...................................................................................................................... 37
Valve / Rocker arm clearance ........................................................................................................................................... 31
Valve guide insertion ......................................................................................................................................................... 35
Valve guides and valve guide housings ............................................................................................................................. 35
Valve material ................................................................................................................................................................... 34
- 7 - 9LD Workshop Manual _ cod. 1.5302.286 - 3° ed_rev. 02
- Chapter index
Valve seat grinding ............................................................................................................................................................ 36
Valve seats and housings ................................................................................................................................................. 36
Valve springs ..................................................................................................................................................................... 34
Valve stem sealing rings - Reassembly ........................................................................................................................... 34
Valve timing - Angles ......................................................................................................................................................... 47
Valve timing check ............................................................................................................................................................ 47
Valve timing without considering timing marks .................................................................................................................. 46
Valves ............................................................................................................................................................................... 34
5 LUBRICATION SYSTEM ____________________________________________________________ 52-55
Lubrication system and breather recirculation system ...................................................................................................... 52
Lubrication system with oil radiator circuit ........................................................................................................................ 53
Oil filter cartridge (external) ............................................................................................................................................... 54
Oil pressure check ............................................................................................................................................................ 55
Oil pressure curve with engine at full speed ...................................................................................................................... 55
Oil pressure curve with engine at idle speed ..................................................................................................................... 55
Oil pressure relief valve ..................................................................................................................................................... 54
Oil pump ........................................................................................................................................................................... 53
Oil radiator ........................................................................................................................................................................ 55
Standard lubrication system circuit ................................................................................................................................... 52
6 FUEL SYSTEM ____________________________________________________________________ 56-65
Fuel feeding / injection circuit with external fuel filter ......................................................................................................... 56
Fuel feeding / injection circuit with external fuel filter and double solenoid valve ............................................................... 56
Fuel feeding / injection circuit with external fuel filter and QSD (Quick Stop System) ....................................................... 57
Fuel feeding / injection circuit with fuel filter inside the fuel tank ........................................................................................ 56
Fuel feeding / injection circuit with fuel filter inside the fuel tank and double solenoid valve ............................................... 56
Fuel feeding /injection circuit ............................................................................................................................................. 56
Fuel feeding pump components ........................................................................................................................................ 58
Fuel filter ........................................................................................................................................................................... 57
Fuel filter (inside fuel tank) ................................................................................................................................................ 57
Fuel filter, external ............................................................................................................................................................. 57
Fuel lift pump .................................................................................................................................................................... 57
How to check injection pump delivery valve sealing .......................................................................................................... 60
How to check plunger and barrel for internal leakage ........................................................................................................ 59
How to mount injection pump on the engine ...................................................................................................................... 61
How to reassemble injection pump components .............................................................................................................. 61
Injection advance adjustment ............................................................................................................................................ 63
Injection pump ................................................................................................................................................................... 58
Injection pump for EPA engines ........................................................................................................................................ 59
Injection pump for Standard and 97/68 CE engines .......................................................................................................... 58
Injection pump/mechanical speed governor timing ........................................................................................................... 62
Injection static advance adjustment .................................................................................................................................. 62
Injector .............................................................................................................................................................................. 64
Injector setting ................................................................................................................................................................... 65
Piston fuel lift pump (on request) ...................................................................................................................................... 58
Plunger and Barrel Assembly ............................................................................................................................................ 59
Size P injector, for 97/68 CE and EPA engines ................................................................................................................. 65
Size P nozzle, for 97/68 CE and EPA engines .................................................................................................................. 65
Size S Injector, only for standard engines ......................................................................................................................... 64
Size S Nozzle, only for standard engines ......................................................................................................................... 64
(Static) injection timing ...................................................................................................................................................... 62
Table “Conversion for establishing advance” .................................................................................................................... 63
Test data for injection pump delivery ................................................................................................................................. 60
7 ELECTRIC SYSTEM________________________________________________________________ 66-75
Alternator ........................................................................................................................................................................... 67
Alternator - 12 V, 14 A ....................................................................................................................................................... 68
Alternator - 12 V, 18A ........................................................................................................................................................ 67
- 8 - 9LD Workshop Manual _ cod. 1.5302.286 - 3° ed_rev. 02
- Chapter index
Alternator - 24 V, 6 A ......................................................................................................................................................... 67
Alternator battery charger curve - 24 V, 6 A ....................................................................................................................... 68
Alternator battery charger curve - external, 12 V, 33 A ...................................................................................................... 69
Alternator battery charger curve (12 V, 18 A) .................................................................................................................... 67
Alternator battery charger curve standard - 12 V, 14 A ..................................................................................................... 68
Alternator, external - 12 V, 33 A ......................................................................................................................................... 69
Characteristic curves for starting motor type Bosch - 12 V, 1.7 kW ................................................................................. 72
Characteristic curves of the 24 V 1.6 kW starting motor ................................................................................................... 73
Checking for cable continuity ............................................................................................................................................ 69
Direct stop electromagnet ................................................................................................................................................. 75
Direct stop electromagnets ............................................................................................................................................... 74
Electric starting layout with internal alternator ................................................................................................................... 66
Electrical starting layout with external alternator ............................................................................................................... 66
How to check voltage regulator for proper operation ......................................................................................................... 70
Magnetization checking tool .............................................................................................................................................. 68
Pre-heating glow plug ........................................................................................................................................................ 74
Reverse electromagnet – FIRE version ............................................................................................................................ 74
Starting motor ................................................................................................................................................................... 72
Starting motor type Bosch DW (R) 12 V, 1.7 kW .............................................................................................................. 73
Voltage regulator ............................................................................................................................................................... 70
Voltage regulator - 12 V, 30 A ............................................................................................................................................ 71
Voltage regulator - 12V, 26A, with “W” terminal ................................................................................................................. 71
Voltage regulator - 12V, 30A, with “W” terminal ................................................................................................................. 71
8 SETTINGS _______________________________________________________________________ 76-79
Full speed setting in no-load conditions (standard) ........................................................................................................... 76
Idling speed setting in no-load conditions .......................................................................................................................... 76
Injection pump delivery setting .......................................................................................................................................... 76
Injection pump delivery setting with dynamometric brake .................................................................................................. 77
lnjection pump delivery limiting and extra fuel device ........................................................................................................ 76
lnjection pump delivery setting without dynamometric brake ............................................................................................. 77
Required settings (as most commonly applies) ................................................................................................................ 78
Setting the stop limit stop .................................................................................................................................................. 78
Speed adjustments ........................................................................................................................................................... 76
9 STORAGE _______________________________________________________________________ 80-81
Engine storage .................................................................................................................................................................. 80
Preparing the engine for operation after protective treatment ............................................................................................ 81
Protective treatment .......................................................................................................................................................... 80
10 TORQUE SPECIFICATIONS AND USE OF SEALANT ____________________________________ 82-84
Table of tightening torques for standard screws (coarse thread) ...................................................................................... 84
Table of tightening torques for standard screws (fine thread) ........................................................................................... 84
Table of tightening torques for the main components ....................................................................................................... 82
11 SPECIAL TOOLS _____________________________________________________________________ 85
Special tools and equipment for maintenance .................................................................................................................. 85
- 9 - 9LD Workshop Manual _ cod. 1.5302.286 - 3° ed_rev. 02
1
- 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 warranty obligations here above described will be cancelled if:
- 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.
GENERAL SERVICE MANUAL NOTES
1 - Use only genuine Lombardini repair parts.
Failure to use genuine Lombardini parts could result in sub-standard performance and low longevity.
2 - All data presented are in metric format. That is, 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) and pressure is
presented in barometric units (bar).
GENERAL REMARKS AND SAFETY INFORMATION
WARRANTY CERTIFICATE
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».
- 10 - 9LD Workshop Manual _ cod. 1.5302.286 - 3° ed_rev. 02
1
• 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.
• 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.
General remarks and safety information
- Important remarks and features of the text are highlighted
using symbols, which are explained below:
Danger – Attention
This indicates situations of grave danger which, if ignored,
may seriously threaten the health and safety of individuals.
SAFETY AND WARNING DECALS
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
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This is a complete factory service repair workshop manual for the Lombardini 9LD Engine. The manual contains easy-to-read text sections with high-quality diagrams and instructions, making it useful for both do-it-yourself enthusiasts and experienced mechanics. It provides step-by-step instructions and highly detailed exploded pictures and diagrams to assist in completing the required job correctly and efficiently.
The Lombardini 9LD Engine Service Repair Workshop Manual covers every single detail of the machine, including general remarks and safety information, technical information, maintenance, disassembly/reassembly, lubrication circuit, coolant circuit, fuel system, electric system, settings, storage, torque specifications and use of sealant, special tools, and more.
File Format: PDF
Compatibility: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & Win
All pages of the manual are printable, and it is designed to save you money on postage and packaging. It is a valuable resource to have for maintaining the Lombardini 9LD Engine.
