Lombardini LDW 492 DCI Engine OEM Service & Repair Manual
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LDW 492 DCI
AUTOMOTIVE
WORKSHOP MANUAL
- 3 -
LDW 492 DCI
AUTOMOTIVE
Workshop Manual_LDW 492 DCI _ cod. ED0053029770 - 3° ed_ rev. 02
PREFACE
- Every attempt has been made to present within this service manual, accurate and up to date technical informa-
tion.
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 equip-
ped 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 infor-
mation 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.
- 4 - Workshop Manual_LDW 492 DCI _ cod. ED0053029770 - 3° ed_ rev. 02
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the following table.
Drafting
body
Document
code
Model
N°
Edition Revision Issue date
Review
date
Endorsed
DICOM/ATLO
ED0053029770 51292 3° 02 21.10.2013 06.03.2020
Original instructions translated from the Italian language
Data reported in this issue can be modified at any time by Kohler Engines .
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
- 5 - Workshop Manual_LDW 492 DCI _ cod. ED0053029770 - 3° ed_ rev. 02
1 GENERAL INFORMATION ON SAFETY .................................................................................. 9-12
WARRANTY CLAUSES ..................................................................................................................................................... 9
SERVICE GENERAL NOTES ............................................................................................................................................ 9
GLOSSARY AND TERMINOLOGY.................................................................................................................................... 9
WARNINGS AND NOTES ................................................................................................................................................ 10
SAFETY RULES .............................................................................................................................................................. 10
GENERAL SAFETY DURING OPERATING PHASES .....................................................................................................11
ENVIRONMENTAL IMPACT .............................................................................................................................................11
ENGINE ON ROTATING STAND - SAFETY PRECAUTIONS ......................................................................................... 12
2 TECHNICAL INFORMATION .................................................................................................. 13-28
GENERAL DESCRIPTION OF THE ENGINE.................................................................................................................. 13
PROBLEMS AND RELATED CAUSES....................................................................................................................... 14-15
DIMENSIONS .................................................................................................................................................................. 16
TECHNICAL SPECIFICATIONS ................................................................................................................................. 16-17
ENGINE AND MANUFACTURER IDENTIFICATION....................................................................................................... 18
PERFORMANCE GRAPH ............................................................................................................................................... 18
LDW 492 DCI ENGINE MAINTENANCE (UNSCHEDULED) .......................................................................................... 19
COOLANT ........................................................................................................................................................................ 20
FUEL SPECIFICATIONS ................................................................................................................................................. 20
LUBRICANTS .................................................................................................................................................................. 21
FUEL SUPPLY CIRCUIT............................................................................................................................................. 22-24
LUBRICATION CIRCUIT.................................................................................................................................................. 25
COOLING SYSTEM - OPERATING PRINCIPLE........................................................................................................ 26-28
3 ENGINE ELECTRICAL CONTROL ......................................................................................... 30-47
ENGINE ELECTRONIC CONTROL SYSTEM ................................................................................................................. 30
WIRING DIAGRAM OF THE ELECTRICAL/ELECTRONIC SYSTEM............................................................................. 31
ENGINE-VEHICLE DIALOGUE SYSTEM ....................................................................................................................... 36
ENGINE WIRING DIAGRAM ...................................................................................................................................... 34-35
ENGINE WIRING HARNESS...................................................................................................................................... 36-37
ACCESSORY WIRING DIAGRAM................................................................................................................................... 38
CONNECTORS REQUESTED FOR INTERFACING WITH LOMBARDINI WIRING HARNESS .................................... 39
COMPONENTS OF ENGINE ELECTRONIC CONTROL SYSTEM ........................................................................... 40-47
E.C.U. (Electronic control unit) ......................................................................................................................................... 40
Control Unit Identification Plate ........................................................................................................................................ 40
Installation Requirements................................................................................................................................................. 40
Common Rail ................................................................................................................................................................... 41
Electronic Injectors ........................................................................................................................................................... 42
IMA Management ............................................................................................................................................................. 42
Water Temperature Sensor .............................................................................................................................................. 43
Oil Pressure Sensor ......................................................................................................................................................... 43
Accelerator Potentiometer inside the Cabin (Pedal-Integrated) ....................................................................................... 44
Accelerator Potentiometre as an Accessory (Remote-Controlled via Accelerator Cable) ................................................ 44
Glow Plugs ....................................................................................................................................................................... 45
Speed Sensor .................................................................................................................................................................. 45
Electric Fan ...................................................................................................................................................................... 46
Starter Motor .................................................................................................................................................................... 46
Alternator.......................................................................................................................................................................... 47
External Alternator Load Curve Graph ............................................................................................................................. 47
4 ENGINE STORAGE AND CONSERVATION........................................................................... 48-49
HANDLING AND LIFTING ............................................................................................................................................... 48
ENGINE STORAGE ......................................................................................................................................................... 49
PROTECTIVE TREATMENT............................................................................................................................................ 49
PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT.................................................... 49
CHAPTER INDEX
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Chapter index
5 DISASSEMBLY........................................................................................................................ 50-71
RECOMMENDATIONS FOR DISASSEMBLY ................................................................................................................. 50
Alternator and Drive Belt .................................................................................................................................................. 55
Alternator Drive Pulley ..................................................................................................................................................... 61
Balance Countershafts ..................................................................................................................................................... 71
Camshaft .......................................................................................................................................................................... 66
Camshaft Cover ............................................................................................................................................................... 66
Connecting Rod Big End Caps ........................................................................................................................................ 69
Coolant Outlet Flange and Thermostatic Valve ................................................................................................................ 60
Crankcase ........................................................................................................................................................................ 70
Crankshaft ........................................................................................................................................................................ 71
Cylinder Head .................................................................................................................................................................. 67
Electronic Injectors ........................................................................................................................................................... 58
Engine Block .................................................................................................................................................................... 71
Engine Wiring Harness ............................................................................................................................................... 50-52
Exhaust Manifold.............................................................................................................................................................. 53
Extracting the Electronic Injectors from the Cylinder Head .............................................................................................. 59
Flywheel ........................................................................................................................................................................... 63
Fuel Distributor ................................................................................................................................................................. 57
Fuel Supply Hoses ........................................................................................................................................................... 55
Gear Cover....................................................................................................................................................................... 68
Glow Plugs ....................................................................................................................................................................... 60
Head Gasket .................................................................................................................................................................... 68
High-Pressure Line between Injection Pump and Rail ..................................................................................................... 58
High-Pressure Pump ........................................................................................................................................................ 65
Injection Pump Supply Hoses .......................................................................................................................................... 56
Injector High-Pressure Hoses ..................................................................................................................................... 56-57
Injector Return Line .......................................................................................................................................................... 56
Inlet Manifold .................................................................................................................................................................... 54
Intake System and Ducts ............................................................................................................................................ 53-54
Oil Filter Cartridge ............................................................................................................................................................ 60
Oil Pump .......................................................................................................................................................................... 69
Oil Pump Gear ................................................................................................................................................................. 68
Oil Sump .......................................................................................................................................................................... 69
Overpressure Return Line ................................................................................................................................................ 57
Piston ............................................................................................................................................................................... 70
Rail ................................................................................................................................................................................... 59
Rocker Arms and Hydraulic Tappets ................................................................................................................................ 67
Service Wiring Harness............................................................................................................................................... 52-53
Speed Sensor .................................................................................................................................................................. 64
Starter Motor .................................................................................................................................................................... 61
Starter Motor Support Plate ............................................................................................................................................. 64
Tightening Pulley .............................................................................................................................................................. 63
Timing System.................................................................................................................................................................. 62
Water Pump ..................................................................................................................................................................... 63
Water Temperature Sensor .............................................................................................................................................. 60
6 OVERHAULING AND TUNING UP ......................................................................................... 72-91
RECOMMENDATIONS FOR OVERHAUL AND TUNING................................................................................................ 72
OVERHAULING THE CRANK MECHANISM AND CRANKCASE .................................................................................. 72
Balance Countershafts ..................................................................................................................................................... 77
Camshaft .......................................................................................................................................................................... 89
Camshaft cover inspection ............................................................................................................................................... 88
Connecting Rod - Check of Axis Parallelism .................................................................................................................... 78
Connecting Rod - Overhauling and Dimensional Check ............................................................................................. 77-78
Crankshaft ........................................................................................................................................................................ 76
Crankshaft - Axial Clearance Check ................................................................................................................................ 76
Cylinder Head and Components - Overhauling ............................................................................................................... 83
Cylinders .......................................................................................................................................................................... 74
Glow Plug Specifications and Injector Protrusion ............................................................................................................ 85
Head Gasket - Determining the Thickness ...................................................................................................................... 79
- 7 - Workshop Manual_LDW 492 DCI _ cod. ED0053029770 - 3° ed_ rev. 02
High-Pressure Pump ................................................................................................................................................... 90-91
Hydraulic Tappet .............................................................................................................................................................. 87
Oil Pressure Relief Valve ................................................................................................................................................. 82
Oil Pump .......................................................................................................................................................................... 81
Piston .......................................................................................................................................................................... 73-74
Rings ................................................................................................................................................................................ 75
Timing System.................................................................................................................................................................. 86
Timing System - Timing Angle Scheme............................................................................................................................ 86
Valve Guides - Overhauling and Check ........................................................................................................................... 84
Valve Seats - Check ......................................................................................................................................................... 84
Valve Springs ................................................................................................................................................................... 83
Valves - Reassembly........................................................................................................................................................ 85
Valves Guides and Housings ........................................................................................................................................... 85
Vapour Recirculation Vent ................................................................................................................................................ 80
Vapour Recirculation Vent - Operating Principle .............................................................................................................. 80
7 REASSEMBLY....................................................................................................................... 92-121
RECOMMENDATIONS FOR REASSEMBLY .................................................................................................................. 92
Air Filter ...........................................................................................................................................................................118
Air Filter Duct - Vent Duct................................................................................................................................................117
Air Filter Support Bracket ................................................................................................................................................117
Alternator.........................................................................................................................................................................116
Alternator Drive Belt ........................................................................................................................................................116
Alternator Drive Pulley ................................................................................................................................................... 107
Balance Countershafts ..................................................................................................................................................... 93
Camshaft ........................................................................................................................................................................ 102
Camshaft Cover ............................................................................................................................................................. 102
Camshaft Seal Rings ..................................................................................................................................................... 103
Camshaft Toothed Pulley ............................................................................................................................................... 105
Clearance Volume .......................................................................................................................................................... 100
Common Rail .................................................................................................................................................................. 111
Common Rail Fixing Columns - Tightening .....................................................................................................................112
Connecting Rod Cap ................................................................................................................................................... 97-98
Coolant Inlet Flange ....................................................................................................................................................... 108
Coolant Outlet Flange .................................................................................................................................................... 108
Crankcase - Fixing ........................................................................................................................................................... 95
Crankshaft ........................................................................................................................................................................ 93
Crankshaft Seal Rings (Flywheel Side).......................................................................................................................... 103
Crankshaft Seal Rings (Timing System Side) ................................................................................................................ 104
Electronic Injector Fixing Bracket ................................................................................................................................... 109
Electronic Injectors ......................................................................................................................................................... 109
Electronic Injectors - Tightening ......................................................................................................................................112
Engine Cylinder Head .................................................................................................................................................... 101
Engine Wiring Harness - Installation ....................................................................................................................... 119-121
Exhaust Manifold.............................................................................................................................................................118
External Timing Belt Guard ............................................................................................................................................ 107
Flywheel ......................................................................................................................................................................... 100
Fuel Hoses ......................................................................................................................................................................113
Gear Cover..................................................................................................................................................................... 104
Glow Plugs ..................................................................................................................................................................... 109
High-Pressure Lines........................................................................................................................................................ 111
High-Pressure Pump ................................................................................................................................................ 110-111
Injector Fittings - Tightening ............................................................................................................................................112
Injector Hose Fittings on Rail and Injection Pump Hose - Tightening .............................................................................112
Injector Return Line .........................................................................................................................................................115
Inlet Manifold ...................................................................................................................................................................117
Internal Timing Belt Guard ............................................................................................................................................. 104
Lower Crankcase - Half-Bearings ............................................................................................................................... 94-95
Oil Filter .......................................................................................................................................................................... 107
Oil Pump - Lobes ............................................................................................................................................................. 94
Oil Pump - Plate ............................................................................................................................................................... 96
Oil Suction Pipe................................................................................................................................................................ 98
Oil Sump .......................................................................................................................................................................... 98
Piston - Connecting Rod- Gudgeon pin - Assembly ......................................................................................................... 97
Chapter index
- 8 - Workshop Manual_LDW 492 DCI _ cod. ED0053029770 - 3° ed_ rev. 02
Rail ...........................................................................................................................................................................113-114
Rocker Arm Cover ...........................................................................................................................................................113
Rocker Arms and Hydraulic Tappets .............................................................................................................................. 101
Service Wiring Harness - Installation .......................................................................................................................118-119
Speed Sensor .................................................................................................................................................................. 99
Speed Sensor - Air gap .................................................................................................................................................. 100
Starter Motor ...................................................................................................................................................................115
Starter Motor Support Plate ............................................................................................................................................. 99
Synchronous Timing Belt - Installation ........................................................................................................................... 106
Synchronous Timing Belt - Tensioning ........................................................................................................................... 106
Thermostatic Valve......................................................................................................................................................... 108
Tightening Pulley ............................................................................................................................................................ 104
Timing Belt Setting ......................................................................................................................................................... 106
Timing System Drive Pulley ........................................................................................................................................... 105
Upper Crankcase - Crankshaft Half-Bearings .................................................................................................................. 92
Water Pump ................................................................................................................................................................... 103
Water Temperature Sensor ............................................................................................................................................ 108
8 TIGHTENING TORQUES AND USE OF SEALANT ......................................................... 123-1225
Table with Tightening Torques for Standard Screws (Coarse Thread) ........................................................................... 123
Table with Tightening Torques for Standard Screws (Fine Thread)................................................................................ 123
Table with Tightening Torques of the Main Components and Use of Sealant ......................................................... 124-135
9 SPECIFIC TOOLS .......................................................................................................................126
10 DIAGNOSIS ......................................................................................................................... 128-132
Chapter index
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1
Workshop Manual_LDW 492 DCI _ cod. ED0053029770 - 3° ed_ rev. 02
GENERAL REMARKS AND SAFETY INFORMATION
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 New-
ton-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).
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 -
1
Workshop Manual_LDW 492 DCI _ cod. ED0053029770 - 3° ed_ rev. 02
General remarks and safety information
• 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 ope-
ration 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.
- 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 igno-
red, may seriously threaten the health and safety of indi-
viduals.
SAFETY AND WARNING DECALS
Caution – Warning
This indicates that it is necessary to take proper precau-
tions to prevent any risk to the health and safety of indivi-
duals and avoid financial damage.
Important
This indicates particularly important technical information
that should not be ignored.
SAFETY REGULATIONS
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Print one or all pages of your manual
$31.99
This is a comprehensive factory OEM service and repair manual for the Lombardini LDW 492 DCI Engine. The manual contains easy-to-read text sections with high-quality diagrams and instructions, making it suitable for both do-it-yourself enthusiasts and experienced mechanics. It provides step-by-step procedures and highly detailed exploded pictures and diagrams to assist in completing the required repairs correctly and efficiently.
The Lombardini LDW 492 DCI Engine OEM Service & Repair Manual covers a wide range of important topics, including:
- General information on safety
- Technical specifications and guidelines
- Engine electrical control
- Engine storage and conservation
- Disassembly procedures
- Overhauling and tuning-up directions
- Reassembly instructions
- Tightening torques and use of sealants
- Special tools requirements
- Diagnosis methods
- And more...
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & Win
All pages are printable, allowing you to save money on postage and packaging. This manual is a valuable resource for maintaining your vehicle and ensuring that all repairs are performed with factory-approved procedures and technical details.
