SERVICE MANUAL
code 1.5302.727
- 2 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
ATLO
REGISTERING DOCUMENT MODIFICATIONS
This document is made up of 98 pages (-sides - excluding the
cover and title page). Pages are numbered in progressive order
from 051135.01 to 051135.98.
Any modifications to this document must be registered by the
drafting body and approved by the head of the Quality
Management System, with completion of the table below.
Copyright 2005 - Lombardini. Reproduction, even partial, of this document is subject to the manufacturer’s written authorisation. The manufacturer is committed to a policy of continuing improvement and reserves the right to modify the
document, with no obligation to notify, providing that omission to do so constitutes no safety risk. The text may be reproduced in part or in whole, providing that the author is cited. Text and graphics by: IDM Esperti in
Comunicazione Tecnica - Forlì
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1-5302-727 2° 30/06/05 10/01/2007
- 3 - Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
1 GENERAL REMARKS AND SAFETY
1.1 PURPOSE OF THE MANUAL ..................................... 5
1.2 USING THIS MANUAL ................................................ 5
1.3 MANUFACTURER AND ENGINE IDENTIFICATION .. 5
1.4 GLOSSARY AND TERMINOLOGY ............................. 6
1.5 WARRANTY CLAUSES .............................................. 6
1.6 GENERAL SAFETY REGULATIONS .......................... 6
1.7 GENERAL SAFETY DURING OPERATING PHASES 6
1.8 SAFETY AND ENVIRONMENTAL IMPACT ................ 7
1.9 PRECAUTIONS WHEN THE ENGINE IS INSTALLED
ON THE MACHINE ..................................................... 7
1.10 PRECAUTIONS WHEN THE ENGINE IS ON THE
ROTATING STAND ..................................................... 7
2 TECHNICAL INFORMATION
2.1 GENERAL DESCRIPTION OF THE ENGINE ............. 9
2.2 TECHNICAL SPECIFICATIONS ................................ 10
2.3 CHARACTERISTIC CURVE DIAGRAMS ................. 12
2.4 ALTERNATOR LOAD CURVE DIAGRAMS .............. 13
2.5 LUBRICANTS ........................................................... 14
2.5.1 SAE Classification ..................................................... 14
2.5.2 API/MIL sequences ................................................... 14
2.5.3 ACEA Standards ....................................................... 14
2.5.4 Recommended oil ...................................................... 14
2.6 OPERATING PRINCIPLE FOR LUBRICATION ........ 15
2.7 OPERATING PRINCIPLE FOR COOLING ............... 15
2.8 OPERATING PRINCIPLE FOR FUEL INJECTION ... 16
2.9 WIRING DIAGRAM ................................................... 17
2.10 SPECIAL TOOLS AND EQUIPMENT FOR
MAINTENANCE ........................................................ 19
2.11 TABLE OF TIGHTENING TORQUES ........................ 19
2.12 TABLE OF SEALANTS ............................................. 21
2.13 ROUTINE ENGINE MAINTENANCE ........................ 21
3 MALFUNCTIONS
3.1 LOOKING FOR MALFUNCTIONS ........................... 23
4 STORING THE ENGINE
4.1 HANDLING AND LIFTING ......................................... 25
4.2 STORING THE ENGINE (UNINSTALLED) ............... 25
4.3 STORING THE ENGINE (INSTALLED) .................... 25
4.4 PROTECTIVE TREATMENT ..................................... 26
4.5 PREPARING THE ENGINE FOR OPERATION
(UNINSTALLED) ....................................................... 26
4.7 PREPARING THE ENGINE FOR OPERATION
(INSTALLED) ............................................................ 27
5 REMOVING THE ASSEMBLIES
5.1 RECOMMENDATIONS FOR REMOVING THE
ASSEMBLIES ........................................................... 29
5.2 REMOVING THE EXHAUST AND INTAKE
MANIFOLDS ............................................................. 29
5.2.1 Disassembling the intake manifold ............................ 29
5.2.2 Disassembling the exhaust manifold ......................... 30
5.3 REMOVING THE COOLING FAN BELT DRIVE ........ 30
5.3.1 Disassembling the cooling fan belt
(with external alternator) ............................................ 31
5.3.2 Disassembling the cooling fan belt
(with internal alternator) ............................................. 31
5.4 REMOVING THE TIMING BELT DRIVE .................... 31
5.4.1 Disassembling the timing belt casing ........................ 31
5.4.2 Disassembling the timing belt .................................... 32
5.4.3 Disassembling the pulleys
(camshaft and crankshaft) ........................................ 32
5.5 REMOVING THE CYLINDER HEAD ......................... 33
5.5.1 Disassembling the rocker arm cover ......................... 33
5.5.2 Disassembling the rocker arms ................................. 33
5.5.3 Disassembling the fuel pump .................................... 33
5.5.4 Disassembling the injection-pumps ........................... 34
5.5.5 Disassembling the precombustion chamber .............. 34
5.5.6 Disassembling the speed governor
and flow limiter .......................................................... 35
5.5.7 Disassembling the camshaft ..................................... 36
5.5.8 Disassembling the cylinder head ............................... 36
5.6 REMOVING THE CRANK GEAR
AND CRANKCASE ................................................... 36
5.6.1 Disassembling the flywheel ....................................... 36
5.6.2 Disassembling the oil pump ....................................... 37
5.6.3 Disassembling the crankcase and crankshaft ........... 38
5.6.4 Disassembling the connecting rod and piston ........... 39
5.7 DISASSEMBLING THE VALVES .............................. 39
5.8 DISASSEMBLING THE PISTON ............................... 40
6 OVERHAULS AND TUNING
6.1 RECOMMENDATIONS FOR OVERHAULS
AND TUNING ............................................................ 41
6.1.1 Shaft seals ................................................................ 41
6.1.2 O-rings ...................................................................... 41
6.1.3 Bearings .................................................................... 41
6.2 OVERHAULING THE CRANK GEARS AND
CRANKCASE ............................................................ 41
6.2.1 Overhauling cylinders and pistons ............................. 41
6.2.2 Dimensional check and overhaul of cylinders ............ 42
6.2.3 Dimensional check and overhaul of pistons ............... 42
6.2.4 Dimensional check of sealing rings ........................... 43
6.2.5 Dimensional check and overhaul of crankshaft ......... 44
6.2.6 Dimensional check and overhaul of
connecting rods ......................................................... 45
6.2.7 Checking parallelism of the connecting rod axes ....... 45
6.2.8 Checking and overhauling the fuel pump ................... 46
6.2.9 Overhauling the decanting device .............................. 47
6.3 OVERHAUL OF CYLINDER HEAD AND RELATED
COMPONENTS ........................................................ 47
6.3.1 Checking and overhauling the cylinder head ............. 47
6.3.2 Checking and overhauling the rocker arm pin ........... 48
6.3.3 Checking and replacing the camshaft ....................... 49
6.3.4 Checking and replacing the fuel pump drive rod ........ 50
6.3.5 Checking and overhauling the valves ........................ 51
6.3.6 Adjusting valve-rocker arm clearance ....................... 52
6.3.7 Checking clearance volume ....................................... 52
6.3.8 Calibrating the injector ............................................... 53
6.3.9 Checking and overhauling the speed governor .......... 53
6.4 CHECKING TIMING BELT RATING .......................... 54
6.4.1 Valve adjustments ..................................................... 54
6.5 DIAGRAM OF TIMING BELT RATES ........................ 55
6.6 ADJUSTING STATIC INJECTION TIMING ............... 55
6.7 BALANCING INJECTION-PUMP DELIVERY ............ 58
GENERAL INDEX
- 4 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
GENERAL INDEX
6.8 ADJUSTING MINIMUM AND MAXIMUM
IDLE SPEED RPMS .................................................. 60
6.9 ADJUSTING INJECTION DELIVERY ....................... 60
6.9.1 Adjusting injection delivery (without dyno brake) ....... 60
6.9.2 Adjusting injection delivery (with dyno brake) ............ 61
6.10 CHECKING OIL PRESSURE .................................... 61
7 INSTALLATION OF ASSEMBLIES
7.1 RECOMMENDATIONS FOR INSTALLING THE
ASSEMBLIES ........................................................... 63
7.2 PRE-ASSEMBLY OF
SEALING RINGS – PISTONS .................................. 63
7.3 PRE-ASSEMBLY OF
CONNECTING RODS – PISTONS ........................... 64
7.4 INSTALLING VALVES ............................................... 64
7.4.1 Assembling the valves ............................................... 64
7.5 INSTALLATION OF CRANK GEAR
AND CRANKCASE … ............................................... 65
7.5.1 Installing piston/connecting rod - engine block .......... 65
7.5.2 Assembling the crankshaft ........................................ 66
7.5.3 Assembling the crankcase ........................................ 66
7.5.4. Measuring crankshaft axial clearance ........................ 67
7.5.5 Assembling the crankshaft flange (flywheel side) ...... 67
7.5.6 Installing the oil pump ................................................ 68
7.5.7 Assembling the flywheel ............................................ 69
7.6 INSTALLATION OF CYLINDER HEAD AND
COMPONENTS…. .................................................... 70
7.6.1 Assembling the precombustion chamber .................. 70
7.6.2 Assembling the cylinder head .................................... 71
7.6.3 Assembling the camshaft .......................................... 71
7.6.4 Assembling the speed governor and flow limiter ........ 72
7.6.5 Assembling injection – pumps ................................... 73
7.6.6 Assembling the mechanical fuel pump ...................... 74
7.6.7 Assembling the rocker arms ...................................... 75
7.6.8 Assembling the rocker arm cover .............................. 75
7.7 INSTALLING THE TIMING BELT DRIVE ................... 76
7.7.1 Assembling the timing belt pulley .............................. 76
7.7.2 Assembling the timing belt ........................................ 76
7.7.3 Assembling the belt drive cover ................................. 77
7.8 INSTALLATION OF THE COOLING FAN
BELT DRIVE ............................................................. 78
7.8.1 Assembling the fan belt drive pulleys ........................ 78
7.8.2 Assembling the fan belt drive .................................... 79
7.8.3 Assembling the cooling fan ........................................ 80
7.9 INSTALLING INTAKE AND EXHAUST MANIFOLDS 80
7.9.1 Assembling the exhaust manifold .............................. 80
7.9.2 Assembling the intake manifold ................................. 80
8 REPLACING PARTS
8.1 RECOMMENDATIONS FOR REPLACING PARTS .. 83
8.2 REPLACING THE ALTERNATOR – FAN BELT ......... 83
8.3 REPLACING THE TIMING BELT .............................. 85
8.4 REPLACING THE OIL FILTER .................................. 85
8.5 REPLACING THE AIR FILTER .................................. 86
8.6 REPLACING THE ALTERNATOR ............................. 87
8.7 REPLACING THE STARTER MOTOR ...................... 87
8.8 REPLACING THE FLYWHEEL RING GEAR ............ 88
8.9 REPLACING THE COOLANT THERMOSTAT .......... 88
8.10 REPLACING THE COOLANT PUMP ........................ 89
8.11 REPLACING THE THERMOSTATIC VALVE …. ....... 89
8.12 REPLACING THE NEGATIVE-PRESSURE VENT
VALVE ....................................................................... 90
8.13 REPLACING THE PRE-HEATING GLOW PLUGS ... 90
8.14 REPLACING INJECTOR PUMP PARTS ................... 91
8.14.1 Pumping element replacement .................................. 91
8.14.2 Replacing the nozzle-injector ..................................... 93
8.15 REPLACING THE COOLING FAN SUPPORT .......... 93
INDEX ................................................................ 95
- 5 - Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
1
GENERAL REMARKS AND SAFETY
1.1 PURPOSE OF THE MANUAL
- 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.
- This information is provided by the manufacturer in its
own language (Italian) and may be translated into other
languages to satisfy legislative and/or commercial
requirements.
- 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 in
the operating phases.
- 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.
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.
1.2 USING THIS MANUAL
- This manual is divided into several chapters.
- The first chapter gives general information and details
about safety (purpose of the manual, safety, etc.).
- The second, third and fourth chapters provide general
technical information (technical specifications,
diagrams, tightening torques, malfunctions, etc.).
- The fifth, sixth, seventh and eighth chapters describe
the most important operating procedures (removal,
overhaul and tuning, installation, replacements, etc.).
- This final section, which is reserved specifically for
LOMBARDINI after-sales service centres, has been
prepared with technical and practical considerations in
mind.
- However, the actual sequence of operations that
LOMBARDINI service centres must use may in some
cases be different from the ones described in this
manual. For this reason, the reader should refer to the
index to find his/her topic of interest quickly.
1.3 MANUFACTURER AND ENGINE IDENTIFICATION
The identification plate shown in the figure
can be found directly on the engine. It
contains the model, engine identity and all
information needed to operate safely.
A) Manufacturer’s identity
B) Engine type
C) Engine serial number
D) Maximum speed
E) Customer code
E) Approval data
- 6 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
1
GENERAL REMARKS AND SAFETY
1.4 GLOSSARY AND TERMINOLOGY
For clarity, here are the definitions of a number of terms
used recurrently in the manual.
- Piston number one: first piston “viewed from the
flywheel side of the engine”.
- Rotation direction: clockwise or anticlockwise “viewed
from the timing belt side of the engine”..
1.5 WARRANTY CLAUSES
LOMBARDINI issues a warranty certificate for each
engine giving details of all relevant general terms.
1.6 GENERAL SAFETY REGULATIONS
- In designing and building its product, the manufacturer
has paid particular attention to those aspects posing
a risk to the health and safety of persons handling the
engine. In addition to legislative requirements, all “rules
for good technical construction” have been applied.
- The purpose of this information is to invite operators
to pay particular attention in order to prevent any form
of risk. Caution is always the best policy. Safety is
also the responsibility of all operators who handle the
- All persons carrying out work on the engine at any
point in its life must possess precise technical
qualifications and skills, as well as experience
recognised and gained in the specific sector. Non-
compliance with these requirements may cause
damage to the health and safety of individuals.
- Do not tamper with, sidestep, eliminate or bypass the
installed safety devices. Non-compliance with this
requirement may be hazardous to the health and
safety of individuals.
- The procedures contained in this manual have been
tested and selected by the manufacturer’s technical
experts, and hence are to be recognised as authorised
operating methods.
- A number of procedures must be carried out with the
aid of equipment and tools that simplify and improve
the timing of operations.
- Some of these tools are normal workshop equipment,
while others are specific instruments that have been
constructed by the engine manufacturer.
- All tools must be in good working condition so that
engine components are not damaged and that
operations are carried out properly and safely.
- It is important to wear the personal safety devices
prescribed by work safety laws and also by the
standards of this manual.
- Holes must be lined up methodically and with the aid
of suitable equipment. Do not use your fingers to carry
out this operation to avoid the risk of amputation.
- Some phases may require the assistance of more than
one operator. If so, it is important to inform and
exercise them regarding the type of activity they will
be performing in order to prevent risks to the health
and safety of all persons involved.
- Do not use flammable liquids (petrol, diesel, etc.) to
degrease or wash components. Use special products.
- Keep flames away from the engine to avoid the risk
of fire.
- Replace worn or damaged parts exclusively with
original LOMBARDINI spare parts. This will contribute
to ensuring better performance and longer product
life.
1.7 GENERAL SAFETY DURING OPERATING PHASES
- 7 - Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
1 GENERAL REMARKS AND SAFETY
- Use the oils and greases recommended by the
manufacturer. Do not mix different brands or oils with
different characteristics.
- Use a torque wrench to tighten the main fixing points
of engine components. Stick to the tightening torques
indicated by the manufacturer.
- Discontinue use of the engine if any irregularities
arise, particularly in the case of unusual vibrations.
- The engine has been designed and built to satisfy
all the operating conditions described by the
manufacturer.
- Do not tamper with any devices to alter the level
of performance guaranteed by the manufacturer.
In order to minimise the impact on the environment, the
manufacturer now provides a number of indications to
be followed by all persons handling the engine, for any
reason, during its expected lifetime.
- All packaging components must be disposed of in
accordance with the laws of the country in which
disposal is taking place.
- Keep exhaust pipes in efficient working order to limit
the noise level of the engine and reduce
environmental pollution.
- When discontinuing use of the engine, select all
components according to their chemical
characteristics and dispose of separately.
- All operations, except where expressly stated
otherwise, must be carried out when the engine is not
running and has cooled sufficiently to avoid the risk of
burns.
- Do not keep the engine running in areas that are closed
and inadequately ventilated. Take all necessary
precautions to prevent a build up of exhaust fumes.
Every organisation has a duty to implement procedures
to identify, assess and monitor the influence of its own
activities (products, services, etc.) on the environment.
Procedures for identifying the extent of the impact on
the environment must consider the following factors:
- Liquid waste
- Waste management
- Soil contamination
- Atmospheric emissions
- Use of raw materials and natural resources
- Regulations and directives regarding environmental
impact
- Before removing the engine from the machine on
which it is installed, disconnect the electric current,
the fuel supply, coolant and all connections including
mechanical ones.
- To lift the engine, attach the lifting device at the points
(eyebolts) specified by the manufacturer.
- Close all engine openings carefully (exhaust, intake,
etc.) wash the outside and dry with a jet of compressed
air.
- Anchor the engine to the rotating stand to facilitate
all operations.
Note:the engine may also be placed on the
workbench, depending on the type of work to
be carried out.
1.10 PRECAUTIONS WHEN THE ENGINE IS ON THE ROTATING STAND
1.8 SAFETY AND ENVIRONMENTAL IMPACT
1.9 PRECAUTIONS WHEN THE ENGINE IS INSTALLED ON THE MACHINE
- 8 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
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Notes :
GENERAL REMARKS AND SAFETY
- 9 - Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
E P F G R T C M
B Q D S H A N
L
2
Main components
A) Cylinder head
B) Engine block
C) Crankcase
D) Timing belt assembly
E) Flywheel and crankshaft assembly
F) Air intake assembly
G) Cooling fan
H) Negative-pressure vent valve
L) Alternator
M) Oil filter
N) Exhaust manifold
P) Starter motor
Q) Camshaft
R) Coolant pump
S) Fuel supply pump
T) Oil pump
2.1 GENERAL DESCRIPTION OF THE ENGINE
TECHNICAL INFORMATION
- 10 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
A
B
C
D
36
280
E
G
451
491
N
P
181
213
H
M
R
S
340
151
182
160
Q
51(
1
)
52(
2
)
353
238
n°
mm
cm
3
2
72x62
505
μm
cm
2
13÷14
4470
Kg 60
35°
25°
910
36
Nl/min
m
3
/min
22,8:1
1:2
3600
9.8 (13.4)
9.1 (12.4)
8.2 (11.2)
28.7
300
kW (CV)
kW (CV)
kW (CV)
Nm
Kg
2
2.2 TECHNICAL SPECIFICATIONS
DIMENSIONS (mm)
GENERAL DETAILS
Operating cycle
Number of cylinders
Bore x stroke
Displacements
Compression rate
Intake
Filter capacity
Filtering surface
Cooling
Driving shaft rotation
Combustion sequence
Timing system
Dry weight of engine
Maximum tilt while operating
Maximum tilt while operating
Volume of air flow (at 3600 RPM)
Volume of cooling air (at 3600 RPM)
(1) with suction fan
(2) with blower fan
Maximum operating speed
Max. power (N 80/1269/EEC - ISO 1585 - DIN 7020)
Max. power (NB ISO 3046 - 1 IFN - DIN 6270)
Max. power (NA ISO 3046 - 1 ICXN - DIN 6270)
Maximum torque (at 2400 RPM)
Axial load allowed on driving shaft
POWER AND TORQUE
4-stroke diesel
no more than 1 minute
no more than 30 minutes
Air filter (dry)
Water
Clockwise (from distribution side)
Synchronous toothed belt
RPM
TECHNICAL INFORMATION
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Lombardini Marine Engines LDW 502 SERVICE MANUAL
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Description
The Lombardini Marine Engines LDW 502 SERVICE MANUAL is a comprehensive guide tailored to assist both professional mechanics and DIY enthusiasts in servicing and maintaining their LDW 502 marine engines. It contains detailed instructions, diagrams, and specifications for all aspects of engine maintenance, including troubleshooting, repair procedures, and routine maintenance tasks. The manual covers all models of the LDW 502 marine engines, ensuring that you have the correct information for your specific engine model.
Designed for easy navigation and understanding, this service manual is a valuable resource for anyone working on or owning a Lombardini LDW 502 marine engine. Purchase the Lombardini Marine Engines LDW 502 SERVICE MANUAL today to ensure proper care and maintenance of your engine.
