Lombardini Marine Engines LGA 280-340 OHC Series Workshop Manual

WORK SHOP MANUAL LGA 280-340 OHC Series engines,code 1-5302- 528 SERVICE LGA 280 OHC LGA 340 OHC COMPILER TECO/ATI REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 ENDORSED DATE 31.07.2001 1st Edition 1

SERVICE 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 continuos. 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 persons performing service work on Lombardini series engines is properly trained and equipped to safely and professionally perform the subject operation; 2- The person or persons 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 persons performing service work on Lombardini series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand. 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).

COMPILER TECO/ATL REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 ENDORSED DATE 31.07.2001 3 WARRANTY CERTIFICATE WARRANTY CERTIFICATE Engine manufactured by Lombardini S.r.l., are warranted to be free of defects in workmanship or materials for 12 months from the date of delivery to the first purchaser or non more than two (2) years from date of engine delivery to the Original Equipment Manufacturer as defined by Lombardini invoicing, whichever occurs firsts, except as defined below. Stationary applications, working at constant speed and/or slightly variable speeds, are excluded from the above terms. Stationary/fixed speed applications will be warranted to be free of material/workmanship defects for a maximum operational period of 1000 hours or 12months from the date of first purchase, whichever occurs first. The two (2) year limitation from date of Lombardini invoice will remain intact as described above. Modification of Lombardini products by the Original Equipement Manufacturer or the end user with respect to cooling systems, filtration systems, induction systems, exhaust systems, lubrication system, fuel system, fuel system settings, etc., will require special written warranty agreements. A test certificate/approval by the R&D/Application engineering department of Lombardini or associated Lombardini companies concerning modified Lombardini products will entitle Warranty as defined above. Warranty will not be granted on any modified Lombardini product without special written approval by Lombardini. Within the above stated periods Lombardini will replace and/or repair, at the option of Lombardini, any part or component that, upon examination by Lombardini or an authorized Lombardini agent, is found to be defective in 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 replacemnt of any component will not extend or renew the warranty period. Direct labor required to make repairs or to replace components found to be defective in materials or workmanship will be completed at no cost to the end user. Lombardini in not responsible however for indirect costs of removing/installing the engine assembly. Further, Lombardini is not responsible for the costs of transportation of the machine or components requiring repair or for service supplies such as lubricating oils and filters. Lombardini Warranty obligations will be cancelled if: - Lombardini engines are applied to a given machine causing working engine parameters outside Lombardini application guidelines. - Lombardini engines are not serviced and maintained according to the "USE and MAINTENANCE" booklet. - Any seal affixed to the engine by Lombardini has been tampered with or removed. - Engines have been disassembled, repaired or altered by any party other than an authorized Lombardini agent. - Spare parts used are not original Lombardini. - Fuel injection system/component failures caused by the use of unauthorized fuel types or poor quality fuels are not covered under the Lombardini warranty policy. - Electrical system failures due to the modification of Lombardini supplied harnesses, modification of Lombardini supplied control panels, OEM/end user supplied/installed relays, controls, etc. are not covered under warranty. Following expiration of the above stated warranty period(s) and limitations, Lombardini will have no further responsibility for warranty and will consider our obligation for warranty complete. The above warranty certificate will be in effect starting July 1, 1993 and cancels/replaces any and all explicit or implicit warranty policies on the part of Lombardini. The above warranty conditions can from this date forward be modified only in writing.

REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 DATE 31.07.2001 ENDORSED COMPILER TECO/ATL 4 INDEX I TROUBLE SHOOTING II WARNING SIGNS - SAFETY INSTRUCTIONS III ENGINE IDENTIFICATION IV TECHNICAL FEATURES V CHARACTERISTICS VI OVERALL DIMENSION VII MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING VIII DISASSSEMBLY/REASSEMBLY General information for correct repairs Engine disassembly Engine preparation Flywheel extraction Head disassembly Disassembly of camshaft-tappets valves Timing pulley removal Timing cover removal Crankshaft extraction Cylinder head Camshaft Valves - guides - seats - valve spring - tappets Valves and valve-guides dimensions after assembly in the head Valves and valve-guides gap Valve guide Oil seal ring on valve guide Valve seats Valve springs Tappets Breather valve Cylinder Connecting rod Piston and rings Crankshaft Main journals and crank pin diameter (mm) Governor and balancing shaft gear command Balancing shaft Speed governor Bearings Crankcase and timing cover Recoil starter Rope and return spring replacement Oil watch device (optional) Crancshaft and oil seal rings Piston and connecting rods Speed governor Timing cover This manual gives the main instructions on how to repair LOMBARDINI LGA 280-340 OHC gasoline-fuelled engines, updated as of 31.07.2001. Page 7 " 8-9 " 10 " 11 " 12 " 13 " 14 " 17 17 17 17 17 17 18 18 18 18 18 19 19 19 20 20 20 21 22 22 22 22 23 23-24 25 25 25 26 26 26 26 27 27 28 28 28 29 29 INDEX

COMPILER TECO/ATL REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 ENDORSED DATE 31.07.2001 5 INDEX Timing pulley assembling Cylinder head assembling Camshaft assembling and valve clearance adjustment Timing adjustement and assembling of the toothed belt Flywheel assembly and coil gap adjustment Carburetor Lubrication IX ELECTRONIC IGNITION Electronic ignition Spark plugs X ELECTRIC STARTING Electric starting Electrical start system standard System checks Alternator Rectifier Starting motor Battery Starting panel Lighting system with alternator Characteristics with alternator 180 W (optional) XI REGISTRAZIONI Engine assembling Governor lever adjustment Engine test Starting with the recoil starter Electric starting Carburetor and R.P.M. adjustment XII STORAGE Storage Temporary inactivity Preparation for starting XIII INSTALLATION - INCLINATION AND OPERATING LIMITS Axial load - radial load and maximum overhang Installation Inclination and operating limits XIV TORQUE SETTING Main torque specifications Standard bolt torque specifications XV SPECIAL TOOLS Special tools XVI PISTON-CYLINDER OVERSIZE TABLE - TOLERANCES OF CRANKSHAFT JOURNAL GRINDINGS - TABLE OF CLEARANCES AND ADJUSTMENTS Piston-cylinder oversize table Tolerances of crankshaft journal grindings Table of clearances and adjustments 29 29 30 31 31 32 32 Page 33 33 33 " 34 34 34 34 34 34 35 35 35 35 35 " 36 36 36 36 37 37 37 " 38 38 38 38 " 39 39 39 39 " 40 40 41 " 42 42 " 43 43 43 43

REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 DATE 31.07.2001 ENDORSED COMPILER TECO/ATL 6 NOTE

COMPILER TECO/ATL REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 ENDORSED DATE 31.07.2001 7 TROUBLE SHOOTING I Listed below are some of the possible causes of engine operating defects. Carry out simple tests before proceeding with disassembly operations or making substitutions. TROUBLE SHOOTING Tank plug breather clogged Tap clogged Fuel filter clogged Dirty carburetor Carburetor needle valve blocked Speed governor rod blocked Grounded spark plug Broken spark plug lead Defective coil Clogged air filter Low oil level (oil watch alerted) Air filter chocked Blocked valves Worn piston rings Excessive valve play Defective oil seals Worn valve guides Worn governor spring Piston seizure Loose head locking-nuts Low idling rate Driving belt broken POSSIBLE CAUSES TROUBLE Noisy No power Starts and stops Does not start Light or white smoke Dark or black smoke Hunts Consumes oil Overheats Does not accel. Spark plug fails to spark • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 DATE 31.07.2001 ENDORSED COMPILER TECO/ATL 8 II WARNING SIGNS - SAFETY INSTRUCTIONS Failure to comply with these instructions may result in damages to persons and property. Failure to comply with these instructions can lead to technical damage to the machine and/or installation. DANGER W ARNING SIGNS CAUTION • Lombardini engines are built to provide safe and longlasting performances, but in order to obtain these results it is essential that the maintenance requirements described in the manual are observed along with the following safety recommendations. • The engine has been built to the specifications of a machine manufacturer, and it is his responsibility to ensure that all necessary action is taken to meet the essential and legally prescribed health and safety requirements. Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by Lombardini, which therefore declines all responsibility for accidents caused by such operations. • The following instructions are intended for the user of the machine in order to reduce or eliminate risks, especially those concerning the operation and standard maintenance of the engine. • The user should read these instructions carefully and get to know the operations described. By not doing so he may place at risk his own health and safety and that of anyone else in the vicinity of the machine. • The engine may be used or mounted on a machine only by personnel suitably trained in its operation and aware of the dangers involved. This is particularly true for standard and, above all, special maintenance work. For special maintenance contact personnel trained specifically by Lombardini. This work should be carried out in accordance with existing literature. • Lombardini declines all responsibility for accidents or for failure to comply with the requirements of law if changes are made to the engine’s functional parameters or to the fuel flow rate adjustments and speed of rotation, if seals are removed, or if parts not described in the operating and maintenance manual are removed and reassembled by unauthorized personnel. • In addition to all other machine specifications, ensure that the engine is in a near horizontal position when starting. lf starting manually, ensure that the necessary operations can be performed without any risk of striking against walls or dangerous objects. Rope starting (except for recoil rope starting) is not permitted even in emergencies. • Check that the machine is stable so that there is no risk of it overturning. • Get to know the engine speed adjustment and machine stop operations. • Do not start the machine in closed or poorly ventilated environments. The internal combustion process generates carbon monoxide, an odourless and highly toxic gas, so spending too long a time in an environment where the engine discharges its exhaust products freely can lead to loss of consciousness and even death. • The engine may not be used in environments containing flammable materials, explosive atmospheres or easily combustible powders, unless adequate and specific precautions have been taken and are clearly stated and certified for the machine. • To prevent the risk of fire, keep the machine at a distance of at least one metre from buildings or other machines. • Children and animals must be kept at a sufficient distance from the machine to prevent any danger resulting from its operation. SAFETY INSTRUCTIONS

COMPILER TECO/ATL REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 ENDORSED DATE 31.07.2001 9 WARNING SIGNS - SAFETY INSTRUCTIONS II • Fuel is flammable, so the tank must be filled only when the engine is turned off. Dry carefully any fuel that may have spilled, remove the fuel container and any cloths soaked in fuel or oil, check that any sound-absorbing panels made of porous material are not soaked with fuel or oil, and make sure that the ground on which the machine is located has not absorbed fuel or oil. • To start the engine follow the specific instructions provided in the engine and/or machine operating manual. Do not use auxiliary starting devices not originally installed on the machine (e.g. Startpilot systems which utilise ether etc.) • Before starting, remove any tools that have been used for carrying out maintenance work to the engine and/or the machine and check that any guards removed have been replaced. In cold climates it is possible to mix kerosene with the diesel fuel to make the engine easier to start. The liquids must be mixed in the tank by pouring in first the kerosene and then the diesel fuel. Consult Lombardini technical office for mixture proportions. Petrol may not be used because of the risk of it forming flammable vapours. • During operation the surface of the engine reaches temperatures that may be dangerous. Avoid in particular all contact with the exhaust system. • Before carrying out any work on the engine, turn it off and allow it to cool down. Do not perform any operation while the engine is running. • The liquid cooling circuit is under pressure. Do not carry out any checks before the engine has cooled down, and even then open the radiator cap or the expansion tank cautiously. Wear protective clothing and glasses. lf there is an electric fan, do not approach the engine while it is still hot as the fan may come on even when the engine is not running. Clean the cooling system with the engine turned off. • While cleaning the oil bath air filter, check that the oil is disposed of in such a way as not to harm the environment. Any filtering sponges in the oil bath air filter should not be soaked with oil. The cyclone pre-filter cup must not be filled with oil. • Since the oil must be emptied out while the engine is still hot (approx. 80°C), particular care should be taken in order to avoid burns. In any case make sure that oil does not come into contact with your skin because of the health hazards involved. • Check that the discharged oil, the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment. • Close the fuel tank filler cap carefully after each fílling operation. Do not fill the tank right up to the top, but leave sufficient space to allow for any expansion of the fuel. • Fuel vapours are highly toxic, so fill up only in the open air or in well ventilated environments. • Do not smoke or use naked flames while filling. • Take care when removing the oil filter as it may be hot. • The operations of checking, filling up and replacing the cooling liquid must be carried out with the engine turned off and cold. Take particular care if liquids containing nitrites are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard. The cooling liquid is polluting, so dispose of in a manner that does not damage the environment. • During operations which involve access to moving parts of the engine and/or removal of the rotary guards, disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter motor. • Check the belt tension only when the engine is turned off. • In order to move the engine use exclusively the eyebolts fitted for this purpose by Lombardini. These lifting points are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer.

REG. CODE 1-5302-528 MODEL N° 50805 DATE OF ISSUE 31.07.2001 REVISION 00 DATE 31.07.2001 ENDORSED COMPILER TECO/ATL 10 III ENGINE IDENTIFICATION LOMBARDINI ENGINE TYPE SWEPT VOLUME CUSTOMER CODE ENGINE IDENTIFICATION NUMBER