Related Manuals for Lombardini 25LD330-2
Summary of Contents for Lombardini 25LD330-2
- Page 1 WORK SHOP MANUAL 25LD330-2, 425-2, series engines, p.no. 1-5302-607 25 LD 330/2 25 LD 425/2 Edition COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-607 50889 06-03 23.06.2003...
-
Page 2: General Service Notes
FOREWORD We have done all in our power to give up to date and accurate technical information in this manual. Lombardini engines are, however, constantly developing thus the data in this publication may be liable to modification without prior notice. - Page 3 WARRANTY CERTIFICATE WARRANTY CERTIFICATE 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.
-
Page 4: Table Of Contents
INDEX This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled, indirect injection Diesel engines type 25LD330-2 and 25LD425-2: updated June 23, 2003. TROUBLE SHOOTING __________________________________________________________ Page SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS ____________________________ " MODEL NUMBER AND IDENTIFICATION _____________________________________________ "... - Page 5 INDEX INJECTION EQUIPMENT ________________________________________________________ Page Assembly of injection pumps ............................28 Checking and setting the injectors ..........................29 Checking injection pumps .............................. 27 Disassembly and re-assembly of injectors ........................29 Fuel circuit ..................................27 Injection pump setting ..............................27 Injection pumps ................................27 Injectors ...................................
- Page 6 INDEX ENGINE TESTING _____________________________________________________________ Page Checking for oil leaks ..............................39 Checking oil pressure ..............................39 Dyno testing of engine ..............................39 Speed adjustment ................................39 STORAGE ___________________________________________________________________ Page How to prepare the engine for operation ........................41 Permanent protection (over 6 months) ........................... 41 Storage ....................................
-
Page 7: Trouble Shooting
TROUBLE SHOOTING POSSIBLE CAUSES AND TROUBLE SHOOTING The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before removing or replacing any part. TROUBLE POSSIBLE CAUSE Clogged pipes Clogged fuel filter Air inside fuel circuit Clogged tank breather hole Faulty fuel pump... -
Page 8: Safety And Warning Decals - Safety Instructions
SAFETY INSTRUCTIONS • 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. - Page 9 • Only check belt tension when the engine is off. • Only use the eyebolts installed by Lombardini to move the engine. These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should be used.
-
Page 10: Model Number And Identification
MODEL NUMBER AND IDENTIFICATION MODEL NUMBER ENGINE IDENTIFICATION Nr. Cylinders R.P.M. Displacement (cc) Customer's code Diesel Approval code LOMBARDINI Engine Serial Number Engine group number COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-607 50889 06-03... -
Page 11: Technical Data
TECHNICAL DATA CHARACTERISTICS ENGINE TYPE 25LD330-2 25LD425-2 Number of cylinders Bore Stroke Swept volume cm³ Compression ratio 19:1 19:1 @ 3000 RPM 10(13,6) 12,5(17) N 80/1269/CEE-ISO 1585 @ 3600 RPM 12(16,3) 14(19) @ 3000 RPM 9,3(12,6) 11,4(15,5) Power kW (HP) -
Page 12: Vcharacteristics
Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C. Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above. COMPILER TECO/ATI REG. -
Page 13: Overall Dimensions
OVERALL DIMENSIONS 25LD330-2 25LD425-2 25LD330-2 25LD425-2 Note: Dimensions in mm COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-607 50889 06-03 23.06.2003... -
Page 14: Special Tools
SPECIAL TOOLS TOOL CODE DESCRIPTION 00365R0020 Flywheel puller 00365R0010 Universal puller 00365R0900 Main bearing extractor 00365R0890 Gear extractor 00365R0910 Central bearing assembly tool 00365R0930 Valve guide rubber fitting tool 00365R0770 Cylinder collar Ø 80/85 mm 00365R0940 Injection advance control tool 00365R0430 Injector test bench COMPILER TECO/ATI... - Page 15 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING VIII Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system MANUTENANCE INTERVAL (HOURS) OPERATION COMPONENT 400 2500 5000 OIL-BATH AIR CLEANER HEAD AND CYLINDER FINS CLEANING INTERNAL OIL FILTER FUEL TANK...
-
Page 16: Maintenance - Recommended Oil Type - Refilling
VIII MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed. Use a suitable oil in order to protect the engine. The lubrication oil influences the performances and life of the engine in an incredible way. -
Page 17: Disassembly Of The Engine
Besides disassembly and reassembly operations this chapter also During repair operations, when includes checking and setting specifications, dimensions, repair using compressed air, wear eye and operating instructions. Always use original LOMBARDINI spare protection. parts for repair operations. Extracting fuel injectors Unscrew the fuel feeding pipes. -
Page 18: Extracting Crankcase Bushes
DISASSEMBLY OF THE ENGINE Extraction of the camshaft gear Use the extractor number 00365R0010 (fig.5). Extracting crankcase bushes From crankcase (fig.6) From main bearing (fig.7) Use extractor number 00365R0900. Extracting the oil pressure indicator plug Loosen the plug securing screw, and remove circlip, spring and ball. -
Page 19: Cylinders Heads
CHECKS AND OVERHAUL Cylinders heads Parts shown in figure 9. 1.Head - 2.Tappets - 3.Valves - 4.Seats - 5.Guides - 6.Seals - 7.Lower washers - 8.Springs - 9.Top washers - 10.Valve locking split cones - 11.Rocker arms - 12.Rocker pins - 13.Gaskets - 14.Push rods - 15.Cover tube - 16.O-ring - 17.Camshaft. -
Page 20: Xchecks And Overhaul
CHECKS AND OVERHAUL After prolonged running of the engine the hammering of the valves on their seats at high temperature tends to harden the faces of the seats and makes manual grinding difficult. It is necessary to remove the hardened surface with a 45° cutter (fig. 12). Grinding of valve seats causes a widening of the valve seat face P (fig.13). -
Page 21: Cylinders
Air cooled with cylinder barrels in special cast iron with integral liners. Use a dial gauge to check internal diameters (C-D) at three different heights (fig.18). Maximum permitted taper (A-B) and ovality (C-D) is 0.06mm. Diameter of cylinders (fig.18): 25LD330-2 Ø 80 ÷ 80,020 25LD425-2 Ø 85 ÷... -
Page 22: Connecting Rods
C = 0,16 Piston rings must always be renewed after dismantling the piston. Piston diameter check: The diameter of the piston must be measured at approximately 18 mm from the base (fig.22). Engine Diameter mm 25LD330-2 79,93 ÷ 79,958 25LD425-2 84,910 ÷... -
Page 23: Crankshaft
CHECKS AND OVERHAUL 2. Position the calibrated pin on two prisms arranged on a check surface. 3. Use a dial gauge to check that the discrepancy between readings at the ends of the calibrated pin is no more than 0.05 mm;... -
Page 24: Camshaft
CHECKS AND OVERHAUL During grinding take care not to remove the shim adjustment material from the main journal thrust face to avoid changing the crankshaft end float; also ensure that the grinding wheel radii are as specified in figure 28 so as not to create crack initiation sections on the crankshaft. -
Page 25: Fuel Pump Push-Rod
CHECKS AND OVERHAUL Tappets and push rods Make sure that the tappet surfaces (fig.32) are free from wear and present no signs of scoring or seizure, otherwise, renew. Assembly clearance between tappets and their housings should Fitting mm Max. wear mm 0,10 0,07 ÷... -
Page 26: Governor Lever And Spring
CHECKS AND OVERHAUL The clearance between the external rotor of the oil pump and the cover facing surface must be: Fitting mm Max. wear mm 0,60 0,27 ÷ 0,47 End float of rotors (fig.36): Fitting mm Max. wear mm 0,01 ÷... -
Page 27: Injection Equipment
INJECTION EQUIPMENT Fuel circuit Fuel feeding can be either gravity type or forced, with a mechanical double diaphragm pump operated a cam located on the camshaft. Fuel is filtered by a filter in the fuel tank or through an external filter cartridge. -
Page 28: Assembly Of Injection Pumps
INJECTION EQUIPMENT The difference between the deliveries of the two pumps when locked must not exceed 0.5 cc. Also check: 1. That the distance between the injection cams in the rest position (bottom dead centre) and the pump supporting face is between 52.8 and 54.4 mm as shown on the data plate;... -
Page 29: Checking And Setting The Injectors
INJECTION EQUIPMENT Injectors Details of fig.46: 1.Injector casing - 2.Adjusting shim - 3.Spring - 4.Rod - 5.Distance ring with locating pin - 6.Nozzle - 7.Ring nut Checking and setting the injectors 1. Clean the nozzle holes with 0.25mm gauge steel wire (fig.47). 2. -
Page 30: Electrical Equipment
ELECTRICAL EQUIPMENT Plant specifications Internal built-in alternator Starter motor: Left rotation, 12V, power from 1.25 to 1.4 kW Built-in alternator: 280W Voltage regulator: Electronic with controlled diodes and connection for battery charge indicator light External alternator: 12V - 400W Recommended battery: Refer to tables in chapters 4 Flywheel ring gear: Check teeth for wear or damage. -
Page 31: Engine Assembly
A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems. Use genuine oil retainers with the LOMBARDINI. Central main bearings Fit the shells into their seats and coat with a thin film of oil. -
Page 32: Crankshaft
XIII ENGINE ASSEMBLY Crankshaft Fit the crankshaft into the crankcase using tool p.n. 00365R0910 as shown in figure 60; make sure that the bearing oil passages are matched to the crankcase oil passages. Torque the bearing screws (fig. 61) to : kgm 2,2 (Nm 21,6) Main bearings - flywheel side Fit the bush to the bearing carriern using a special tool of... -
Page 33: Camshaft
ENGINE ASSEMBLY XIII Camshaft Prepare the camshaft assembly (fig.66) as described below: 1. Fit adjustment shim (nr. 3) and governor washer (nr. 4) onto the camshaft. 2. Fit snap ring (nr. 5) and key (nr. 7) into their respective seats. 3. -
Page 34: Oil Pump
XIII ENGINE ASSEMBLY Oil pump See pag. 25 if you wish to check the rotors. Fit the external oil pump rotor with the bevel toward the inside of the cover (fig.70). Torque the bolts to: kgm 0,5 ÷ 0,6 (Nm 4,9 ÷ 5,9) It is good practive to fill the oil suction pipe in order to aid pump priming when the engine is started up for the first time. -
Page 35: Connecting Rods
ENGINE ASSEMBLY XIII Pistons Lubricate the following parts with oil before mounting: the piston pin, the piston, the cylinder and the big-end bearing Fit the piston rings onto the pistons (fig.73) in the following order: 1. Chromed compression ring 2. Torsional compression ring (with internal bevel facing upward) 3. -
Page 36: Checking Injector Protrusion
XIII ENGINE ASSEMBLY Checking injector protrusion Before mounting the heads to the cylinders fit the injectors into their housings and, after having secured them temporarily, check the protrusion of the nozzles from the head faces (fig.77). Protrusion S should be: 1,75 ÷... -
Page 37: Injection Check
ENGINE ASSEMBLY XIII 5. Release the control sleeves: - on the traditional pumps by loosening the pins (E, fig.80) and inserting the appropriate distance collars (F, fig.80). - on the BOSCH type PF30 pumps by removing the pins (H, fig.80) and closing the hole on the pump body using plug G. Important: injection pumps should be released only after they have been connected to the governor tie rod and secured to the crankcase. -
Page 38: Electric Shut Off
XIII ENGINE ASSEMBLY Injectors and injector pipes Mount injectors to heads placing copper gaskets in between (see pag. 36). Connect the injectors to the pumps by way of the injection lines. Important: always use two wrenches to loosen or tighten the unions on the injector pipes (fig.86) thereby ensuring that the position of the delivery valve holder on the pumps is not changed (see pag.27). -
Page 39: Engine Testing
ENGINE TESTING Speed adjustment (fig.91) When the engine is hot set idle speed at 1000 rpm and maximum no-load speed at: 3150 rpm for engines at 3000 rpm 3750 rpm for engines at 3600 rpm Checking oil pressure 1. Remove the bolt from the hole in the crankcase and fit a pressure gauge with 0 to 10 kg/cm²... -
Page 40: Xiv Engine Testing
ENGINE TESTING Running-in table Time (min) Load 2000 3000/3600 3000/3600 3000/3600 3000/3600 3000/3600 100% Engine power curves are reported at page 12. In order to check that the setting is correct, without tools, accelerate the engine a few times with no load and check the exhaust fumes. -
Page 41: Storage
STORAGE Storage Prepare engines as follows for storage over 30 days Temporary protection (1/6 months) • Let engine run at idling speed in no-load conditions for 15 minutes. • Fill crankcase with protection oil MIL-1-644-P9 and let engine run at 3/4 full speed for 5/10 minutes. •... -
Page 42: Quick Reference Charts
QUICK REFERENCE CHARTS Couplings Spiel (mm) Grezen (mm) Camshaft and central bearings (aluminium crankcase) 0,070 ÷ 0,105 Camshaft and central bearings (cast iron crankcase) 0,040 ÷ 0,075 Camshaft and flywheel side bearing 0,025 ÷ 0,075 End gap of compression rings 0,30 ÷... -
Page 43: Standard Screw Tightening Torques
QUICK REFERENCE CHARTS (Nm) Tightening torques Big ends 3,6 ÷ 3,8 (35,3 ÷ 37,3) Timing cover 2,2 ÷ 2,4 (21,6 ÷ 23,5) Injector ring nut (34,3) Injectors 2 ÷ 2,3 (19,6 ÷ 22,6) Injection pump 2 ÷ 2,3 (19,6 ÷ 22,6) Oil pump 0,5 ÷... - Page 44 E-MAIL: atl@lombardini.it Internet: http://www.lombardini.it La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione. Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication. Data reported in this issue can be modified at any time by Lombardini .
Need help?
Do you have a question about the 25LD330-2 and is the answer not in the manual?
Questions and answers