Workshop Manual Lombardini - Red

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This manual contains the most important information for the repair of LOMBARDINI
air-cooled, direct injection Diesel engines type 8LD600-2, 8LD665-2, 8LD665-2/L and
8LD740-2. This information is current upto November 1, 1988.
INDEX
I MODEL NUMBER AND ENGINE IDENTIFICATION page 5

II CHARACTERISTICS page 6
III MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING page 8
IV TROUBLE SHOOTING page 9
V OVERALL DIMENSIONS page 11
VI TORQUE SPECIFICATIONS page 12
VII DISASSEMBLY/REASSEMBLY page 15
VIII LUBRICATION CIRCUIT page 39
IX FUEL SYSTEM page 43
X ELECTRICAL SYSTEM page 50
XI MANUAL STARTING page 56
XII SETTINGS page 57
XIII STORAGE page 60
GENERAL ALPHABETICAL INDEX page 61
CHARACTERISTICS 6
CHARACTERISTICS CURVES 7
INTRODUCTION 3
MAIN TORQUE SPECIFICATIONS 12
MAINTENANCE-RECOMM ENDED OIL TYPE-REFILLING 8
MODEL NUMBER AND ENGINE IDENTIFICATION 5
OVERALL DIMENSIONS 8LD600-2; 8LD665-2; 8LD665-2/L and 8LD740-2 11
STANDARD BOLT TORQUE SPECIFICATIONS 13
TROUBLE SHOOTING 9
USE OF SEALANTS 12
DISASSEMBLY/REASSEMBILY 15
Air cleaner 15
Air cleaner components 15
Air shroud and plates 18
Axial blower belt 16
Belt tension adjustment 16
Blower assembly 17
Blower assembly components 17
CAMSHAFT 32
Camshaft end play 33
Camshaft gear 27
Camshaft timing 33
Center main bearing support, locating bolt 28
Checking main journals and crank pins 29
Checks and cylinder roughness 23
Clearance between main journals/crank pins and connecting rod bearings 30
Compression release 19
CONNECTING ROD 25
Connecting rod alignment 26
Connecting rod big end bearing 26
Connecting rod small end bearing and pin 26
Connecting rod weight 26
CRANKSHAFT 28
Crankshaft center main bearing support 28
Crankshaft end play 31
Crankshaft gear 27
Crankshaft journal radii 29
Crankshaft lubrication ducts 29
Crankshaft pulley 17
Crankshaft removal 28
Cranshaft pulley 17
CYLINDER 23
CYLINDER HEAD 20
Dimensions and clearance between guides and valves 21
Dimensions of camshaft journals and housings 32
ELECTRONIC SPEED GOVERNOR 37
Electronic speed governor components 37
Electronic speed governor control box 38
Electronic speed governor layout 37
Engine running with electronic speed governor 38
Exhaust manifold 16
Flywheel 18
Gear cover, timing side 18
How to measure main bearing inside diameter 30
Hydraulic pump mounths IP and 2P, for 4th p.t.o. 35
Hydraulic pump p.t.o. 35
Hydraulic pump p.t.o. 1P, for external mountin 35
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Hydraulic pump, group 2P, 4th p.t.o. 35
Injector protrusion 20
Injectors 19
Intake manifold 16
Intake/exhaust lobe height 32
Main bearing and connecting rod big end bearing I/D 30
Main bearing support, gear side 27
Main bearing supports 31
Main journal and crank pin diameter 29
MECHANICAL SPEED GOVERNOR 36
Mechanical speed governor components 36
Mechanical speed governor operation 36
Oil pump gear 27
PISTON 23
Piston clearance 25
Piston refitting 25
Piston rings - Clearance between grooves 24
Piston rings end gaps 24
Piston rings fitting sequence 8LD600-2; 8LD740-2 24
Piston rings fitting sequence 8LD665-2/L; 8LD665-2 25
Piston weight 24
Pushrod tube 22
Rocker arm assembly 19
Spring for extra fuel supply at starting 36
Starting with electronic speed governor 38
Tank 18
To measure camshaft journals and housing 32
Valve guide and cylinder head 21
Valve guide insertion 21
Valve material 21
Valve seat lapping 22
Valve seats and cylinder head 22
Valve springs 20
Valve timing check 24
Valve timing without considering timing marks 33
Valve/rocker arm clearance 19
Valves 20
LUBRICATION SYSTEM LAYOUT 39
Oil filter cartridge 40

Oil pressure check 40
Oil pressure curve at full speed 41
Oil pressure curve at idling speed 41
Oil pressure relief valve 40
Oil pump 40
Oil pump rotor clearance 40
FUEL SYSTEM 43
Assembly of injection pump components 46

Checking plunger and barrel for internal leakage 45
Fuel feeding pump 43
Fuel feeding pump drive rod projection 43
Fuel filter 43
How to check injection pump delivery valve sealing 45
INJECTION 49
INJECTION PUMP 44
Injection pump components 44
Injection pump/mechanical speed governor adjustment 46
Injection timing check 47
Injection timing checking device 47
Injection timing correction 48
Injection timing reference marks on crankcase and flywheel 48
Injection timing reference marks on the pulley 48
Injector setting 49
Mounting injection pump on the engine 46

Nozzle 49
Plunger 43
STATIC INJECTION TIMING 47
Test data for injection pump delivery 45
STANDARD ELECTRIC EQUIPMENT 50
12.5V - 14A alternator 50

12V - 21A alternator 51
14V - 33A Bosch G1 alternator battery charger curve 54
Alternator battery charging curve 12.5V - 14A 51
Alternator battery charging curve 12V - 21A 51
Alternator type Bosch G1 14 V - 33 A 54
Characteristic curves for starting motor type Bosch DW (R)-12 V - 1.7 kW 53
Characteristic curves for starting motor type Bosch GF-12 V, class 1.5 55
Characteristic curves for starting motor type Magneti Marelli E100-1.5/12 V 55
Checking for alternator cable continuity 52
Electrical starting layout with battery charging light 50
Electrical starting layout without battery charging light 50
How to check voltage regulator for proper operation 53
Magnetization checking tool 52
STARTING MOTOR 55
Starting motor type Bosch GF-12 V class 1.5 55
Starting motor type Marelli E100-1.5/12 V 55
VOLTAGE REGULATOR 52
MANUAL STARTING 56
Crank starting 56
Crank starting system 56
Rope starting 56
SETTINGS 57
Full speed setting in no-load conditions (standard) 57

Idling speed setting in no-load conditions (standard) 57
Injection pump delivery limiting and extra fuel device 57
Injection pump delivery setting 57
Injection pump delivery setting with engine at the torque dynam. 58
Stop setting 59
STORAGE 60
How to prepare the engine for operation 60

Permanent protection 60
Temporary protection 60
MODEL NUMBER AND ENGINE IDENTIFICATION
8LD6OO-2 8LD665-2 8LD665-2/L 8LD740-2
Engine group number Slow speed version
Lombardini No. oi cylinders
Diesel Unit cylinder displacement
Once the model number has been correctly interpreted, identify the engine through the serial num
ber indicated both on the nameplate lined to the blower housing and on the crankcase

CHARACTERISTICS OF MODELS 8LD600-2. 8LD665 2 8LD665-2/L 8LD7402
TYPE BLD600-2 BLD665-2 BLD665-2/L BLD740-2
Number nf cylinders N, 2 2 2 2
Bore mm 90 95 95 100
Stroke mm 94 94 94 94
Displacemant mm^3 1 196 1332 1332 I476
Compression ratio 17,8:1 1 7.8.1 17.8 1 17,8 1
R.P.M 3000 3000 2200 2600
N DiN 70020 18.8/25.6 2‘ 0/28,6 — 21.0/28 ii
Pw kW./HP NB DiN 6270 16,9/23.0 19.1/26.0 16 3/22.0 18,9/25
NA DiN 82 70 15.4;2’.D 17.6/24.0 14.7/20.0 17.5'23.8
Max 'ornnft Kgm 6.50 7 80 6.50 B.25
a 2200 a 1800 a 2000 a 1800
Mar torque at 3rd p'u Kgm 4 4 4 4
a 2540 a 2540 a 1860 a 2170
Specific luei consumption . g/.Cv h 196 200 178 190
Tank capacity 1, 10 10 15 10
Oil consumption kg/h 0 045 0.052 0,045 0,052
Oil sump capacity 1, IM 2,50 2,50 2.50
Dry weight M 128 130 132 132
Combustion and volume al 3000 r p m 1 St’ I470 1640 1250 ** 1600 .***
Cooling an volume at 3000 i p m ur 75800 25800 18900 .. 24300 ***
Max penti ssible dnving shall axial loud ir both duet;Boris Kg 300 300 300 300
rriDiue'ilarv 11 35' 35’ 35’ 35’
Max ircimanon lasting up lo 1 Ii. a 25" 25" 2b* 25’
peimanar’1 a **** **** **** ****
» Rel*i r*a Id max r;B EK'wei
** A: 2200 RPM
• •• A 2600 RPM
• ••• Depending an !'■« apo icaban

CHARACTERISTIC POWER, TORQUE AND SPECIFIC CONSUMPTION CURVES
8LD665-2/L
N (DIN 70020), Automotive rating, intermittent operation with variable speed and variable load.
Nb (DIN 6270), Rating with no overload capability, continuous light duty operation with constant speed and variable load.
NA (DIN 6270), Continuous rating with overload capability, continuous heavy duty with constant speed and constant load.
The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions
of 20°C and 1 bar.
Max. power tolerance is 5%. Power decreases by approximately 1% every 100m altitude and by 2% every 5°C above 20°C.
C (Nb): Specific fuel consumption at Nb power

Mt : Torque at N
(a) : Range of application for continuous operation. In case of application outside this range please contact LOMBARDINI.

MAINTENANCE
INTERVAL (HOURS)
OPERATION COMPONENT
10 50 125 250 500 1000 2500 5000
AIR CEANER (*) •
FEED PUMP FILTER •
HEAD AND CYLINDER FINS (*) •

CLEANING
FUEL TANK •
INJECTORS •
INTERNAL OIL FILTER •
AIR CLEANER OIL •
LEVEL CRANKCASE OIL •
BATTERY FLUID •
CHECK DELIVERY VALVE TIGHTNESS •
FAN BELT TENSION •
VALVE AND ROCKER ARM CLEARANCE •
INJECTOR SPRAY PATTERN •
AIR CLEANER (“) (“*) •

OIL
CRANKCASE (***) •
REPLACEMENT OIL FILTER CARTRIDGE •
FUEL FILTER CARTRIDGE •
FAN BELT •
OVERHAUL
PARTIAL (““) •
INSPECTION
COMPLETE •
(*) Under severe working conditions, clean daily.

(“) Under extremely dusty conditions, change every 4-5 hours.
(’“) See recommended oil type.
(**“) Includes checking cylinders, piston rings, guides, springs grinding valve seats, de-carboning heads and cylinders as well as checking injection pump and injectors.
RECOMMENDED OIL TYPE CAPACITIES (LITERS)

AG IP DIESEL SIGMA S SAE 30-40 spe- Standard fuel tank 10.0
cification MIL-L-2104 C Standard oil sump 2.5
ESSOLUBE D3, specification Air cleaner oil tank 0.3
MIL-L-2104 D and UNIFARM specification As for filters, tanks and special crankca
MIL-L-2104 C ses please refer to LOMBARDINI in
In countries where AGIP and ESSO pro structions.
ducts are not available use diesel engine
oil API SERVICE CD or a similar type com
plying with the military specification
MIL-L-2104 C and MIL-L-2104 D.
Suggested oil grades

SAE 40
SAE 20
SAE 10
SAE 5 '

POSSIBLE CAUSES AND TROUBLE SHOOTING
The following table contains the possible cause of some failures which may occur during operation. Always perform the simplest checks
before removing or replacing any part.
TROUBLE
Engine starts
White smoke
Black smoke
Engine does
Non-uniform
acceleration
Too low oil

POSSIBLE CAUSE
but stops
pressure
not start
speed
No
Clogged pipings •
Clogged fuel filter • • •
Air inside fuel circuit • • 9
•
FUEL CIRCUIT
Clogged tank breather • •

Faulty feed pump • •
Stuck injector •
Stuck injection pump valve •
Wrong injector setting •
Sticking injection pump rack • • •
Wrong injection pump setting • •
Too high oil level • •
Stuck pressure relief valve •
LUBRICATION
Incorrect relief valve setting •

Worn-oil pump •
Air inside oil suction pipe •
Faulty pressure gauge or switch •
Clogged oil suction pipe •
Battery dis-charged •
ELECTRIC
SYSTEM
Wrong or inefficient cable connection •

Defective starter switch •
Defective starter •
Clogged air filter • • •
MAINTE
NANCE
Excessive idle operation •

Incomplete running-in •
Engine overloaded • •
Advanced injection timing •
Retarded injection timing •
Incorrect governor linkage adjustment • •
SETTINGS/REPAIRS
Broken or loose governor spring •

Too low idle-speed setting •
Worn-out or stuck piston rings •
Worn-out cylinders •
Sticking valves •
Worn-out bearings •
Governor linkage not freely operating • • •
Crankshaft not turning freely •

OVERALL DIMENSIONS 8LD600-2, 8LD665-2. 8LD665-2/L, 8LD740-2

MAIN TORQUE SPECIFICATIONS
Diameter and pitch Torque
COMPONENT
mm Kgm
Connecting rod 10x1.50 5.0
Injection pump delivery valve union 18x1.50 4.0
Rocker arm cover 8x1.25 2.0
Center main bearing support 8x1.25 2.5
Intake manifold 8x1.25 2.5
Exhaust manifold 8x1.25 2.5
Gear cover plate 8x1.25 2.5
External oil filter 8x1.25 2.5
Camshaft gear 20x1.50 15.0
Oil pump gear 12x1.50 4.0
Starting motor 10x1.50 4.0
Rocker arm shaft 8x1.25 2.5
Camshaft thrust plate 8x1.25 2.5
Engine mounting foot 10x1.50 3.5
Fuel feeding pump 8x1.25 1.5
Nozzle holder 6x1.00 1.0
Oil pan 8x1.25 2.5
Oil pressure switch 12x1.50 3.5
Starting pulley 10x1.50 4.0
Crankshaft pulley 27x2.00 30.0
Blower pulley 12x1.50 4.0
Crankshaft center suppor 10x1.50 4.0
Head 10x1.50 5.0
Flywheel 20x1.50 30.0
USE OF SEALANTS
POSITION Type of sealant

Tank bracket vibration dampers Loctite 270
Camshaft cover, flywheel side Gasket cement Arexon
Tank bracket (Rubber sheet) Loctite IS 495
Crankshaft thread, to fix pulley Loctite 270
Air shroud gasket Loctite IS 495
Cylinder head stud, to crankcase Loctite 270
Oil pump flange support Gasket cement Arexon
Rocker arm shaft plug Loctite 270

STANDARD BOLT TORQUE SPECIFICATIONS
DESCRIPTION
8.8 10.9 = R10 12.9 = R12
High-carbon steel Alloy steel Special alloy steel

Diameter per Pitch (mm)
Kgm Kgm Kgm
4x0.70 0.37 0.52 0.62
5x0.80 0.72 1.01 1.22
6x1.00 1.23 1.73 2.08
7x1.00 2.02 2.84 3.40
8x1.25 3.02 4.25 5.10
9x1.25 3.88 5.45 6.55
10x1.50 5.36 7.54 9.05
12x1.75 9.09 12.80 15.30
14x2.00 13.80 19.40 23.30
16x2.00 21.00 29.50 35.40
18x2.50 26.30 37.00 44.40
20x2.50 36.60 51.50 61.80
22x2.50 44.40 62.40 74.90
24x3.00 56.90 80.00 96.00

DISASSEMBLY AND REASSEMBLY
Besides disassembly and reassembly operations this chapter also in
cludes checking and setting specifications, dimensions, repair and ope
rating instructions. Always use original LOMBARDINI spare parts for
proper repair operations.
Air cleaner
Oil-bath air cleaner with two filtering elements.
The lower filtering element is made of metal while the upper one is ma
de of polyurethane.
Check gaskets and replace as necessary.
Check that welds are free of defective spots.
Carefully clean bowl and filtering elements with Diesel fuel. Blow through
the lower filtering element with compressed air and dry the upper filte
ring element with a rag.
To up with engine oil to the mark.
When refitting tighten nuts at 3 Kgm.
See Page 8 for periodic maintenance details.
Air cleaner components

1 Cover
2 Polyurethane upper filtering element
3 Internal seal ring
4 External seal ring
5 Metal lower filtering element
6 Bowl
7 Oil level mark
8 Centrifugal prefilter cover
9 Centrifugal prefilter

Exhaust manifold
Check that the inside is free of carbon deposits.
To avoid manifold breakage and to insure a good exhaust gas seal-check
exhaust flange alignment on each cylinder head relative to the other.
Intake manifold
Check flange surface for warpage and correct if necessary.
Before refitting check that heads are in line.
Replace self-locking nuts and tighten them at 1.8 Kgm. Replace gaskets.
Note: In case of low temperature starting we can supply a manifold with

provision for an air preheating glow plug.
Axial blower belt

Components:
1 Guard
2 Pulley
3 Spacers
4 “V”-belt
Loosen the belt guard bolts and the nuts retaining the pulley.
Remove “V”-belt and check for wear.
See Page 8 for periodic maintenance details.
Belt tension adjustment

Belt tension can be adjusted by adding or removing the spacers loca
ted between the pulley halves. Spacers are 0.5, 1.0 and 2.0 mm thick.
Tension check
A 4 Kg. load located halfway between the pulleys should cause the belt
to deflect 5-15 mm.

Blower assembly
Data plate and voltage regulator are fixed outside the blower housing.
A 14A or 21A alternator is housed inside the blower housing.
See Page 50 and 51 for the alternator technical data.
See Page 6 for the cooling air volume.
Blower assembly components

1 Blower housing
2 Fan
3 21A alternator bell
4 21A alternator
5 Key
6 Ball bearing
7 Nut
8 Washer
9 Pulley
10 Shaft
11 Belt
12 Bolt
13 Shim
Note: The 14A alternator thickness is smaller compared to the 21A

alternator; furthermore, the 14A alternator is housed inside a different
type of bell and features a spacer in place of shim. 13.
Crankshaft pulley
Components:
1 Nut
2 Washer
3 Puller, Part No. 7271-3595-048
Loosen the nut and remove the pulley using the puller.
The pulley has reference marks for the top dead center and the injection
timing (See Page 48).
Check pulley hub surface close to the oil seal ring, and if necessary,
polish with a fine grain emery cloth. When reassembling apply a few
drops of Loctite 270 on the crankshaft thread and tighten nut at 30 Kgm.
Note: The crankshaft end play can be checked only after tightening the
pulley.

Tank
Remove fuel filter and loosen clamp screws.
Completely empty the tank and check that no impurities are found inside.
Check that cap breather is not clogged.
When refitting fix gasket to the tank bracket by using Loctite IS 495.
See Page 43 for refitting fuel filter.
Air shroud and plates

By means of plates 2, 3 and 4 the air shroud 1 sends air to the cylin
ders for cooling purposes; by means of plates 5 and 6 it also conveys
air to the crankcase and the oil pan for cooling oil.
Gear cover timing side

Before removing the gear cover remove cover 1, nut 2 and washer 3.
Check crankshaft oil seal and replace if warped, hardened or worn.
When refitting replace gear cover gasket and tighten screws at 2.5 Kgm.
Tighten the camshaft gear nut 2 at 15 Kgm.
Flywheel
Loosen bolt 1 and remove flywheel with puller 2 (Part. No.
7271-3595-048).
Check starter ring gear and tapered crankshaft mating surfaces.
When refitting tighten bolt at 30 Kgm.
Note: To replace starter ring gear heat it up to 300°C for 15 minutes.

Drive it onto the flywheel carefully checking that it perfectly fits into its
seat.
Let it cool down slowly.

Valve I rocker arm clearance
Remove rocker arm cover and check gaskets for breakage. Setting
should be performed when the engine is cold: bringing each cylinder
piston to the top dead center on the compression stroke and setting
clearance at 0.15-0.20 mm.
When refitting tighten cover screws to 2 Kgm.
Compression release
Bring piston to top dead center on the compression stroke.
Measure clearance A with a thickness gauge.
For setting purposes unscrew nut 1 and set clearance A at 0.30 - 0.40
mm. by turning screw 2; finally lock nut 1.
Rocker arm assembly

Components:
1 Rocker arm 2 Shaft
3 Support 4 Lubrication shaft bore
5 Plug
Dimensions:
A = 15.032-15.050
B = 14.989-15.000
Clearance (mm):
(A-B) = 0.032-0.061 (A-B) Limit Value = 0.120
Note: To clean the lubrication shaft bore unscrew plug 5. When refit
ting apply a drop of Loctite 270 on the cap threads before screwing.
Injectors
Disconnect injection lines and remove injectors.
Clean and check calibrated pressure (See Page 49).
When refitting tighten the fixing nuts at 1 Kgm.
Note: Extreme care should be taken not to loose injector sealing

gaskets/shims.
New shims of the same thickness should be installed.

Injector protrusion
Check injector protrusion after removing the cylinder head.
The end of nozzle A should protrude 4.0 -4.5 mm from the cylinder
head plane.
Adjust injector projection by means of copper shims B measuring 0.5
and 1.00 mm. in thickness.
CYLINDER HEAD
Do not remove when hot to avoid deformation.
If cylinder head is warped level it off by removing a maximum of 0.3
mm of material.
When refitting, tighten only if sure that both heads are in line.
Always replace copper head gasket; see Page 25 for choosing the right
thickness.
Progressively tighten nuts in the 1, 2, 3, 4, sequence at 5 Kgm.
Valves
Components:
1 Intake valve
2 Spring seat
3 Valve stem oil seal
4 Spring
5 Retainer
6 Half collets
To remove half collets firmly press down as shown in the figure.
Note: Valve stem oil seal, 3 must be fitted to the intake valve only.
Valve springs
Measure free length with a gauge.
Using a spring tester check that the spring length under two different
loads corresponds to the values below.
Free length A = 52 mm
Length B compressed by a 21 Kg weight = 34.8 mm
Length C compressed by a 32 Kg weight = 25.8 mm

Valve material
Intake valves A
Material: X 45 Cr Si 8 UNI 3992
1 Chromium-plated portion
a 45° 15’- 45°25'
Exhaust valve B
Shaft and head are made of 2 different materials.
2 Welded portion
3 Chromium-plated portion
4 Portion made of X 45 Cr Si 8 UNI 3992
5 Portion made of X 70 Cr Mn Ni N 216 UNI 3992
a 45°15’ 4-45°25’
Valve guides and cylinder head

Intake and exhaust valve guides are both made of phosphoric cast iron.
Components'.
1 = Exhaust valve guide
2 = Intake valve guide
Dimensions (mm)
A = 42.00
B = 48.50
C = 14.000-14.018
D = 14.050-14.060
Valve guides with outside diameter increased by 0.5 mm. are also avai
lable; in such cases valve guide bore C should be increased by 0.5 mm.
Valve guide insertion

Heat cylinder head up to 160-r180°C
Press guides considering the A and B distances from the head plane.
Dimensions (mm):
A = 30.804-31.20
B = 24.80 4-25.20
Note: If guides are seated with stop ring C, first locate the ring in place
and then position guides without considering A and B.
Dimensions and clearance between guides and valves (mm)

A = 8.030-8.060
B = 7.985-8.000
(A-B) = 0.030-0.060
(A-B) limit value = 0.15

Valve seats and cylinder head
Dimensions (mm.):
A = 41.990-4-42.020 (intake valve housing dia.)
B = 42.120 -42.140 (intake valve seat dia.)
C = 35.990-36.020 (exhaust valve housing dia.)
D = 36.120-36.140 (exhaust valve seat dia.)
Press valve seats into the housing and cut a at 45°
Valve seat lapping

After cutting lap valve seats with fine emery paste in oil suspension.
(Lapping compound)
The sealing surface S should not exceed 2 mm.
Valve recess after lapping D = 0.75-1.25 mm; maximum worn limit
1.65 mm.
Pushrod tube
When refitting check that gaskets A and rocker arm lubrication tube
C are inside their seats.
22

CYLINDER
Measure diameter between two diametrically opposed points at three
different heights.
For 8LD600-2 0 = 90.00 - 90.02 mm
For 8LD665-2 and 8LD665-2/L 0 = 95.00-95.02 mm.
For 8LD740-2 0 = 100.00-100.02 mm
In case wear exceeds 0.10 mm bore the cylinder and fit oversize piston
and rings.
In case of less wear replace piston rings only.
Checks and cylinder roughness

The cylinder should show no blowholes or porosity.
Seal both ends of cylinder and pressurize with compressed air at 4 Bar
for 30 secs. Immerse in water and check for leakage.
Fins must be intact.
Cross hatch pattern must range between 115° -140°: they must be uni
form and clear in both directions.
Average roughness should range between 0.5 and 1 pm.
PISTON
Remove circlips and remove piston pin.
Remove piston rings and clean grooves.
Measure diameter at 2 mm from the bottom of skirt.
For 8LD600-2 0 = 89.840-89.850 mm
For 8LD665-2 and 8LD665-2/L 0 = 94.920-94.940 mm
For 8LD740-2 0 = 99.800-99.810 mm
In case of diameter wear above 0.05 mm replace piston and piston rings.
Note: Oversize pistons of 0.5 and 1.0 mm. are available.
Checking that piston is an original part

When replacing piston as well as any other engine component check
that spare parts are original.
The logo confirming this is stamped inside.

Piston weight
Weigh pistons when replacing them in order to avoid unbalance.
The difference in weight should not exceed 6 g.
Piston rings - End gaps (mm)

Place piston rings squarely into the unworn part of the lower cylinder
and measure the end gap.
1st chromium-plated ring A = 0.40-0.65
2nd torsional (internal tapered) ring A = 0.40-0.65
3rd torsional (internal tapered) ring A = 0.40-0.65
4th oil control ring A = 0.30-0.60
Note: 8LD600-2 and 8LD740-2 pistons feature 4 piston rings; 8LD665-2
and 8LD665-2/L pistons have 3 piston rings (one internal tapered ring
missing).
In 8LD600-2 the 3rd ring is stepped (see below).
Piston rings - Clearance between grooves (mm)

For 8LD600-2 and 8LD740-2
A = 0.110-0.147; limit value = 0.250
B = 0.060-0.097; limit value = 0.190
C = 0.060-0.097; limit value = 0.190
D = 0.050-0.090; limit value = 0.180
For 8LD665-2 and 8LD665-2/L
A = 0.070-0.110; limit value = 0.220
B = 0.050-0.090; limit value = 0.180
D = 0.040-0.080; limit value = 0.170
Piston rings - Fitting sequence 8LD600-2 and 8LD740-2

A = 1st chromium-plated ring
B = 2nd torsional (internal tapered) ring for 8LD740-2, with rectangu
lar section for 8LD600-2
C = 3rd torsional (internal tapered) ring for 8LD740-2 and stepped for
8LD600-2
D = 4th oil control ring
Note: Before fitting the piston into the cylinder stagger the ring gaps
at approximately 90°.

Piston rings - Fitting sequence (8LD665-2 and 8LD665-2/L)
A = 1st chromium-plated ring
B = 2nd torsional (internal tapered) ring
D = 3rd oil control ring
Nota: Before fitting the piston into the cylinder stagger the ring gaps
at approximately 120°.
Piston - Refitting
Connect piston to connecting rod in a way that the combustion cham
ber center b is directly under nozzle tip a.
Lubricate piston pin and introduce it into the piston by exerting pressu
re with your thumb.
Check that both circlips are well inside their seats.
Piston clearance
A = Piston clearance
B = Copper head gasket
A (0.75 - 0.80 mm) is determined by placing the piston at top dead center
and measuring with a feeler gauge and straight edge, the distance the
piston is below or above the cylinder face. B copper gasket (available
in various thicknesses) is then selected to ensure clearance is correct.
Gaskets are available in the following thicknesses: 0.45; 0.50; 0.55; 0.60;
0.65; 0.70; 0.75; 0.80; 0.85; 0.90; 0.95; 1.00; 1.05; 1.10; 1.15 mm.
CONNECTING ROD
Remove oil pan and internal oil screen.
Straighten locking tab and unscrew connecting rod, big end bolts.
Both connecting rod/piston units should be fitted back into the corre
sponding cylinders; mark them to avoid mistakes.
See Page 26 for specifications as to the tightening of connecting rod
big end bearing.

Connecting rod small end bearing and pin
Dimensions (mm):
C = 28.020 - 28.030 (with machined bushing in place)
D = 27.995 -28.000
Clearance (mm):
(C-D) = 0.020-0.035 (C-D) limit value = 0.070
Connecting rod alignment

Check alignment of small end and big end bearing bores using fitted
mandrels; axial mis-alignment A = 0.02 mm; maximum limit 0.05 mm.
Connecting rod weight

Weigh connecting rods when replacing them in order to avoid unbalance.
The difference in weight should not exceed 10 g.
Connecting rod big end bearing

Both locating notches A and B must be on the same side when refitting.
Tighten bolts at 5 Kgm and close locking tab.
See Page 30 for dimensions.

Camshaft gear
Remove lubrication tube 1, if any, and remove camshaft gear.
The cylindrical type of coupling makes gear removal easier since no
puller is required.
See Page 18 for nut tightening.
See Page 33 for timing.
Note: When hydraulic pump is not assembled on engine, also tube 1

has not to be fitted.
In this case be sure there is a cap on hole 2.
Oil pump gear

Besides driving the oil pump via coupling 3, this gear connects the crank
shaft gear with the camshaft gear. Remove nut 1, washer 2, coupling
3 and circlip 4.
When refitting match the two timing marks with those of the crankshaft
gear and camshaft gear.
Tighten nut 1 at 4 Kgm.
Crankshaft gear
Components:
1 Crankshaft gear
2 Governor crankshaft gear bell
3 Thrust bearing
The crankshaft gear can be extracted together with the governor using
a puller for bearings.
Clamp with both puller ends behind governor bell 2. Move thrust bea
ring 3 to prevent it from becoming damaged.
Main bearing support, gear side

Remove main bearing by means of two M8x1.25 screws with fully threa
ded length of 30 mm.
When refitting check that oil seal ring 1 is well inside its seat.
See page 31 for dimensions.
Engines for generator sets have different supports (see Page 36).

CRANKSHAFT
Center main bearing support, locating bolt

Straighten locking tab 1 and unscrew bolt 2 before removing crankshaft.
Crankshaft removal
To remove the crankshaft tap lightly on the flywheel side end using a
soft-headed hammer.
When refitting align center main bearing support so that the locating
bolt hole coincides with the crankcase hole.
Crankshaft center main bearing support

When refitting, both locating notches A and B must be located on the
same side.
Tighten screws at 2.5 Kgm.
See Page 31 for dimensions.

Crankshaft lubrication ducts
Remove plugs, clean duct A with a pointed tool and blow in compres
sed air.
Screw plugs back in place and check for sealing.
Crankshaft journal radii

The radius R connecting journals to shoulders is 2.8-?3.2 mm.
Note: When grinding main journals or crank pins restore the R value
to original specification.
Checking main journals and crank pins

Use an outside micrometer gauge
Main journal and crank pin diameter (mm)

A = 54.930-54.950
B = 49.989-50.000
C = 55.340-55.350
D = 54.930-54.950

To measure main bearing inside diameter
Use an inside micrometer gauge
Main bearing and connecting rod big end bearing inside

diameter
Dimensions (mm):
E = 55.000-55.020
F = 50.035-50.066
G = 55.404-55.435
H = 55.000-55.020
The above dimensions refer to installed or tightened bearings.
Note: Both main bearings and connecting rod big end bearings are avai
lable with inside diameter size measuring 0.25 and 0.50 mm less than
the standard version.
Clearance between main journals/crank pins and connecting

rod bearings (mm)
(E-A) = 0.050-0.084; limit value = 0.160
(F-B) = 0.035-0.077; limit value = 0.150
(G-C) = 0.051 -0.094; limit value = 0.190
(H-D) = 0.050-0.084; limit value = 0.160

Main bearing supports
1 Flywheel side
2 Center
3 Gear side
Dimensions (mm)
A = 60.000 4- 60.020
B = 59.074 - 59.093
C =155.000- 155.017
D = 156.980-157.000
E = 60.000- 60.020
Note: Flywheel side support 1 is part of the crankcase and cannot be
pulled out.
If, due to seizure, the housing of bearing support 1 is damaged, increa
se diameter A by 1 mm and fit a bearing with 1 mm larger outside dia
meter, available from your dealer.
Main bearing housings

Dimensions (mm):
F = 155.000 -155.025
G = 157.000 -157.025
Crankshaft end play

Dimensions (mm):
A = 34.10-34.15
B = 33.90-33.95
Check crankshaft end play after refitting the crankshaft pulley and tigh
tening its nut at 30 Kgm; the crankshaft end play is equal to 0.15 4- 0.25
mm and is not adjustable. If this value cannot be obtained check A and
B, and possibly replace the parts whose size is inadequate.

CAMSHAFT
To measure camshaft journal and housings

Use an inside micrometer gauge for housings and an outside micro
meter gauge for journals.
Dimensions of camshaft journals and housings (mm)

A = 40.940-4-40.960
B = 29.940 -?29.960
C = 41.000 -41.025
D = 30.000-4-30.025
Clearance (mm)
(C-A) = 0.040-4-0.085; (C-A) limit value = 0.170
(D-B) = 0.040-? 0.085; (D-B) limit value = 0.170
Intake/exhaust lobe height

A1 = 1st cylinder intake cam
S1 = 1st cylinder exhaust cam
A2 = 2nd cylinder intake cam
S2 = 2nd cylinder exhaust cam
Exhaust and intake cams feature the same height H.
H = 34.02-4-34.07 mm
Replace camshaft if wear has caused H to exceed the above minimum
value by 0.1 mm.

Camshaft end play
Check camshaft end play after removing cylinder head, injection pump
and fuel feed pump from the engine. Camshaft end play should be
0.10-0.32 mm but is not adjustable.
Check that cover 1 screws and thrust plate bolts inside the gear cover
are tightened at 2.5 Kgm.
Place the dial gauge on the camshaft gear outer part; push and pull
the gear as required.
Camshaft timing
Fit camshaft gear by making timing mark 2 coincide with timing mark
1 on the camshaft gear and timing mark 4 with timing mark 3 on the
crankshaft gear.
Valve timing without considering timing marks

Locate piston 1 (on flywheel side) at the top dead center. Position two
small cylinders A of the same height onto the tappets.
Rotate camshaft stopping when cylinder 1 tappets are in overlap po
sition.
By means of straight edge B check that tappets are at the same height.
Place oil pump gear between crankshaft and camshaft gear.

Valve timing check
Check valve timing at the crankshaft. The values shown are checked
at the flywheel circumference (with flywheel of 291 mm. diameter each
degree corresponds to 2.5 mm).
Set valve clearance at 0.65 -? 0.70 mm (after checking restore the va
lue at 0.15-?0.25).
Set dial gauge on intake valve to a zero value; by rotating the crank
shaft according to its direction of rotation you can measure a (intake
valve opening advance relative to top dead center S) and p (intake val
ve closing delay relative to bottom dead center I).
Follow the same procedure for exhaust valves checking y (exhaust valve
opening advance) and 3 (exhaust valve closing delay).
a = 2°
P = 34°
y = 34°
6 = 2°

Hydraulic pump p.t.o.
Hydraulic pumps of group 1 or 2 can be installed on the 3rd p.t.o.
Note: The maximum torque from the 3rd p.t.o. is 4 Kgm i.e. 14 HP at
2540 r.p.m. for 3000 r.p.m. engines and 12 HP at 2200 r.p.m. for 2600
r.p.m. engines.
Recution ratio: 1:1.18
The figure shows details of a group 1 hydraulic drive for the 3rd p.t.o.
Hydraulic pump p.t.o., group 1, for external mounting

Components:
1 Pump support
2 Centering ring
3 Seal ring
4 Seal ring
5 Pump drive
6 Support
7 Bearing
8 Drive gear
9 Circlip
10 Washer
11 Cover
12 Circlip
Hydraulic pump, group 2, for 4th p.t.o.
Hydraulic pump mounts, group 1 and 2, for 4th p.t.o.

Components:
1 Cover 2 Bracket
3 Bearing 4 Gear
5 Circlip 6 Washer
7 Gr. 2 pump support 8 Gr. 1 pump support
9 Seal ring 10 Centering ring
11 Seal ring 12 Seal ring
13 Coupling 14 Half coupling
Note: It is possible to install pumps on both the 3rd and 4th p.t.o. - Thus
driving two (2) pumps simultaneously.
35

MECHANICAL SPEED GOVERNOR
Ball type, centrifugal governor housed inside the crankcase. The num
ber of balls is a function of the set peak speed: 4 balls are usually pro
vided from 2600 to 3000 r.p.m. while 6 are required below 2600 r.p.m.
Components:
1 Fixed bell
2 Ball
3 Mobile bell
4 Thrust washer
5 Circlip
6 Governor fork
7 Bracket
Mechanical speed governor operation

Balls are moved to the periphery of the fixed bell by the centrifugal for
ce and thus axially shift the mobile bell connected to the injection pump
rack by a yoke and linkage.
The governor spring B placed under tension by the accelerator control
offsets the balls centrifugal force. Balance between the two forces keeps
speed at an almost constant level in spite of load variations.
Mechanical speed governor components for special

generator sets
Main bearing support 1 has two ball bearings 3. Journal 2 measures
7 mm. in diameter which is suitable for bearings 3.
The mobile bell 4 has two areas 5 where fork 8 blocks become engaged.
Sleeve 6 of the fixed bell 7 is grooved.
Note: 1500 r.p.m. engines features a different type of spring B. Futher-

more, the journal contains three ball bearings.
Spring for extra fuel supply at starting

Components:
1 Extra fuel spring (for starting)
2 Injection pump control yoke
3 Governor spring
The device is operated automatically: when the engine is stopped spring

1 acts on injection pump control yoke 2 providing maximum fuel deli
very, until the engine starts and the governor controls the injection pump
rack.

ELECTRONIC SPEED GOVERNOR
A = Actuator
S = r.p.m. sensor
T = Electromagnet
An electronic speed governor can be fitted upon request. The crankca

se features a hole for sensor S introduction.
Electronic speed governor

Components:
1 Injection pump
2 Delivery control level
3 Actuator A mounting flange
4 Mobile retainer
5 Actuator magnet
6 Stator coils
7 Stator
8 Cable ends for connection to control box E (Page 38)
9 Electromagnet
Electronic speed governor layout

Components: A = actuator; C = key; P = potentiometer; T = electro
magnet; S = sensor
The device consists of an actuator A controlling the injection pump rack,

an r.p.m. sensor S and an electromagnet T controlling fuel delivery and
supplying extra fuel at starting. Control box E (see Page 38) Controls
fuel delivery as a function of the load and of the speed set through po
tentiometer P.
The potentiometer can be fitted on the control box or on the control pa
nel (see P1 Page 38).
The whole system makes it possible to keep the engine speed constant
independently of the load conditions. It detects speed through the r.p.m.
sensor mounted on the crankcase at the ring gear level. As the num
ber of revolutions changes the device immediately performs the requi
red corrections by means of the actuator acting on the injection pump.
Electromagnet T responds to max. fuel delivery (fuel flow setting) and
(when energized) enables the injection pump rack to reach its maxi
mum stroke (extra fuel supplied at starting).

Starting with electronic speed governor
(see layout on Page 37)
In position O the engine is not working and no part is energized. The
rack rod is in stop position (retained by two springs 10 inside actuator A).
By rotating key C to position 2 the electromagnet withdraws allowing
the rack rod to reach its highest delivery being connected to the actua
tor at its max. level of energization. When the engine, immediately af
ter starting, reaches 1000 r.p.m. the controller reduces the actuator
position and, after one second, switches off the electromagnet then,
0.5 seconds later, returns to its normal position with engine speed set
throught potentiometer P.
Engine running with electronic speed governor

The engine starts running at the pre-set speed.
Potentiometer P is located either inside the control box E or on control
panel P1.
In case of an external potentiometer P1 the engine speed can be set
at any point between the idling and full speed in on-load conditions (set
ting performed on the control box in the test room).
The electronic control box E controls actuator A (by sending or cutting
off the power supply) to keep the speed set through P1 independently
of the absorbed load.
Control box E prevents the engine from starting (or stops it) in case of
no power supply or in case connection with r.p.m. sensor S is broken
(or short-circuited).
Electronic speed governor control box

Control box E features four setscrews which must be positioned on the
test bed (torque dynamometer) along with the engine.
a) Setscrew for speed control (r.p.m.)
b) Setscrew for sensitivity adjustment when the engine is running at
full speed
c) Setscrew for sensitivity adjustment at low speed
d) Setscrew for extra fuel release; once correctly positioned, this set
screw is generally sealed.

LUBRICATION SYSTEM VIII '
LUBRICATION SYSTEM LAYOUT
Components:
1) Rocker arm shaft - 2) Breather 3) Compressing
non big end bearing - 4) Hydraulic pomp drive -
5) Crankshaft - 6) Oil pump - 7) Camshaft
8) Camshaft center support - 9) Oil fill cap 10) Oil
dipstick -11) Spin-on filter - 12) Oil presure relief
valves ■ 13) Oil-strainer.

Oil pump
Components:
1 Flange
2 Internal rotor
3 External rotor
4 Crankcase
Check rotors 2 and 3, especially for flatness, and replace them if war
ped; when refitting apply a few drops of gasket cement Arexon between
flange 1 and crankcase 4.
Tighten bolts at 2.5 Kgm and check that end play does not exceed 0.13
mm.
Oil pump rotor clearance (mm).

In position A check minimum clearance between the internal rotor 2
and the external rotor 3; it should be 0.12-0.063 with maximum limit
of 0.10.
In position B check maximum clearance, it should be 0.025-0.10 with
maximum limit of 0.17.
Oil pump capacity at 3000 r.p.m. is 12 l/min.
Oil pressure relief valve

Components:
1) Cap - 2) Copper gasket - 3) Bushing - 4) Piston - 5) Rubber ga
sket - 6) Ring - 7) Hole for pressure switch connection - 8) Spring
Note: By-pass at an oil temperature of 40 - 50°C and pressure of 3 bar

should be less than 1 l/min.
When refitting, screw bushing 3 so that it touches gasket 5.
Do not tighten excessively since gasket 5 might be damaged causing
an oil pressure drop in the system.
Oil filter cartridge

Components: 6 Upper cover
1 Retainer 7 Blade
2 Plate 8 Filtering element
3 Valve 9 Assembly
4 Gasket 10 Belleville washer
5 Gasket 11 Canister
Characteristics:
Max. working pressure = 13 bar
Working pressure in a 3000 r.p.m. engine with oil temperature of
40-50°C is 4.5-5.5 bar.
Filtering area = 955 cm2
Type of filtration 20 mkm
By-pass valve opening pressure 1.4-1.8 bar.

Oil pressure check
Once the engine is filled with oil and fuel, connect a 10 bar pressure
gauge to the oil filter fitting.
Start the engine and check pressure as a function of the oil temperature.
Oil pressure curve at idling speed

The curve is obtained at the oil filter with constant engine speed of 1200
r.p.m. in no-load conditions.
Pressure is given in bar and temperature in centigrades.
Oil pressure curve at full speed

The curve is obtained at the oil filter with engine working at 3000 r.p.m.
at the N power.
Pressure is given in bar and temperature in centigrades.
Note: After the running-in period the lube oil maximum temperature
should be below the sum of the environmental temperature +95°C.

Fuel feeding/injection circuit
Components:
1 Tank
2 Filter
3 Fuel feeding tube
4 Injection pump
5 Fuel feeding pump
6 Injection line
7 Injector
8 Injector leakoff line and self-bleeding system
Fuel filter
Components:
1 Spring
2 Disc
3 Ring
4 Cartridge
5 Gasket
6 Gasket
7 Cap
8 Ring
9 Bolt
Fuel feeding pump

The fuel feeding pump is of the diaphragm type operated by a cam
shaft eccentric through a push rod. It features an external lever for ma
nual operation.
Characteristics: when the control eccentric rotates at 1500 r.p.m. mi
nimum delivery is 64 l/h while self-regulation pressure is 0.4- 0.5 bar.
Fuel feeding pump drive rod protrusion

Components:
1 Camshaft eccentric
2 Crankcase
3 Push rod
4 Gasket
5 Support
6 Gasket
Drive rod A protrudes 0.8 -1.2 mm. from the crankcase; it can be adju
sted by means of gaskets.
Gaskets 4 and 6 are supplied in the following thicknesses: 0.50; 0.80;
1.00 mm.
Push rod 3 length is 119.95-120.05 mm.

INJECTION PUMP
The Bosch injection system consists of a single-body pump with plun
gers featuring constant stroke and feeding one cylinder each.
The pump, mounted on the crankcase, is directly operated by the
camshaft.
Speed governor, extra fuel and stop device are separate from the pump
(see Page 36 and 59).
Injection pump
Components:
1 Pump body 2 Union
3 Seal ring 4 Filler
5 Shim 6 Spring
7 Delivery valve 8 Seat
9 Gasket 10 Plunger
11 Barrel 12 Rack rod
13 Sector gear 14 Spring
15 Upper retainer 16 Lower retainer
17 Tappet 18 Tappet roller
Plunger
1 Barrel
2 Fuel feeding port
3 Control helix
4 Plunger
Plunger diameter is 7.0 mm, in all series of engines.
Note: Every plunger matches with its own barrel. For this reason they
are not interchangeable.

Checking plunger and barrel for internal leakage
Connect the delivery union with a 600 bar pressure gauge with safety
valve. Adjust rack rod at half-stroke. Turn flywheel according to its di
rection of rotation so that the plunger puts the circuit under pressure.
Replace plunger if the displayed pressure is below 300 bar. Repeat the
same operation for the other plunger.
Checking injection pump delivery valve sealing

Components:
1 Valves
2 Seat
Adjust pump rack at half-stroke. Turn flywheel according to its direc
tion of rotation so that the plunger puts the circuit under pressure.
During this operation the displayed pressure will gradually reach a peak
followed by a sudden drop which corresponds to valve closing.
Pressure drop should be 30 - 50 bar. Replace the valve if pressure drop
is below this value.
Repeat the same operation for the other plunger.
Test data for injection pump delivery
Control rod Rod stroke from Max. plunger

R.P.M. Delivery
max. force max deliv. point difference
Newton mm mm3 ■ stroke mm3 ■ stroke
10 750 23-27 3
10 1500 26-33 4
0.50
11.5 500 7-14 3.5
0 150 80-95 —

Assembly of injection pump components
After replacing the worn-out components, reassemble the pump as
follows:
Introduce sector gears into the pump body by making reference points
C match will the B points on the rack.
Fix barrels with the eccentric screws F on the pump body.
Fit valves with seats, springs, fillers and delivery unions tightening them
at 3.5-4 Kgm.
Fit plungers by making reference points E match with the sector gear
D points.
Fix retainers and springs; lock tappet with special stop.
Check that both plungers have the same delivery by performing the ne
cessary measurements at the test bed; if delivery is not the same set
screw F.
Mounting injection pump on the engine

Tighten screws at 2.5 Kgm
Check that rack rod slides smoothly: if not, the engine may fail to start
or hunt.
Injection pump/mechanical speed governor adjustment

Loosen screw 1
Move injection pump lever 2 to maximum delivery (to the right).
Check that drive rod 3 closes the speed governor; keeping lever 2 pres
sed to the right the drive rod should have no clearance.
Tighten screw 1.

(STATIC) INJECTION TIMING
Disconnect injection line on cylinder 1 making sure not to loosen the
pump delivery union. Attach the timing tool shown below.
Injection timing checking device

Components:
1 Fitting
2 Tube
3 Sleeve
4 Transparent body, part. No. 7271-9727-003;
This device allows for immediate monitoring of the fuel flow through
its transparent portion.
Dimensions (mm):
n1 = 10.00; n2 = 0.60; n3 = 2.00; n4 = 6.50.
A = 29.00; B = 20.00; C = 25.00; D = 45.00
Injection timing check

Top up the tank checking that fuel level is at least 10 cm above chec
king device.
Adjust injection pump rack rod at half-stroke.
Turn the flywheel according to the engine direction of rotation and check
that fuel reaches the checking device.
Repeat this last operation; during compression proceed slowly and stop
immediately when the fuel is seen to pass through the checking device
hole; bring flywheel back by 5 mm: this is the so-called static injection
timing.

Injection timing reference marks on crankcase and flywheel
A = Piston reference mark at the top dead center
B = Injection timing reference mark compared to A
A-?B = Distance in mm.
C = Piston reference mark in injection timing position.
a = Reference angle in degrees.
Engine type (A- B) mm * a

8LD600-2
8LD665-2 61 -?66 24°-26°
8LD740-2
8LD665-2/L 53-58 21°-23°
* Values given in mm. have been detected at the periphery of a
standard flywheel with 291 mm. diameter.
Injection timing reference marks on the pulley

A = Piston reference mark at top dead center
B = Piston reference mark in injection timing position
(A-B) = Distance in mm.
D = Piston reference arrow at top dead center, obtained with a ca
sting process
a = Reference angle in degrees
(A- B) mm
Engine type Pulley dia. Pulley dia. a
136 mm 140 mm
8LD600-2 ____
28.4- 30.8 24°-26°
8LD665-2
8LD665-2/L — 25.6- 28.0 21 °-23°
8LD740-2 — 29.3- 31.7 24°-26°
Injection timing correction

If reference mark C does not match with B follow examples 1 and 2.
1) Example of late injection timing: remove shims under the pump to
make C match with B.
2) Example of early injection timing: add shims under the pump to ma
ke C match with B.
Note: By adding or removing a 0.1 mm shim under the pump C is

delayed or advanced by approximately 3 mm.
48

INJECTOR
Components:
1 Intake fitting
2 Nozzle holder
3 Shim
4 Spring
5 Pressure rod
6 Intermediate flange
7 Nozzle
8 Needle valve
9 Fixing flange
10 Taper pin
11 Gasket
12 System duct
13 Sump
Nozzle
Features:
Hole number and diameter = 4x0.28 mm.
Jet angles = 160°.
Needle valve elevation = 0.20 + 0.22 mm
Hole length = 0.7 mm
Sump diameter and length = 1x1.5 mm
Clean nozzle tip with a brass brush.
Check that holes are not obstructed using a mandrel with steel wire with
0.28 mm. dia.
160'
Injector setting
Connect injector to a hand pump and check that setting pressure is
210 + 220 bar; make the required adjustments, if any, by changing the
shim over the spring.
When replacing the spring, setting should be performed at a 10 bar grea
ter pressure (220 + 230 bar) to allow fo bedding during operation.
Check needle valve sealing by slowly moving hand pump until approxi
mately 180 bar.
Replace nozzle in case of dripping.

STANDARD ELECTRIC EQUIPMENT
Electric starting layout without battery charging light

Components:
1 Alternator
2 Starting motor
3 Voltage regulator
4 Battery
5 Pressure switch
6 Oil pressure warning light
7 Key switch
Electrical starting layout with battery charging light

Components:
1 Alternator
2 Starting motor
3 Voltage regulator
4 Battery
5 Pressure switch
7 Key switch
8 Battery charging light
Note: Battery, which is not supplied by Lombardini, should feature 12V

voltage and capacity not below 70 Ah.
1
2.5 V, 14 A Alternator
Features a fixed armature winding housed in the bell inside the blower
housing.
The rotating permanent magnet inductor is located on the blower shaft.
Dimensions (mm):
A = 111.701 -111.788
B = 31.000- 33.500
C = 76.226- 76.300
D = 77.400- 77.474
Note: Clearance between armature winding and inductor (air gap) should
be 0.55-0.63 mm.
50

Alternator battery charger curve (12.5 V, 14A)
The curve was obtained at room temperature of +25°C with 12.5V
battery voltage.
Note: The r.p.m. shown in the table refers to the engine.
12 V, 21 A Alternator
Features a fixed armature winding housed in the bell inside the blower
housing.
The rotating permanent magnet inductor is located on the blower shaft.
See Page 12.
Diameter size (mm):
A = 111.701 -111.788
B = 49.500- 52.000
C = 76.226- 76.300
D = 77.400- 77.474
Note:Clearance between armature winding and inductor (air gap) should

be 0.47-0.63 mm.
Alternator battery charger curve (12 V, 21 A)

The curve was obtained at room temperature of +25°C with 12.5V
battery voltage.
Note: The r.p.m. shown in the table refers to the engine.

Magnetization checking tool (Part No. 7000-9727-001)
Components:
1 Casing
2 Slider
3 Casing reference line
4 Slider reference line
Rest the tool end horizontally onto the magnetic poles. Hold slider so
that its reference line coincides with the casing reference line. Release
slider: if no attraction occurs the rotor is demagnetized; therefore replace
alternator.
Checking for cable continuity

Check that stator windings have no unsoldered connections, burnt areas
or grounded wires.
Using an ohmmeter check for continuity between the red cable and the
two yellow ones.
Furthermore, check that they are insulated from the ground.
VOLTAGE REGULATOR
Type LOMBARDINI, supplied by SAPRISA and DUCATI: Voltage 12V,
maximum current 26A. References for SAPRISA connections with the
corresponding DUCATI connections.
SAPRISA DUCATI
G
R R
+ B
LE L
ckiS C
To avoid wrong connections 3 different size connections are supplied.
CONNECTION SIZE mm
SAPRISA DUCATI
WIDTH THICKNESS
G 6.25 0.8
R R 9.50 1.2
+ B 9.50 1.2
LE L 4.75 0.5
C 6.25 0.8

The voltage regulator fits to both circuits with and without battery char
ging light; in the latter case connections LE (SAPRISA) and L (DUCA-
Tl) are not used.
How to check voltage regulator for proper operation

Check that connections correspond to the layout.
Disconnect the terminal from the battery positive pole.
Connect a d.c. voltmeter between the two battery poles.
Fit an ammeter between the positive pole and the corresponding cable
1 terminal.
The ammeter should be suitable for reading the required value (14
or 21 A) and for withstanding the starting motor peak absorption
(400 4-450 A).
Start a couple of times unti battery voltage drops below 13V.
When battery voltage reaches 14.5V the ammeter current suddenly
drops down to almost zero.
Replace regulator if recharge current is zero with voltage below 14V.
Warning: When the engine is running do not disconnect battery cables

or remove the key from the control panel.
Keep regulator away from heat sources since temperatures above 75°C
might damage it.
No electric welding on engine or application.

Alternator type Bosch G1 14 V, 33 A
The alternator is of the claw-pole rotor type with build-in voltage regulator.
The rotating motion is conveyed by the engine through a “V” belt and
sheave.
Features: 12V rated voltage. Max. current 33A at 7000 alternator r.p.m.
RH direction of rotation.
Alternator type Bosch G1 14 V, 33 A layout

Components:
1 Alternator
2 Starting motor
3 Battery
4 Key switch
5 Pressure switch
7 Battery charging light
14 V, 33A Bosch G1 alternator battery charger curve

The curve was obtained at room temperature of +25°C
Battery terminal voltage is 12.5 Volt
The r.p.m. shown on the table refers to the engine.

STARTING MOTOR
Made by MARELLI and BOSCH.
Apply to their distributors for any type of repair.
1) Magneti Marelli starting motor type E100, 1,5/12 V

RH direction of rotation
A = 29.5-31.5 mm
B = Ring gear plane
C = Flange plane
Warning: The flywheel should not project from ring gear plane B.
Characteristic curves for starting motor type Magneti Marelli

E100, 1.5/12 V
Curves were obtained at room temperature of +20°C with 88 Ah bat
teries.
V = Motor terminal voltage in Volt
P = Power in kW
C = Torque in N/m
N = Motor speed in r.p.m.
I (A) = Absorbed current in Ampere
2) Bosch starting motor type GF - 12V, class 1.5 (optional)

RH direction of rotation
A = 29.5-31.5 mm
B = Ring gear plane
C = Flange plane
Warning: Flywheel should not project from ring gear plane B.
Characteristic curves for starting motor type Bosch GF

-12 V, class 1.5
Curves were obtained at room temperature of + 20°C with 66 Ah battery.
V = Motor terminal voltage in Volt
P = Power in kW
C = Torque in N/m
N = Motor speed in r.p.m.
J (A) = Absorbed current in Ampere

MANUAL STARTING
Crank starting
Fitted to the crankshaft with reduction ratio 2:1.
Compression release is required on both heads.
A heavy flywheel is also required.
Start by actuating compression release, introducing the crank and quick
ly turning it by hand according to the engine direction of rotation. Dis
connect compression release immediately afterwards.
Crank starting system

Components:
10 11
1 Circlip
2 Ring
3 Release spring
4 Housing
5 Lubrication hole
6 Plug
7 Roller bushing
8 Pin
9 Drive gear
10 Bracket
11 Driven gear
12 Sprocket flange
Rope starting
Compression release is required.
Start by winding the rope as indicated by the arrow on the pulley.
Actuate compression release.
Slowly pull the rope until compression is eliminated, then stop. Rewind
the rope, pull it very quickly and finally disconnect compression release.

SETTINGS
1) Idle speed setting in no-load conditions

After filling with oil and fuel, start the engine and let it warm up for 10
minutes.
Adjust idle speed at 1000-1200 r.p.m. by turning setscrew 1; then
tighten lock nut.
2) Full speed setting in no-load conditions (standard)

After setting idle speed turn screw 2 and set full speed in no-load con
ditions at 3200 r.p.m.; then tighten lock nut.
Note: When the engine reaches the pre-set power full speed stabilizes
at 3000 r.p.m.
Injection pump delivery setting

This setting should be performed at the torque dynamometer. If not,
setting is only approximate.
The following steps are required:
Loosen delivery limiting device C by 5 turns.
Bring engine to full speed in no-load conditions i.e. 3200 r.p.m.. Tigh
ten limiting device until the engine shows a drop in r.p.m.
Unscrew limiting device C by 11/2 turn. Tighten lock nut.
Note: If the engine, under full load, generates too much smoke tighten
C; if no smoke is observed at the exhaust and the engine cannot reach
its full power unscrew C.
Injection pump delivery limiting and extra fuel device

Limiting device C limits the injection pump maximum delivery. It also
acts as a torque setting device since spring N opposes the resistance
of spring M inside the cylinder through lever L.
The torque setting device allows lever L to move over stroke H corre
sponding to 0.15-0.25 mm.
This consequently increases injection pump delivery with torque rea
ching its peak value.
Note: In generator sets and power welders, the torque setting device
acts as a delivery limiter only. It therefore does not feature spring M or
stroke H.

Injection pump delivery setting with engine at the torque
dynamometer
1) Bring engine to idling speed
2) Unscrew delivery limiting device C (see page 54)
3) Bring engine to the power and r.p.m. as shown on power curve.
4) Check that consumption falls within the table specifications (see be
low). If consumption is not as indicated change balance conditions
at the torque dynamometer by varying the load and adjusting the
governor. Under stable engine conditions check consumption again.
5) Tighten limiting device C until the engine r.p.m. decreases. Lock the
limiting device by means of lock nut.
6) Release brake completely and check at what speed the engine be
comes stable.
Speed governor should comply with the requirements of the class
indicated by the manufacturer of the device.
7) Stop the engine
8) Check valve clearance when the engine has cooled down.
Required settings (as most commonly applies)

Power Specific fuel consumption. *
Engine R.P.M. HP Time (sec.) rev/HP h
(kW) per 100 cm3 (rev/kW h)
N 209-198
8LD600-2 3000 57- 60
25 (18,38) (284-270)
N 209-199
8LD600-2 2600 62- 65
23 (16,91) (284 - 270)
NB 209-199
8LD600-2 3000 62- 65
23 (16,91) (284 - 270)
NB 207-198
8LD600-2 2600 68- 71
21 (15,44) (284-272)
NB 212-200
8LD665-2 3000 50- 53
28 (20,59) (288 - 272)
N 207-197
8LD665-2 2600 55- 58
26 (19,12) (282 - 268)
NB 207-197
8LD665-2 3000 55- 58
26 (19,12) (282 - 268)
NB 209-198
8LD665-2 2600 58- 61
24,5 (18) (284 - 272)
NB 180-175
8LD665-2/L 2200 75- 77
22 (16,18) (245 - 238)
NB 180-175
8LD665-2/L 1800 87- 89
18,5 (13,60) (245 - 238)
NB 180-175
8LD665-2/L 1500 113- 116
14,7 (10,81) (245-238)
N 198-188
8LD740-2 2600 54- 57
27,88 (20,50) (269-255)
NB 195-185
8LD740-2 2600 59- 62
25,84 (19) (266 - 253)
NB 179-174
8LD740-2 2200 70- 72
23,80 (17,50) (243-236)
NB 179-173
8LD740-2 1800 83- 86
20 (14,71) (244-236)
NB 179-174
8LD740-2 1500 102- 105
16,32 (12) (244 - 236)
* The indicated specific fuel consumption refers to the period following

approximately 100 working hours.

Stop setting
1) Completely turn lever C counterclockwise and keep it in this posi
tion. Retainer F should not be in contact with lever C.
2) Unscrew nut G and bring retainer F in contact with lever C
3) Push retainer F so that lever C is moved backwards clockwise by
1.0-1.5 mm.
4) Lock retainer F by screwing nut G
Note: Under these conditions no damage can be caused to the injec

tion pump rack rod stops by sudden impacts due to the available electric
stops.

STORAGE
Prepare engines as follows for storage over 30 days:
Temporary protection (1 -6 months).

• Let engine work 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.
• When engine is warm empty oil pan and fill with standard new oil.
8 Remove fuel tube and empty the tank.
• Remove fuel filter, replace cartridge if dirty and refit.
• Carefully clean cylinder fins, heads and fan.
• Seal all openings with tape.
• Remove injectors, pour a spoonful of oil type SAE 30 into the cylin
ders and rotate manually to distribute the oil. Refit injectors.
• Spray oil type SAE 10W into exhaust and intake manifolds, rocker
arms, valves, tappet etc. Grease all unpainted parts.
• Loosen belt.
• Wrap the engine in a plastic film.
• Store in a dry place, if possible not directly on the soil and far from
high voltage electric lines.
Permanent protection (over 6 months)

The following is recommended apart from the above instructions:
• For the lubrication and injection system as well as for moving parts
use rustproof oil type MIL-L-21260 P10, grade 2, SAE 30 (Ex. ESSO
RUST - BAN 623 - AGIP, RUSTIA C. SAE 30). Let the engine run
with rustproof oil and drain any excess.
• Coat external unpainted surfaces with antirust type MIL-C-16173D,
grade 3 (Ex. ESSO RUST BAN 398 - AGIP, RUSTIA 100/F).
How to prepare the engine for operation

• Clean engine outside
* Remove protections and covers.
• Remove antirust by an appropriate solvent or degreaser.
• Remove injectors, fill with standard oil, turn crankshaft by a few
revolutions, remove oil pan and drain the protective oil.
• Check injectors, valve clearance, belt tension, head tightening, oil
filter and air cleaner for proper setting. If the engine is stored over
a long period of time (over 6 months) check one of the bushings for
corrosion.

Workshop Manual Lombardini - Red

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com manuals search engine

I MODEL NUMBER AND ENGINE IDENTIFICATION page 5

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LUBRICATION SYSTEM LAYOUT 39

Oil filter cartridge 40

Assembly of injection pump components 46

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STANDARD ELECTRIC EQUIPMENT 50

12.5V - 14A alternator 50

Full speed setting in no-load conditions (standard) 57

How to prepare the engine for operation 60

8LD6OO-2 8LD665-2 8LD665-2/L 8LD740-2

Engine group number Slow speed version

Lombardini No. oi cylinders

Diesel Unit cylinder displacement

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TYPE BLD600-2 BLD665-2 BLD665-2/L BLD740-2

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C (Nb): Specific fuel consumption at Nb power

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AIR CEANER (*) •

FEED PUMP FILTER •

HEAD AND CYLINDER FINS (*) •

INTERNAL OIL FILTER •

AIR CLEANER OIL •

LEVEL CRANKCASE OIL •

CHECK DELIVERY VALVE TIGHTNESS •

FAN BELT TENSION •

VALVE AND ROCKER ARM CLEARANCE •

INJECTOR SPRAY PATTERN •

AIR CLEANER (“) (“*) •

REPLACEMENT OIL FILTER CARTRIDGE •

FUEL FILTER CARTRIDGE •

(*) Under severe working conditions, clean daily.

RECOMMENDED OIL TYPE CAPACITIES (LITERS)

Suggested oil grades

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Too low oil

Clogged tank breather • •

Incorrect relief valve setting •

Wrong or inefficient cable connection •

Excessive idle operation •

Broken or loose governor spring •

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POSITION Type of sealant

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8.8 10.9 = R10 12.9 = R12

High-carbon steel Alloy steel Special alloy steel

4x0.70 0.37 0.52 0.62

5x0.80 0.72 1.01 1.22

6x1.00 1.23 1.73 2.08

7x1.00 2.02 2.84 3.40

8x1.25 3.02 4.25 5.10

9x1.25 3.88 5.45 6.55

10x1.50 5.36 7.54 9.05

12x1.75 9.09 12.80 15.30

14x2.00 13.80 19.40 23.30