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Transcript of LDW 194 JMtI LDW 245 JMtI/A - Lombardini Marine · This manual has been specially designed to...
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1
LDW 194 JMtILDW 245 JMtI/A
Installation - Use-maintenance
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This manual has been specially designed to provide you with all the necessary information to keep your engine perfectly efficient for many years.
Please read it carefully and follow precisely any described installation and maintenance operations.
Lombardini Marine service network shall, in any case, be at your complete disposal for any clarifica-tions or advice.
LoMbardini Marine
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3
Coolant replenishing Prescribed coolant:
50% Total antifreeze50% Water
Reduction-reversing gear oil filling Prescribed lube:
Total SAE 15W40(API CG4/ACEA E2)Total Rubia 4400 15W40
Oil level check Prescribed lube:
Total quartz SAE 10W40Quartz Diesel 7000 10W40Activa Disel 7000 10W40
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4
Index
Pag. 7
Pag. 9
Pag. 16
Pag. 33
Pag. 35
Pag. 54
Pag. 88
Pag. 91
Pag. 94
Pag. 6
OveRAll DimensiOn
iiDenTificATiOn
Use
mAinTenAnce
sTORAge
mAin ciRcUiTs
insTAllATiOn
seRvice
WARRAnTy clAUses
cHARAcTeRisTics
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Prior to starting read and follow instructions. failure to do so will make warranty void.
Accessory set supplied with the engine Request if not to supply
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Characteristics
* With TM 485 a reversing gear box
194 245
extreme power kw/cv 132.3/180 176.4/240
r.P.M. 3900 4200
bore mm 82.0 82.0
Cylinders n. 4 5
Max. running inclination β 20° 20°
Max. installation inclination α 10° 10°
Cooling system capacity l 7.5 8.5
dry weight with reversing gear Kg 284* 315*
reduction/reversing gear oil quantity l 2.6* 2.6*
engine oil quantity l 5.5 7.0
displacement cm3 1910 2387
Stroke mm 90.4 90.4
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7
Overall dimensions
With Tm 485 A reversing gear box
LDW 194 JMtI
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With Tm 485 A reversing gear box
LDW 245 JMtI/A
Overall dimensions
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9
Heat exchanger
Sea water pump
exhaust line outlet
Turbocharger protection
Upper cover
intercooler
Identification
oil suction pump
Turbocharger
air filter
oil filter and cooler
eyebolt
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belts protection
Cooling fluid filling cap
oil dipstick
oil filling cap
alternatoraccelerator lever
Fuel filter
Low pressure diesel oil pump
eyebolt
Identification
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Fuse
Start
Starter switch
oil Thermometer or Gauge
revolution counter
De Luxe maxi panel
Water thermometer
Voltmeter/Hour counter (LCd)
Identification
Warning lamps
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De Luxe maxi panel
Identification
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Vibration mounts
Identification
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To accelerateTo decelerate
Accelerator lever
Predisposed for c3 cable
Identification
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15
Reduction reversing gear technodrive tM 485 A
P.T.o.
reverse reduction gear lever
oil filling cap
Identification
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Installation
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When you design the engine room, observe accessibility necessary for main-tenance and repairs on the engine.also ensure that whole engine can be removed without damaging the structure of the boat.Maintenance which requires accessibility:engine and gearbox oil draining and refilling;engine coolant draining and refilling;oil filter exchange;Fuel filters exchange;air filter exchange;belts check and replacement;Hoses check and replacement;raw water pump impeller replacement;Strainer cleaning.
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18
PropellerPropeller shaftCoupling flanges Waterline
Raw water system
1
23 4
4
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Ø min. 1” 1/2 (38.1 mm)
Ø min. 1” 1/4 (31.75 mm)
min. 110 l/min
sea cock1
Water intake valve2
Raw water strainer3
Ø min. 1” 1/4 (31.75 mm)
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Use a semiflexible hose with steel core and smooth internal surface
Øi 30.0 mm
suction hose4
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Layout beneath the water line
Part A
if <200 mm, part B
if sea water outlet is at height of less than 200 mm from the water line, fit an air vent system.
air vent
Part B
300 mm
> 200 mm
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exhaust line must be linear and descending.
Øi 90 mm
1 engine installed - suggested2 engines installed - mandatory
exhaust hose
non return valve
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23
Muffler
Muffler must hold a large volume of water included between the muffler and the exhaust exit.
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if the exhaust line is ascending and the sea water exit from the engine is under the waterline, install a muffler and a non-return siphon.
Muffler must hold a large volume of water included between the muffler and the exhaust exit.
no return siphon
Muffler
>50mm
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Diesel system
1
2
3
4
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shut off solenoid min. 200 l/h
fuel hose
a1 Class
Water separator prefilter
Øi 10 mm
30-40 µm
Suggested
Montatory
1
2
3
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Diesel cooler
Use diesel clean and without presence of water
4
Fit a warning lamp in order inform in case of water presence in the fuel.
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28
Extraction and ventilation engine room - Belüftung/ Entlüftung des Maschinenraums
BlOWeRmin. 10 m3/min
min. 176 cm2
omin. ø = 15 cm
Mandatory 50°c 122°f
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29
Wiring box positioning - Positionierung des Anschlusskastens
OK
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Vibration mounts
A B
OK
1 2
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Maximum inclinations permitted
βα
γγ
LDW 194 JMtI
LDW 245 JMtI/A
engine αMaximum installation tilt
βMaximum running tilt
γMaximum side tilt
10° 20°20°
10° 20°20°
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Vibration mounts
Use those recommended by Lombardini Marine only. Wrong fitting of the vibration-damping mounts causes considerable engine vibrations and sets a limit to their duration. nut 1 in fig. b makes it possible to adjust the engine at the rights inclination to the axis. The upper lock nut 2 should then be firmly tightened. (see page 30).
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Main circuits
exhaust line outlet
Sea water pump
intercooler
Heat exchangeroil filter and cooler
Thermostatexpansion tank
diesel cooler Sea cock
raw water filter
reverse gear oil cooler
Water intake valve
engine
Water pump
coolant
sea water
gearbox oil
engine oil
fuel
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Main circuits
Tank
Prefilter
High pressure pump
injectors
return line
return manifolddiesel oil cooler
Filter
Feeding pump
Pressure regulatorrail
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Use
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36
carry out these operations while engine is cold
carry out these operations while engine is off
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37
remove oil filler cap. Prescribed lube:
Total Quartz SAE 10W40Quartz Diesel 7000 10W40Activa Diesel 7000 10W40
Before starting Fill crankcase with oil
Pour the oil in and reassemble oil cap.
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38
remove dipstick.
Before starting Oil level check
Make sure that it is at maximum line, if not, add oil. do not overfill.
To check oil level, wipe off dipstick with absorbent cloth or towel and check level.
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39
reassemble dipstick.
Oil level above the upper threshold may cause seriously damage to the engine
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40
Reduction-reversing gear oil fillingBefore starting
remove oil filler cap. Prescribed lube:
tOtAL sAE 15W40(API CG4/ACEA E2)
Total Rubia 4400 15W40
Pour the oil in and reassemble oil cap.
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Oil level checkBefore starting
remove dipstick. Check that level is at max.
reassemble dipstick.
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Before starting Water drain from fuel prefilter
remove cap and let water drain from filter bottom.
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Coolant replenishing Before starting
Prescribed coolant:
50% Total antifreeze50% Water
remove cap and pour liquid into heat exchanger.
Fill until level mark. Put heat exchanger cap back.
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44
Turn the key to the first click. The dashboard switches on.
starting
open the cock for seawater intake. intake pipes should be watertight, otherwise the pump could get damaged.
do not use sprays to make starting easier.
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45
Start engine after about 10”. Key always in on (first) position when engine is running.
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46
Check seawater outlet checkAfter starting
if no water comes out of the exhaust pipe, bring the engine to 1800-2000 rpm to make pump priming easier.
Warm up as per sheet:
Temperature Duration
< -20°c 10’
-20°c ÷ 0°c 8’
0°c ÷ 5°c 6’
> 5°c 5’
do not warm up the engine at idle speed. Keep the engine at 1300÷1500 rPM. Check that there are no oil, fuel or water leakages.
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47
Driving positionsAfter starting
Forward neutral
reverse
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48
After starting
at idle speed for a few minutes.
Before stopping
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49
stopping
Key “0” position. remove the key from the switch.
Lower the cap of the switch.
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50
After stopping Drain sea water from the pump (temperature below 32°F)
detach the suction line from the sea water pump.
remove the screws and the protection belts .
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51
rotate 90° the pump group.
remove screws and pump cover.
Unscrew the 3 bolts which fix the raw water pump.
Unscrew the zinc and let the water drain .
reassemble the zinc.
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52
reassemble gasket, cap and screws.
Screw the 3 bolts which fix the raw water pump.
reassemble the protection belts.
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Run-in During first 125 hours do not exceed 70% of maximum rated power
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Maintenance
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carry out these operations while engine is cold
carry out these operations while engine is off
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remove dipstick.
Make sure the oil is at the maximum. if level is under the minimum, fill up.
sump oil level checkEvery 10 hours
h 10
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remove oil filler cap.
Pour the oil in and reassemble oil cap.
Clean, fit in and remove dipstick.
Prescribed lube:
Total Quartz SAE 10W40Quartz Diesel 7000 10W40Activa Diesel 7000 10W40
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Check that level is at max. reassemble dipstick
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remove dipstick. if level is under the minimum, fill up.
remove oil filler cap.
How to check reduction-reversing gear oil levelEvery 10 hours
h 10
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Pour the oil in and reassemble oil cap.
Clean, fit in and remove dipstick.
Check that level is at max. reassemble dipstick.
Prescribed lube:
tOtAL sAE 15W40(API CG4/ACEA E2)
Total Rubia 4400 15W40
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remove the expansion tank cap. if level is below reference mark, fill up and put the cap on.
Coolant level checkEvery 10 hours
h 10
Prescribed coolant:
50% Total antifreeze50% Water
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After the first 50 working hours End of the run in period
see the scheduled maintenance booklet
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sump oil replacement
remove oil using the hand pump.
remove oil filler cap.
Every 250 hours or 1 year
h 250 1 Year
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Make sure oil is at maximum level .
Take the used oil to the appropriate collection site.
Pour the oil in and reassemble oil cap.
Prescribed lube:
Total Quartz SAE 10W40Quartz Diesel 7000 10W40Activa Diesel 7000 10W40
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remove the filter and take it to the appropriate collection site.
replace with original Lombardini Ma-rine filter type.
reassemble the filter.
Oil filter replacementEvery 250 hours or 1 year
h 250 1 Year
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detach the lower connector. den Sensor des Wasserbscheiders abschrauben.
remove the filter and take it to the appropriate collection site.
replace with original Lombardini Ma-rine filter type.
Diesel filter replacementEvery 250 hours or 1 year
h 250 1 Year
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reassemble the filter. install the water level sensor.
Connect the lower connector.
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remove the screws and the protection belts.
The belt must be in good condition, without abrasions or fraying, otherwise change it.Check the belt.
Visual check of sea water pump beltEvery 250 hours or 1 year
h 250 1 Year
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69
replace the belt, if worn. Loosen the 3 bolts which fix the raw water pump.
Push toward the internal side of the engine the group.
remove the belt and dispose of it in accordance with applicable laws.
replace by a Lombardini Marine genuine belt.
reassemble the belt.
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Push strongly the group toward the external side of the engine.
reassemble the protection belts
Screw the 3 bolts which fix the raw water pump.
Press on the belt (approx. 10 kg). if flexure is over 1 cm., strech the belt.
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remove the screws and the protection belts.
Check the sea water pump impellerEvery 250 hours or 1 year
rotate 90° the pump group.Unscrew the 3 bolts which fix the raw water pump.
h 250 1 Year
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remove screws and pump cover.
replace with Lombardini Marine genuine parts.
if the impeller is worn, dispose of it in accordance with applicable laws.
reassemble impeller.
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73
reassemble gasket, cap and screws.
reassemble the protection belts.
Screw the 3 bolts which fix the raw water pump.
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remove the filter and take it to the appropriate collection site.
replace with original Lombardini Ma-rine filter type.
assemble the new filter.
Air filter replacementEvery 250 hours or 1 year
h 250 1 Year
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apply grease resistant to high temperature (1000°C) on the pivot pin of wastegate.
Lubrication of wastegate control lever.Every 250 hours or 1 year
Grease suggested.
tOtALsPECIs CU
h 250 1 Year
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replace with Lombardini Marine genuine plug.
if the plug is worn, dispose of it in accordance with applicable laws.
Loosen plug and see if worn out
Check the zinc anodesEvery 250 hours or 3 months
h 250 3 Month
Put plug back.
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77
Squeeze hoses to check for wear. replace hoses if worn out.
Loosen hose clamps.
Check cooling circuit sleevesEvery 250 hours or 1 year
h 250 1 Year
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remove and throw hose away.
replace with original Lombardini Marine hose.
Fit hose and clamps back in place.
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The belt must be in good condition, without abrasions or fraying, otherwise change it.
remove the screws and the protection belts.
Check the belt.
Visual check of alternator beltEvery 250 hours or 1 year
h 250 1 Year
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Loosen the tightening belt.**
Loosen the tightening belt.**
replace the belt, if worn.
replace by a Lombardini Marine genuine belt.
remove the belt and dispose of it in accordance with applicable laws.
reassemble the belt. **
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reassemble the protection
Loosen the upper bolt of the tightening belt.
Loosen the lower bolt of the tightening belt.
** LDW 245 JMtI/A
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rotate the belt tightening pulley.
Tighten the upper bo l t o f the tightening belt.
Tighten the upper bo l t o f the tightening belt.
rotate the belt tightening pulley.
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remove cap and drain oil. reassemble oil drain cap.
remove oil filler cap.
How to replace reduction-reversing gear oil levelEvery 250 hours or 1 year
h 250 1 Year
Prescribed lube:
tOtAL sAE 15W40(API CG4/ACEA E2)
Total Rubia 4400 15W40
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Pour the oil in and reassemble oil cap.
Check that level is at max.
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Loosen hose clamp on engine oil cooler. detach the clamp from the exchanger and let the cooling liquid drain.
Coolant replacementEvery 500 hours or 2 years
Fit sleeves and clamps back in place.
h 500 2 Years
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Prescribed coolant.
50% Total antifreeze50% Water
remove cap and pour liquid into the tank.
Fill unitl level mark. Put tank cap back.
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timing belt replacement
Contact authorized service centers
Clean exchanger and intercooler tube bundlesEvery 500 hours or 2 years
Every 1000 hours or 3 years
h 1000 3 Years
h 500 2 Years
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Sea water drainage from the pump. See page 50 oil sump and oil filter replacement. See page 63
Storage. Close suction and delivery outlets with tape.
Fuel filter replacement. See page 66
1 ÷ 6 monthsstorage
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Wrap engine with plastic and put it on a wood base.
If storage exceeds 6 months, please contact Lombardini Marine authorized service centers
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Battery not supplied
In case of damage to the electrical system, contact authorized service centers
ground rubber mounted engines
never disconnect the battery while the engine is running
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service
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for spare parts and after sale assistance contact authorized lombardini marine service centers.Tel. no. appears on service booklet and telephone directory.
Where it’s possible and in the if the user can’t reach the authorized service, the personnel of service will assist you on place
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engine type and serial number
For any spare parts order please specify following details:
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Warranty clauses
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WARRANtY CLAUsEs
The engines manufactured by Lombardini Marine are covered by a 24-months warranty beginning on the date of delivery to the first user in accordance with european directive 1999/44/eeC and for at most 36 months from date of delivery to the manufacturer or shipyard; of the two alternatives, that which occurs first shall apply.in the case of special applications requiring major alterations to the cooling, lubrication, supercharging and-filtering circuits, the special warranty clauses agreed in writing shall apply or the general clauses indicated above in the event of an application approval test certificate being produced, issued by the Technical department of Lombardini Marine.Within the above time-frame, Lombardini Marine undertakes to make any repairs under warranty, either directly or through authorized workshops.The obligations of Lombardini Marine, as indicated in european directive 1999/44/eeC, shall not be valid in the following cases:- engines not installed and used in conformity with the instructions of Lom-
bardini Marine shown in the operator’s and maintenance booklet;- Seals affixed by Lombardini Marine tampered with;- engines repaired, dismantled or modified by workshops not authorized by
Lombardini Marine;- Fitting of not-original Lombardini Marine spare parts;- injection Systems damaged by unsuitable or polluted fuel.Upon expiry of the 24-months period from the date of delivery of the engine to the first user, without Lombardini Marine or its authorized workshops having received notification of any faults, Lombardini Marine shall consider itself exempted from all liability or obligations, as set forth in european directive 1999/44/eeC.This warranty, effective from 23/3/2002, cancels and replaces all other previous warranties and any amendments made to it shall be made in writing.
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aTTenTionFor any law’s effect, the engine is not made to be installed by end-user, therefore, possible conformity defects caused from installation, will not be recognized if the installation is not made by workshop or authorized Lombardini Marine shipyard.
lombardini marine can modify data reported in this issue at any time.
factory:02100 vazia - Rieti - italiavia e. grecoTel. +39 (0746) 220131Tel. +39 (0746) [email protected]
sales Office:42124 Reggio emilia - italiavia cav. Del lavoro Adelmo lombardini, 2Tel. +39 (0522) 934598Tel. +39 (0522) [email protected]
42124 Reggio emilia - italia - via cav. del lavoro Adelmo lombardini, 2 - cas. post. 1074Tel. +39 0522.3891 - Telefax +39 0522.389241 - Telegr.: lombarmotor - www.lombardini.itCod. Fiscale/N° Iscr. Reg. Impr. 01829970357- P. IVA/CEE code: IT 01829970357 - R.E.A. 227083
capitale sociale 44.000.000,00 euro int. vers.
Rev
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2 d
el 1
1-08
co
d. 0
0530
2726
0
lombardini marine is a division of:®