2COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
FOREWORD
We have done all in our power to give up to date and accurate technical information in this manual. Ruggerini engines
are, however, constantly developing thus the data in this publication may be liable to modification without prior notice.
The information in this manual is the exclusive property of Ruggerini. Neither partial nor total duplications or reprints
are therefore permitted without the express authorization of Ruggerini.
The information in this manual is given on the assumption that:
1- The persons who service Ruggerini engines have been adequately trained and outfitted to safely and
professionally carry out the necessary tasks;
2- The persons who service Ruggerini engines possess the necessary skills and special Ruggerini tools to safely
and professionally carry out the necessary tasks;
3- The persons who service Ruggerini engines have read the specific information concerning the above mentioned
Service operations and that they have clearly understood the operations required.
GENERAL SERVICE NOTES
1 - Only use genuine Ruggerini spare parts. Use of spurious spares may lead to incorrect performance and shorten
the life of the engines.
2 - The metric system is used to express all data, i.e. the dimensions are given in millimeters (mm), torque is
expressed in Newton-meters (Nm), weight in kilograms (Kg), volume in liters or cubic centimeters (cc) and
pressure in barometric units (bar).
3
COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
WARRANTY CERTIFICATE
WARRANTY CERTIFICATE
Products Ruggerini Motori manufactured by Lombardini Srl are warranted to be free from non-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.
If no hour-meter is fitted, 12 working hours per calendar day will be considered.
For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling
system, sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above-
mentioned period (24 months) is not expired.
For correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the
documentation supplied with each engine.
To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be
carried out by qualified personnel only.
The list of the Lombardini authorized dealers for Ruggerini Motori products is reported in the “World Service
Organisation” booklet, supplied with each engine.
Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump),
filtering system, turbo-charged models, will require special written warranty agreements.
Within the above stated periods Lombardini Srl directly or through the Ruggerini Motori authorized network will repair
and/or replace free of charge any own part or component that, upon examination by Ruggerini Motori Service Dept. or
by an authorized Ruggerini Motori agent, is found to be defective in conformity, workmanship or materials.
Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine
use or from both the total or partial impossibility of use, is excluded.
The repair or replacement of any component will not extend or renew the warranty period.
Lombardini Srl warranty obligations here above described will be cancelled if:
- Engines are not correctly installed and as a consequence the correct functional parameters are not respected and
altered.
- Engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied with
each engine.
- Any seal affixed to the engine by the Manufacturer has been tampered with or removed.
- Spare parts used are not original from Manufacturer.
- Feeding and injection systems are damaged by unauthorized or poor quality fuel types.
- Electrical system failure is due to components, connected to this system, which are not supplied or installed by
the Manufacturer.
- Engines have been disassembled, repaired or altered by any part other than an authorized Ruggerini Motori agent.
Following expiration of the above stated warranty periods and working hours, Lombardini will have no further
responsibility for warranty and will consider its here above mentioned obligations for warranty complete.
Any warranty request related to non-conformity of the product must be addressed to the Ruggerini Motori service
agents.
4COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
INDEX
I TROUBLE SHOOTING __________________________________________________________ Page 7
II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS ____________________________ " 8-9
III MODEL NUMBER AND IDENTIFICATION _____________________________________________ " 10
IV TECHNICAL DATA ______________________________________________________________ " 11
V CHARACTERISTICS _____________________________________________________________ " 12
VI OVERALL DIMENSIONS __________________________________________________________ " 13
VII SPECIAL TOOLS________________________________________________________________ " 14
VIII MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING _______________________________ " 15-16
IX DISASSEMBLY OF THE ENGINE ___________________________________________________ " 17
Extracting crankcase bushes ......................................................................................................................................... 18
Extracting fuel injectors ................................................................................................................................................... 17
Extracting the oil pressure indicator plug ....................................................................................................................... 18
Extraction of crankshaft gear .......................................................................................................................................... 17
Extraction of flywheel side main bearing ........................................................................................................................ 17
Extraction of the camshaft gear ...................................................................................................................................... 18
Removing the flywheel .................................................................................................................................................... 17
X CHECKS AND OVERHAUL ______________________________________________________ Page 19
Camshaft ........................................................................................................................................................................ 24
Central main bearings .................................................................................................................................................... 24
Connecting rods ............................................................................................................................................................. 22
Crankshaft....................................................................................................................................................................... 23
Cylinders ......................................................................................................................................................................... 21
Cylinders heads .............................................................................................................................................................. 19
Fuel pump push-rod ....................................................................................................................................................... 25
Governor lever and spring .............................................................................................................................................. 26
Injection pump plug nuts and control rods..................................................................................................................... 25
Oil pump .......................................................................................................................................................................... 25
Oil seal rings ................................................................................................................................................................... 24
Piston rings - Pistons - Piston pins ................................................................................................................................ 22
Rocker arms ................................................................................................................................................................... 21
Tappets and push rods ................................................................................................................................................... 25
Valves - Guides - Seats ................................................................................................................................................... 19
Valves and springs ......................................................................................................................................................... 21
This manual contains pertinent information regarding the repair of RUGGERINI air-cooled, indirect injection Diesel engines
type MD150 - MD151, MD190 - MD191: updated June 23, 2003.
5
COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
INDEX
XI INJECTION EQUIPMENT ________________________________________________________ Page 27
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........................................................................................................................................................................... 29
Testing air tightness ....................................................................................................................................................... 28
XII ELECTRICAL EQUIPMENT ______________________________________________________ Page 30
Checking electrical equipment ....................................................................................................................................... 30
Checking the alternator ................................................................................................................................................... 30
Plant specifications......................................................................................................................................................... 30
XIII ENGINE ASSEMBLY ___________________________________________________________ Page 31
Camshaft ........................................................................................................................................................................ 33
Central main bearings .................................................................................................................................................... 31
Checking injector protrusion .......................................................................................................................................... 36
Connecting rods ............................................................................................................................................................. 35
Crankshaft ....................................................................................................................................................................... 32
Crankshaft end float ........................................................................................................................................................ 32
Cylinder heads ................................................................................................................................................................ 36
Cylinders ......................................................................................................................................................................... 35
Electric shut off ................................................................................................................................................................ 38
Feed pump ...................................................................................................................................................................... 38
Governor tie rod adjustment ........................................................................................................................................... 33
Injection check ................................................................................................................................................................ 37
Injection pumps .............................................................................................................................................................. 36
Injectors and injector pipes ............................................................................................................................................ 38
Main bearings - flywheel side ......................................................................................................................................... 32
Oil filter ............................................................................................................................................................................ 38
Oil pump .......................................................................................................................................................................... 34
Pistons ............................................................................................................................................................................ 35
Preparing the crankcase ................................................................................................................................................ 31
Pulley and flywheel ......................................................................................................................................................... 34
Timing cover .................................................................................................................................................................... 34
Valve clearance ............................................................................................................................................................... 36
6COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
INDEX
XIV ENGINE TESTING _____________________________________________________________ Page 39
Checking for oil leaks ..................................................................................................................................................... 39
Checking oil pressure .................................................................................................................................................... 39
Dyno testing of engine .................................................................................................................................................... 39
Speed adjustment ........................................................................................................................................................... 39
XV STORAGE ___________________________________________________________________ Page 41
How to prepare the engine for operation........................................................................................................................ 41
Permanent protection (over 6 months)........................................................................................................................... 41
Storage ............................................................................................................................................................................ 41
Temporary protection (1/6 months) ................................................................................................................................ 41
XVI QUICK REFERENCE CHARTS ____________________________________________________ Page 42
Adjustments .................................................................................................................................................................... 42
Couplings........................................................................................................................................................................ 42
Standard screw tightening torques ................................................................................................................................. 43
Tightening torques .......................................................................................................................................................... 43
7
COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
ITROUBLE SHOOTING
Clogged pipes
Clogged fuel filter
Air inside fuel circuit
Clogged tank breather hole
Faulty fuel pump
Injector jammed
Jammed injection pump delivery valve
Wrong injector setting
Excessive plunger blow-by
Jammed injection pump delivery control
Wrong injection pump setting
Oil level too high
Jammed pressure relief valve
Worn oil pump
Air inside oil suction pipe
Faulty pressure gauge or switch
Clogged oil suction pipe
Battery discharged
Wrong or inefficient cable connection
Defective ignition switch
Defective starter motor
Clogged air filter
Excessive idle operation
Incomplete running-in
Engine overloaded
Advanced injection
Delayed injection
Incorrect governor linkage adjustment
Broken or loose governor spring
Idle speed too low
Worn or jammed piston rings
Worn or scored cylinders
Worn valve guides
Jammed valves
Worn bearings
Governor linkage not free to slide
Drive shaft not free to slide
Damaged cylinder head gasket
TROUBLE
LUBRICATION
POSSIBLE CAUSE
FUEL CIRCUIT
ELECTRIC
SYSTEM
MAINTE-
NANCE
SETTINGS/REPAIRS
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.
Engine does not
start
No acceleration
Black smoke
Excessive oil
consumption
Too low oil
pressure
Engine starts but
stops
Non-uniform speed
White smoke
Oil and fuel
dripping from
exhaust
Increase oil level
8COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS
Failure to comply with the
instructions could result in
damage to persons and
property
Failure to comply with the
instructions could lead to
technical damage to the
machine and/or system
SAFETY AND WARNING DECALS
SAFETY INSTRUCTIONS
DANGER CAUTION
• Ruggerini 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.
• The engine has been made according to a machine manufacturer's specifications and all actions required to meet the
essential safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit. All
uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use
defined by Ruggerini which thus declines all liability for any accidents deriving from such operations.
• The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine
operation in particular, along with the relative routine maintenance work.
• The user must read these instructions carefully and become familiar with the operations described. Failure to do this
could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of
the machine.
• The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation
and the deriving dangers. This condition is also essential when it comes to routine and, above all, extraordinary
maintenance operations which, in the latter case, must only be carried out by persons specifically trained by Ruggerini
and who work in compliance with the existing documentation.
• Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal of
seals, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized
personnel shall relieve Ruggerini from all and every liability for deriving accidents or for failure to comply with the laws
in merit.
• On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the
case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous
objects, also considering the movements made by the operator. Pull-starting with a free cord (thus excluding self-
winding starting only), is not permitted even in an emergency.
• Make sure that the machine is stable to prevent the risk of overturning.
• Become familiar with how to adjust the rotation speed and stop the engine.
• Never start the engine in a closed place or where there is insufficient ventilation. Combustion creates carbon monoxide,
an odourless and highly poisonous gas. Lengthy stays in places where the engine freely exhausts this gas can lead
to unconsciousness and death.
9
COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
IISAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS
• The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is dust
that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been
certified for the machine.
• To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.
• Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving
from their operation.
• Fuel is inflammable. The tank must only be filled when the engine is off. Thoroughly dry any spilt fuel and move the
fuel container away along with any rags soaked in fuel or oil. Make sure that no soundproofing panels made of
porous material are soaked in fuel or oil. Make sure that the ground or floor on which the machine is standing has
not soaked up any fuel or oil.
• Fully tighten the tank plug each time after refuelling. Do not fill the tank right to the top but leave an adequate space
for the fuel to expand.
• Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place.
• Do not smoke or use naked flames when refuelling.
• The engine must be started in compliance with the specific instructions in the operation manual of the engine and/or
machine itself. Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).
• Before starting, remove any tools that were used to service the engine and/or machine. Make sure that all guards
have been refitted.
• During operation, the surface of the engine can become dangerously hot. Avoid touching the exhaust system in
particular.
• Before proceeding with any operation on the engine, stop it and allow it to cool. Never carry out any operation whilst
the engine is running.
• The coolant fluid circuit is under pressure. Never carry out any inspections until the engine has cooled and even in
this case, only open the radiator plug or expansion chamber with the utmost caution, wearing protective garments
and goggles. If there is an electric fan, do not approach the engine whilst it is still hot as the fan could also start
operating when the engine is at a standstill. Only clean the coolant system when the engine is at a standstill.
• When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to
safeguard the environment. The spongy filtering material in oil-cooled air filters must not be soaked in oil. The
reservoir of the separator pre-filter must not be filled with oil.
• The oil must be drained whilst the engine is hot (oil T ~ 80°C). Particular care is required to prevent burns. Do not
allow the oil to come into contact with the skin.
• Make sure that the drained oil, the oil filter and the oil it contains are disposed of in the correct way in order to
safeguard the environment.
• Pay attention to the temperature of the oil filter when the filter itself is replaced.
• Only check, top up and change the coolant fluid when the engine is off and cold. Take care to prevent fluids
containing nitrites from being mixed with others that do not contain these substances since "Nitrosamine",
dangerous for the health, can form. The coolant fluid is polluting and must therefore be disposed of in the correct
way to safeguard the environment.
• During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect
and insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter motor from
being energized.
• Only check belt tension when the engine is off.
• Only use the eyebolts installed by Ruggerini 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.
11
COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
IV
N.
mm
mm
cm³
Nm
g/kW.h
g/kW.h
lt
Ah -A
kg
m³/h
m³/h
kg.
N 80/1269/CEE-ISO 1585
NB ISO 3046 - 1 IFN
NA ISO 3046 - 1 ICXN
2
80
65
654
19:1
—
12(16,3)
—
11,2(15,2)
—
10,3(14)
32@2400
246
0,8
1,8
66-300
50
62
700
100(300)
25°(30°)
25°(35°)
25°(40°)
2
85
75
851
19:1
—
14(19)
—
13(17,7)
—
12(16,5)
40,5@2400
246
0,8
1,8
66-300
53
80
850
100(300)
25°(30°)
25°(35°)
25°(40°)
MD151 MD191
2
80
65
654
19:1
10(13,6)
—
9,3(12,6)
—
8,6(11,7)
—
32@2400
246
0,8
1,8
66-300
50
50
600
100(300)
25°(30°)
25°(35°)
25°(40°)
2
85
75
851
19:1
12,5(17)
—
11,4(15,5)
—
10,5(14,3)
—
40,5@2400
246
0,8
1,8
66-300
53
75
750
100(300)
25°(30°)
25°(35°)
25°(40°)
MD150 MD190
TECHNICAL DATA
* Referred to N power
** Consumption at max torque
CHARACTERISTICS
ENGINE TYPE
Number of cylinders
Bore
Stroke
Swept volume
Compression ratio
@ 3000 RPM
@ 3600 RPM
@ 3000 RPM
@ 3600 RPM
@ 3000 RPM
@ 3600 RPM
Max. torque *
Fuel consumption **
Oil consumption
Capacity of standard oil sump
Recommended battery 12V
Dry weight
Combustion air volume
Cooling air volume
Max.permissible driving shaft axial: continuous (instantaneous)
Flywheel site: continuous (instantaneous)
Max. inclination Power take off site: continuous (instantaneous)
Lateral: continuous (instantaneous)
Power kW (HP)
12 COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
V
MD150 - MD151 MD190 - MD191
CHARACTERISTICS
CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES
N (80/1269/EEC - ISO 1585) AUTOMOTIVE RATING : Intermittent operation with variable speed and variable load.
NB (ISO 3046 - 1 IFN) RATING WITH NO OWERLOAD CAPABILITY: continuos ligth duty operation with constant speed and variable load.
NA (ISO 3046 - 1 ICXN) CONTINUOS RATING WITH OVERLOAD CAPABILITY: continuos heavy duty with constant speed and constant load.
Mt-N Torque at N power.
CSpecific fuel consumption at N power.
U1: Standard utilization range of engines rated at 3000 rpm
U2: Standard utilization range of engines rated at 3600 rpm
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 100 m di altitude and by 2% every 5°C above 25°C.
Note: Consult RUGGERINI for power, torque curves and specific consumptions at rates differing from those given above.
14 COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
VII
00365R0020
00365R0010
00365R0900
00365R0890
00365R0910
00365R0930
00365R0770
00365R0940
00365R0430
Flywheel puller
Universal puller
Main bearing extractor
Gear extractor
Central bearing assembly tool
Valve guide rubber fitting tool
Cylinder collar Ø 80/85 mm
Injection advance control tool
Injector test bench
SPECIAL TOOLS
TOOL CODE DESCRIPTION
15
COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
VIII
(*)
(*)
(**)
(**)(***)
(x)
(xx)
8 50 200 300 400 2500 5000
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING
Failure to carry out the operations described in the table may lead to technical damage to the machine
and/or system
First replacement
(*) Under severe working conditions, clean daily.
(**) Under extremely dusty conditions, change every 4-5 hours.
(***) See recommended oil type.
(x) The partial overhaul includes the following operations: valve and seat lapping, injector and injection pump overhaul,
injector projection check, fuel injection spark advance check, check of the harmful area between head and piston,
camshaft and crankshaft end float check, tightening of bolts.
(xx) The general overhaul includes - in addition to all partial overhaul - the following procedures: cylinder and piston
replacement, seat, guide and valve refacing, crankshaft replacement or grinding, bench bearing and connecting rod
replacement.
To avoid explosions or fire outbreaks, do not smoke or use naked flames during the operations.
Fuel vapours are highly toxic. Only carry out the operations outdoors or in a well ventilated place.
Keep your face well away from the plug to prevent harmful vapours from being inhaled. Dispose of fuel in the
correct way and do not litter as it is highly polluting.
FUEL
When refuelling, it is advisable to use a funnel to prevent fuel from spilling out. The fuel should also be filtered to prevent dust
or dirt from entering the tank.
Use the same type of diesel fuel as used in cars. Use of other types of fuel could damage the engine. The cetane rating of
the fuel must be higher than 45 to prevent difficult starting. Do not use dirty diesel fuel or mixtures of diesel fuel and water
since this would cause serious engine faults.
The capacity of the standard tank is: lt. 4,0
The maintenance operations listed above refer to an engine operating in normal conditions (temperature, degree of humidity,
dust in the working environment). They may vary significantly according to the type of use.
INTERVAL (HOURS)
COMPONENT
OPERATION
MANUTENANCE
CLEANING
CHECK
OVERALL
INSPECTION
REPLACEMENT
OIL-BATH AIR CLEANER
HEAD AND CYLINDER FINS
INTERNAL OIL FILTER
FUEL TANK
INJECTOR
AIR CLEANER OIL
LEVEL OIL SUMP
BATTERY FLUID
VALVE/ROCKER ARM CLEARANCE
INJECTOR SETTING
AIR CLEANER
SUMP
INTERNAL OIL FILTER CARTRIDGE
EXTERNAL OIL FILTER CARTRIDGE
FUEL FILTER CARTRIDGE
DRY AIR CLEANER CARTRIDGE
PARTIAL
COMPLETE
OIL
16 COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
VIII
-
30
-
25
-
20
-
15
-
10
-
50
+
5
+
10
+
15
+
20
+
25
+
30
+
35
+
40
+
45
SAE 20W
SAE 10W
+
50
SAE 30
SAE 40
SAE 10W-30
SAE 10W-40
SAE 10W-60
SAE 15W-40 base minerale
SAE 15W-40 base semi-sintetica
SAE 20W-60 base semi-sintetica
SAE 5W-30 base sintetica
SAE 0W-30 base sintetica
SAE 5W-40 base sintetica
-
35
-
40
CCMC G- 2
CF CE CD CC CB CA SA SB SC SD SE SF SG
DIESEL BENZINA - ESSENCE - PETROL
BENZIN - GASOLINA
CCMC G- 3 G- 5
CCMC PD - 1 / PD - 2
CCMC D- 2
D- 4
CCMC D- 3
D- 5
MIL - L - 2104 D
MIL - L - 2104 E
MIL - L -46152 C
MIL - L- 46152 D/E
MB 226.1 MB 226.5
MB 227.1 MB 227.5
228.3 MB 228.1
VW 501.01
VW 500.00
SHAPI
G- 4
SJ
VOLVO VDS
MAN QC 13-017
VW 505.00
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.
The risk of piston seizure, jammed piston rings and rapid wear of the cylinder liner, the bearings and all moving
parts increases if oil whose characteristics differ from the recommended type is used, or if the oil is not regularly
changed. All this notably reduces engine life.
Oil viscosity must suit the ambient temperature in which the engine operates.
Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the
oil is inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible.
Appropriate protective gloves etc should be wore during this operation.
Old oil is highly polluting and must be disposed of in the correct way. Do not litter.
GRADERECOMMENDED OIL
AGIP SINT 2000 5W40 specification API SJ/CF ACEA A3-96 B3-
96 MIL-L-46152 D/E.
ESSO ULTRA 10W40 specification API SJ/CF ACEA A3-96 MIL-L-
46152 D/E.
In countries where AGIP and ESSO products are not available,
use API SJ/CF oil for gasoline-fuelled engines or oil that
complies with military specification MIL-L-46152 D/E.
OIL SUPPLY ( liters )
Standard oil sump
filter included 1,8 l.
ACEA SEQUENCES
A = Gasoline (Petrol)
B = Light Diesel fuels
E = Heavy Diesel fuels
Required levels :
A1-96
A2-96
A3-96
B1-96
B2-96
B3-96
E1-96
E2-96
E3-96
17
COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
IX
1
3
2
4
DISASSEMBLY OF THE ENGINE
During repair operations, when
using compressed air, wear eye
protection.
Extracting fuel injectors
Unscrew the fuel feeding pipes.
Remove the injectors using a commercial extractor tool as shown in
fig. 1.
Removing the flywheel
Use the extractor number 00365R0020 as shown in figure 2.
During the demounting phases, pay particular attention to
prevent the flywheel from dropping as this could seriously
injure the operator.
Wear protective goggles when removing the flywheel ring.
IMPORTANT: Do not tap the end of the extractor when
removing the flywheel.
Extraction of flywheel side main bearing
Withdraw the bearing using two M8 screws taking care to tighten
them evenly; alternatively use a commercial extractor, as shown in
figure 3.
Extraction of crankshaft gear
Use extractor tool number 00365R0890 (fig.4).
DISASSEMBLY AND REASSEMBLY
Besides disassembly and reassembly operations this chapter also
includes checking and setting specifications, dimensions, repair
and operating instructions. Always use original RUGGERINI spare
parts for repair operations.
18 COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
5
IX
67
8
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.
Cut a thread on the inside of the plug body and then withdraw it
using a commercial extractor tool (fig. 8).
19
COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
X
9
10
11
c mm
13,025÷13,037
a mm
6,960÷6,970
6,945÷6,955
b mm
7,00÷7,01
e mm
13÷13,01
d mm
0,8÷1,0
CHECKS AND OVERHAUL
Guide
Inlet
Exhaust assembly
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.
The heads are made off aluminium with valve guides and seats are
made of cast iron.
Do not disassemble the head when the engine is hot to
avoid deformation.
Clean heads of carbon deposits and check the cylinder mating
surfaces; if they are deformed they must be ground to a maximum
of 0.3 mm. Check that there are no cracks or other imperfections in
the heads. If defects are encountered the heads must be renewed.
In this case consult the spare parts catalogue.
Valves - Guides - Seats
Clean the valves with a wire brush and renew them if the valve
heads are deformed, cracked or worn.
Check the dimensional conformity of the valve stems (fig. 11) and
the clearance between valve and guide, bore out the guides to the
dimensions indicated in the table (fig. 10).
Renew both guide and valve if the clearance is greater than 0.1mm.
It is always necessary to grind the valve seats when new guides are
fitted.
Oversize valve guides with external diameter increased by 0.10 are
available.
20 COMPILER TECO/ATI ENDORSEDDATE
23.06.2003
REG. CODE
1-5302-602
MODEL N°
50884
DATE OF ISSUE
06-03
REVISION 00
X
12
13
14
15
d= 0,8 ÷1,0 d=1,3
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).
Final lapping of the valve on the seat must be carried out by coating
the seat with a fine lapping compound and rotating the valve in a
clockwise and counterclockwise direction with slight pressure until
a perfect surface finish is obtained (fig.14).
Observe the valve seating clearances indicated in the following
table (fig.10).
Fitting mm Max. wear mm
In the case of lower values the valve may strike the piston.
In the case of values in excess of 1.3 mm the valve seat
rings must be replaced.
Fitting of new seats or valves always requires preparatory grinding.
Valves are available with the external diameter increased by
0.5 mm.
After grinding wash the valve and seat carefully with petrol or
paraffin in order to remove residual grinding paste and chips. Once
you have finished grinding check the efficiency of the seal between
the valve and seat as outlined below:
1.Fit the valve on the head with spring, washers and split cones
(fig.9).
2.Invert the head and pour in a few drops of diesel fuel or oil
around the edges of the valve head.
3.Blow compressed air into the inlet of the cylinder head taking
care to seal the edges so that the air does not escape (fig.15).
Should air bubbles form between the seat and the valve remove the
valve and regrind the seat.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
-
21
-
22
-
23
-
24
-
25
-
26
-
27
-
28
-
29
-
30
-
31
-
32
-
33
-
34
-
35
-
36
-
37
-
38
-
39
-
40
-
41
-
42
-
43
-
44
Ask a question and I''ll find the answer in the document
Finding information in a document is now easier with AI
Other documents
-
Kohler KD15-441 User manual
-
V-TUF SE130PST Pipe System Tester User manual
-
-
Secure 425 Tiara User manual
-
Motorline MD150 User manual
-
INTEREQUIP BulletPro Elite X6-X8 Fuel Injector Cleaner User manual
-
LOMBARDINI LGA 340 OHC Workshop Manual
-
-
-
Miller KB067430 Owner's manual