Ruggerini Ry100, Repair Manual

Page 1: ...Repair Manual for Diesel engines series RY cod 00497R0990 ...

Page 2: ......

Page 3: ... wooden mallet in order to split the assemblies To facilitate the re assembly operations mark any parts without reference points Separate the various components into distinct groups retighten the nuts and bolts of each assembly Wash each component with Diesel fuel or petroleum before proceeding with the dimensional inspections During the assembly operations thoroughly clean all parts spread lubric...

Page 4: ...4 0 00497R0990 15 07 2000 DI ESEL ...

Page 5: ...3600 Compression ratio 19 5 1 19 5 1 18 5 1 18 5 1 18 5 1 18 5 1 PTO spinning direction anti clockwise Maximum torque Nm rpm 19 2200 19 2200 22 2200 22 2200 27 2200 27 2200 Governor rpm error margin 5 5 5 5 5 5 Recommended battery Ah Amp 60 300 60 300 60 300 60 300 60 300 60 300 Max intake vacuum KPa 4 5 5 5 5 5 5 5 6 Max exhaust back pressure KPa 6 5 7 3 7 7 8 7 5 8 4 Quantity of air for combusti...

Page 6: ...e and 1 for every 100 meters of increased altitude 2000 2400 3600 2 4 6 NA NB N CV kW rpm g min U2 U1 g CV h 185 205 1 9 2 Kg m Mt N 1600 C N 2800 3200 1 3 5 7 8 9 10 1 2 3 4 5 6 7 8 1 8 1 7 260 280 240 g kW h N m 20 19 18 17 260 280 240 g kW h N m 23 22 21 20 2 2 1 8 7 6 5 4 3 2 1 10 9 8 7 5 3 1 3200 2800 C N 1600 Mt N Kg m 2 3 2 2 205 185 g CV h 1 U 2 U g min rpm kW CV HP N NB NA 6 4 2 3600 2400...

Page 7: ...7 0 service 00497R0990 15 07 2000 3 OVERALL DIMENSIONS ...

Page 8: ...eries engines Tool to mount and demount main bearings also used for MD series engines Plug to mount and demount main bearings Sleeve to insert main bearings Injector test bench Punch to insert By pass valve Tool to stagger injection lead Piston mounting tool 366 23 366 22 365 90 365 02 365 77 365 10 366 21 365 43 366 24 Capillary tube for injection lead 365 94 ...

Page 9: ...tions with detergent degree S 3 MIL L 45199B type AGIP SUPERDIESEL MULTIGRADE 15W 40 use SAE 5W 30 oil if the engine operates in places where the temperature is below First oil change The maintenance operations refer to engines that operate in normal environmental conditions temperature degree of humidity degree of dust in the environment and can sensiblyvary dependingonthetypeofuse theairfilteroi...

Page 10: ... Clearance insufficient Clearance excessive Timing system gears defective Head and cylinder fins clogged Valve guides worn Piston seized Cylinder worn Excessive rocker arm play Regulator spring defective Pipe clogged Incorrect injection lead Injection pump defective Injection pump valve defective Intake valve without play Injector defective Injector with clogged holes Oil splash guard seals defect...

Page 11: ...WARNING do not strike the puller in an axial direction during this operation 4 1 2 3 8 DEMOUNTING THE ENGINE 8 1 Removing the injector Slacken off the fuel delivery pipe remove the fixing bracket and take out the tube Remove the injector by levering it out with a screwdriver as indicated in fig 2 8 2 Removing the injection pump Markthepositionoftheinjectionpumpinrelationtotheengine casing if this ...

Page 12: ...assembly Cover on timing system side Cover on timing system side Cover on timing system side Cover on timing system side Cover on timing system side The main bearing must project 1 7 to 2 mm 1 7 to 2 mm 1 7 to 2 mm 1 7 to 2 mm 1 7 to 2 mm in relation to the bearing surface of the bull ring inner side of cover Engine casing Engine casing Engine casing Engine casing Engine casing The main bearing mu...

Page 13: ... at 45 Fig 12 The valve retention track will widen when the valve housing is machined Finaladaptationofthevalveinthehousingmustbe carried out by smearing fine grain lapping compound in the housing and turning the valve with a light pressure and with an alternate movement until the surfaces bed perfectly fig 13 Comply with the valve embedding values as indicated in the table G fig 10 Warning Warnin...

Page 14: ...ew valves or housings are mounted Valve housings oversized on the outside by 0 5 mm are available Thoroughly wash the valve and housing with petroleum or gasoline to eliminate lapping paste residues or swarf Proceed in the following way to make sure that the valve and seat are tight 1 Mount the valve on the head with cap string and cotters see fig 9 2 Overturn the head and pour a few drops of dies...

Page 15: ...2 0 02 0 02 0 02 0 02 0 02 0 02 0 02 0 02 0 02 0 02 0 02 0 0 0 0 0 0 02 0 02 0 02 0 02 0 02 0 0 0 0 0 9 7 Connecting rod Coupling between the small end hole of the connecting rod and pin is made without a bearing Play between connecting rod small end and pin mm Check connecting rod axes parallelism in the following way 1 Insert the pin into the small end hole of the connecting rod and a calibrated...

Page 16: ...out mm should not be carried out mm should not be carried out mm should not be carried out Illustration in fig 24 1 Internal intake oil filter in casing 2 Oil pump 3 By pass valve 4 Engine oil filter 5 Pressure switch 6 Main bearing 7 Big end bearing 9 10 Lubrication circuit Lubrication of the main bearings and connecting rod big end is the forced type with a rotor oil pump Excessive pressure in t...

Page 17: ... 215 0 345 Make sure that the oil pump recess in relation to the surface of the timing system cover fig 26 is between Assembly mm Assembly mm Assembly mm Assembly mm Assembly mm Wear limit mm Wear limit mm Wear limit mm Wear limit mm Wear limit mm 0 03 to 0 07 0 11 Make sure that there are no impurities in the by pass valve on the cover on the timing system side by unscrewing the inspection plug n...

Page 18: ...mp 6 Injection pump tappet 7 Bleed tubes 8 Injection pipe 9 Injector 10 Washer 11 Fuel return pipe 32 31 29 30 198 8 198 8 198 8 198 8 198 8 to 199 2 199 2 199 2 199 2 199 2 Ø7 986 Ø7 986 Ø7 986 Ø7 986 Ø7 986 to 7 995 7 995 7 995 7 995 7 995 Ø18 9 Ø18 9 Ø18 9 Ø18 9 Ø18 9 to 19 19 19 19 19 4 45 4 45 4 45 4 45 4 45 to 4 55 4 55 4 55 4 55 4 55 2 2 2 2 2 216 8 216 8 216 8 216 8 216 8 to 217 2 217 2 21...

Page 19: ...ressive pressure increase until reaching a maximum value after which it will drop sharply back and stop at a lower pressurevalue Replacethevalveifthepressuredropismore that 50 Kg cm 50 Kg cm 50 Kg cm 50 Kg cm 50 Kg cm and continues to slowly drop lower The pressure must drop from 200 Kg cm 200 Kg cm 200 Kg cm 200 Kg cm 200 Kg cm to 150 Kg cm 150 Kg cm 150 Kg cm 150 Kg cm 150 Kg cm in not less than...

Page 20: ... 2 9 9 9 9 9 7 7 7 7 7 5 5 5 5 5 3 3 3 3 3 4 4 4 4 4 6 6 6 6 6 8 8 8 8 8 1 0 1 0 1 0 1 0 1 0 6 Kg cm air G G G G G F F F F F E E E E E B B B B B C C C C C A A A A A H H H H H L L L L L I II II M M M M M O O O O O P P P P P N N N N N 2 Mount the injector on the test bench code 365 43 fig 41 Disconnect the pressure gauge and rapidly operate the lever The nozzle must make the characteristic trilling ...

Page 21: ...nternal alternator Internal alternator Internal alternator Internal alternator Internal alternator 12V 280W Voltage regulator Voltage regulator Voltage regulator Voltage regulator Voltage regulator electronic with controlled diodes and indicator connection for battery recharger Recommended battery Recommended battery Recommended battery Recommended battery Recommended battery 12V 60Ah 300A Optiona...

Page 22: ...or and replace the voltage regulator if necessary 11 3 Checking the alternator With the engine at a standstill disconnect the alternator wires from the regulator and check 1 using an ohmmeter that the windings fig 46 null resistance and the insulation between wires and ground fig 47 infinite resistance are unbroken Replace the stator if interruptions are discovered 2 with a voltmeter the voltage b...

Page 23: ...plate or lapping stone then proceed in the following way 1 Fit on the oil drain plugs without tightening them too much max 2 Kgm to prevent damage to the threads 2 Mountthemainbearingasindicatedinsection8 6onpage 12 3 Fit the benzing ring on to the pin of the regulator levers fig 49 A apply Loctite 648 to the zone where the pin touches the engine casing Insert the stop lever fig 49 B the accelerat...

Page 24: ...y pass valve inspection plug on the outside of the cover on the timing system side 5 Fit the retainer cap on the oil intake duct at the base of the cover on the timing system side using Loctite 648 fig 54 B 6 Tighten the internal oil filter fig 54 C 7 Fit on the engine oil filter and relative plug including the O Ring fig 54 D 8 Mounttherpmgovernor incompliancewiththealphabetical sequence given in...

Page 25: ... the connecting rod cap with the reference numbers matching those on the rod WARNING for series RY120 and RY121 engines mount the connecting rod half bearing with the positioning mark on the cap and that without positioning mark in the center of the rod in compliance with the dimensions indicated in fig 59 Evenly tighten the connecting rod bolts to the following value 3 8 3 8 3 8 3 8 3 8 to to to ...

Page 26: ... check the distance between the bearing ring and bar fig 63 Note down the value measured The sum of the two measured values must be within 0 10 to 0 30 mm 0 10 to 0 30 mm 0 10 to 0 30 mm 0 10 to 0 30 mm 0 10 to 0 30 mm Camshaft float Camshaft float Camshaft float Camshaft float Camshaft float Place a calibrated bar on the casing on a level with the timing system retention cover and use a thickness...

Page 27: ...fig 68 and torque the nut to value 2 7 to 2 8 Kgm 26 5 to 27 5 Nm 2 7 to 2 8 Kgm 26 5 to 27 5 Nm 2 7 to 2 8 Kgm 26 5 to 27 5 Nm 2 7 to 2 8 Kgm 26 5 to 27 5 Nm 2 7 to 2 8 Kgm 26 5 to 27 5 Nm 18 to 20 Kgm 176 5 to 1961 Nm 18 to 20 Kgm 176 5 to 1961 Nm 18 to 20 Kgm 176 5 to 1961 Nm 18 to 20 Kgm 176 5 to 1961 Nm 18 to 20 Kgm 176 5 to 1961 Nm Counter shaft float optional Counter shaft float optional Co...

Page 28: ...rmal ring mounting tool code 365 77 365 77 365 77 365 77 365 77 as indicated in fig 71 Piston projection mm Piston projection mm Piston projection mm Piston projection mm Piston projection mm Seal thickness mm Seal thickness mm Seal thickness mm Seal thickness mm Seal thickness mm 0 00 to 0 10 0 10 to 0 20 0 20 to 0 30 0 30 to 0 40 0 8 0 9 1 0 1 1 NOTE The distance between piston crown and the cor...

Page 29: ...6 and the reference mark of the tool code 366 24 366 24 366 24 366 24 366 24 match when the piston is at top dead center 12 16 Valve play Adjusttheplaybetweenvalvesandrockerarmsineitherahot hot hot hot hot or cold condition or cold condition or cold condition or cold condition or cold condition to the following values fig 75 76 75 73 74 Lead values in degrees and millimeters on the flywheel The pu...

Page 30: ...the injection pipe Warning Warning Warning Warning Warning always use two wrenches to slacken off or tighten injection pipes fig 79 Time min Time min Time min Time min Time min 5 15 30 30 30 5 Load Load Load Load Load 0 0 30 50 70 100 Rpm Rpm Rpm Rpm Rpm 2000 3000 3600 3000 3600 3000 3600 3000 3600 3000 3600 Running in table Running in table Running in table Running in table Running in table Consu...

Page 31: ...iodically inspect the engine and make sure that there are no traces of rust or corrosion 14 3 Setting at work remove the protective covers remove the external protective coating with solvent or degreaser check the injector settings the valve play Make sure that the heads and filters are well tightened proceed with the normal preliminary inspections prior to starting if the engine has been filled w...

Page 32: ...appets and housing 0 021 0 059 0 1 Tappets and housing 0 005 0 029 0 1 Pin and piston 0 003 0 013 0 04 Intake guide and valve 0 030 0 050 0 1 15 2 Adjustments MIN mm MAX mm Camshaft float 0 1 0 25 Countershaft float 0 1 0 25 Crankshaft float 0 1 0 3 Connecting rod float 0 3 0 5 Connecting rod radial play 0 019 0 046 Regulator pin float 0 2 0 3 Valve play when hot cold 0 15 0 20 0 15 0 20 Valve rec...

Page 33: ... 1 50 5 36 52 6 7 54 73 9 9 05 88 7 13 x 1 75 9 09 89 1 12 80 125 5 15 30 150 0 14 x 2 00 13 80 135 3 19 40 190 2 23 30 228 5 16 x 2 00 21 00 205 9 29 50 289 3 35 40 347 1 18 x 2 50 26 30 257 9 37 00 362 8 44 40 435 4 20 x 2 50 36 60 358 9 51 50 505 0 61 80 606 0 22 x 2 50 44 40 435 4 62 40 611 9 74 90 734 5 24 x 3 00 56 90 558 0 80 00 784 5 96 00 941 4 8 8 8 8 8 8 8 8 8 8 R10 10 9 R10 10 9 R10 10...

Page 34: ...10 5 Injection pump assembly 19 0 10 6 Leak test 20 0 10 7 Injector 20 0 10 8 Injector inspection and calibration 20 0 10 9 Injector demounting and remounting 21 0 11 ELECTRICAL EQUIPMENT 21 0 11 1 Characteristics of the system 21 0 11 2 Checking the system 22 0 11 3 Checking the alternator 22 0 11 4 Ring gear 22 0 12 ENGINE ASSEMBLY 23 0 12 1 Preparing the engine block 23 0 12 2 Injection pump ta...

Page 35: ...4 code 365 94 code 365 94 code 365 94 on the injection pump delivery fitting fig 3 9 Turn the accelerator lever to the MAX position and the stop lever to about half travel 10 Turn the drive shaft anti clockwise by no more than 1 4 of the pipe wrench turn 11 Pressurize the circuit by turning the drive shaft several times in an alternate clockwise anti clockwise way until fuel splashes out of the ca...

Page 36: ... il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione Ruggerini se rèserve le droit de modifier à n importe quel moment les données reportées dans cette publication Data reported in this issue can be modified at any time by Ruggerini Ruggerini vorbehält alle Rechte diese Angabe jederzeit verändern La Ruggerini se reserva el derecho de modificar sin previo aviso lo...