Ruggerini MD/3 Series Workshop Manual Download Page 14 | Manualshive

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Ruggerini MD/3 Series Workshop Manual Download Page 14

14

COMPILER TECO/ATI

ENDORSED

DATE

14.07.2003

REG. CODE

1-5302-612

MODEL N°

50894

DATE OF ISSUE

07-03

REVISION

00

VII

00365R0010

00366R0060

00365R0880

00365R0910

00365R0930

00365R0770

00365R0940

00365R0430

Universal puller

Main bearing extractor

By-pass valve 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

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12
13
14
15
16
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Summary of Contents for MD/3 Series

Page 1: ...1 COMPILERTECO ATI ENDORSED DATE 14 07 2003 REG CODE 1 5302 612 MODEL N 50894 DATE OF ISSUE 07 03 REVISION 00 MD350 MD351 MD358 1st Edition WORK SHOP MANUAL MD 3 series engines p no 1 5302 612...

Page 2: ...ines 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 Ruggerin...

Page 3: ...ire 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 par...

Page 4: ...____________ 15 16 IX DISASSEMBLY OF THE ENGINE ___________________________________________________ 17 Extracting crankcase bushes 18 Extracting fuel injectors 17 Extracting the oil pressure indicator...

Page 5: ...____________________________________________________ Page 30 Checking electrical equipment 30 Checking the alternator 30 Plant specifications 30 XIII ENGINEASSEMBLY ___________________________________...

Page 6: ...pressure 39 Dyno testing of engine 39 Speed adjustment 39 XV STORAGE ___________________________________________________________________ Page 41 How to prepare the engine for operation 41 Permanent pr...

Page 7: ...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 pis...

Page 8: ...ous danger for his personal safety and health and that of any persons who may be in the vicinity of the machine Theenginemayonlybeusedorassembledonamachinebytechnicianswhoareadequatelytrainedaboutitso...

Page 9: ...ever 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 ra...

Page 10: ...07 2003 REG CODE 1 5302 612 MODEL N 50894 DATE OF ISSUE 07 03 REVISION 00 III MODEL NUMBER AND IDENTIFICATION ENGINE IDENTIFICATION Engine Serial Number Approval code Customer s code R P M setting R P...

Page 11: ...8 3 85 92 1566 18 1 14 19 12 5 17 92 1450 235 0 8 4 3 70 350 147 83 950 650 300 25 45 25 35 25 40 TECHNICAL DATA CHARACTERISTICS ENGINE TYPE Number of cylinders Bore Stroke Swept volume Compression ra...

Page 12: ...INUOS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and constant load Mt N Torque at N power C Specific fuel consumption at N power U1 Standard utilization range of engines...

Page 13: ...13 COMPILERTECO ATI ENDORSED DATE 14 07 2003 REG CODE 1 5302 612 MODEL N 50894 DATE OF ISSUE 07 03 REVISION 00 VI OVERALL DIMENSIONS Note Dimensions in mm...

Page 14: ...0365R0010 00366R0060 00365R0880 00365R0910 00365R0930 00365R0770 00365R0940 00365R0430 Universalpuller Mainbearingextractor By passvalveextractor Central bearing assembly tool Valve guide rubber fitti...

Page 15: ...edures 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...

Page 16: ...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...

Page 17: ...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 Remo...

Page 18: ...removed manually as shown in figure 5 Extraction of the camshaft gear Use the extractor code 00365R0010 fig 6 Extracting crankcase bushes From crankcase fig 7 From main bearing fig 8 Use extractor cod...

Page 19: ...ion Clean heads of carbon deposits and check the cylinder mating surfaces if the are deformed they must be ground to a maximum of 0 3mm Check that there are no cracks or other imperfections in the hea...

Page 20: ...following table d fig 11 Fitting mm Max wearmm In the case of lower values the valve may strike the piston In the case of values in excess of 1 3mm the valve seat rings must be replaced Fitting of new...

Page 21: ...ght surface scores on the cylinder it will be sufficient to change the piston rings Do not manually hone the cylinder bore surfaces with emery cloth or other means The cross hatch pattern should be at...

Page 22: ...ing the piston Piston diameter check The diameter of the piston must be measured at approximately 18 mm from the base fig 23 Check the clearance between cylinder and piston if it is greater than 0 120...

Page 23: ...the necessary sizes without requiring any adjustment by boring Dimensions Crankshaft Whenever the engine is dismantled particularly for the replacement of cylinders and pistons due to wear caused by...

Page 24: ...ain bearings are of different external diameters fig 30 and are machined with a bevelled edge to assist their insertion into the crankcase Check the dimensions of the shells and renew them if they are...

Page 25: ...should be The push rods must be straight and with the spherical surfaces at either end in good condition fig 33 Make sure that the lubrication holes inside the tappets and push rods are free of dirt...

Page 26: ...or N Supplement H Spring Fitting mm Max wearmm Fitting mm Max wearmm CHECKS AND OVERHAUL The clearance between the external rotor of the oil pump and the cover facing surface must be End float of roto...

Page 27: ...or BOSCH pump type PF30 Checking injection pumps Before dismantling the injection pumps check for pressure leak of the pumping unit plunger and valve as follows 1 Connect a pressure gauge with 600 Kg...

Page 28: ...n the delivery connection 3 Insert plunger with helical profile A fig 44 on the opposite side of the sleeve pin B fig 44 into the internal groove of the control sleeve make sure the helical profile is...

Page 29: ...20 Kg cm below the opening pressure of the needle valve The nozzle can be considered well sealed if there no Diesel fuel accumulates at the nozzle tip after 10 seconds Disassembly and re assembly of...

Page 30: ...g that resistance is zero and the insulation between the windings and ground fig 54 by ensuring that the ohmmeter gives a reading of infinite resistance If these readings are not obtained the stator m...

Page 31: ...m damage Complete the external assembly with plate spring lever etc as shown in figure 56 3 Mount the timing system side bearing bush using either a standard press or a made to measure punch as shown...

Page 32: ...if you wish to check the rotors Fit the external oil pump rotor with the bevel toward the inside of the cover fig 63 Mount the pump to the crankcase ensuring that the locating pin is correctly seated...

Page 33: ...s flywheel side Fit the bush to the bearing using a normal punch of appropriate diameter as shown in figure 69 Insert the bush arranging the groove so that it is aligned with the seat on the bearing s...

Page 34: ...s match those on the camshaft gear fig 72 the pulley and the washer and then tighten the nut securing the pulley Use a feeler gauge to check the clearance between the clearance adjustment ring and the...

Page 35: ...20 with the end gap of the first compression ring aligned with the axis of the gudgeon pin The lower face of the cylinders are chamfered to permit the easy insertion of the piston rings The operation...

Page 36: ...a cross pattern tighten the head nuts in increments of 1 kgm until you reach the value This value is adjusted by inserting copper washers between the injectors and the injector supporting faces on th...

Page 37: ...fig 85 to a position mid way between minimum and maximum 4 Fit the special tool p n 00365R0940 to the delivery valve holder timing case side as shown in figure 86 5 Turn the flywheel slowly until the...

Page 38: ...not changed see pag 27 4 With the fuel feed pump cam in the rest position mount the pump and actuate it manually fig 92 Electric shut off If the engine is equipped with an electric shut off insert the...

Page 39: ...Checking for oil leaks 1 Remove the exhaust gas collection pipe from the inlet manifold and close the connection with a plug fig 96 2 Start the engine and let it run for a few minutes The high pressur...

Page 40: ...0 ENGINE TESTING Running in table Load Time min RPM In order to check that the setting is correct without tools accelerate the engine a few times with no load and check the exhaust fumes Delivery of d...

Page 41: ...jectors 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...

Page 42: ...mm 0 25 0 5 0 15 1 3 2 25 0 20 Couplings Camshaft and central bearings Camshaft and flywheel side bearing End gap of compression rings End gap of oil scraper rings Connecting rod and wrist pin Rocker...

Page 43: ...30 35 40 44 40 61 80 74 90 96 00 Nm 6 11 9 20 4 33 50 64 2 88 7 150 228 347 435 605 734 940 R 800 N mm2 R 1000 N mm2 R 1200 N mm2 Nm 3 6 7 12 19 8 29 6 38 52 5 89 135 205 257 358 435 557 kgm 0 37 0 72...

Page 44: ...r n importe quel moment les donn es report es dans cette publication Data reported in this issue can be modified at any time by Lombardini Lombardini vorbeh lt alle Rechte diese Angabe jederzeit ver n...

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