Ruggerini SERIES RY Istruzioni operative

Repair Manual

for Diesel engines series

cod. 00497R0990

Ruggerini

FOREWORD

This instruction manual includes all the technical information needed to

make any of the repairs required for the engines in question.

It is very important to strictly comply with all the instructions given to

ensure that the repair work is carried out as quickly and safely as

possible.

WORKSHOP REGULATIONS

- Always use the right tools for the repairs. Use of makeshift equipment

could damage the engine components

- Lightly tap solidly joined parts with a plastic or 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

lubricating oil on the mobile engine components and replace pins,

retention rings, seals, washers and self-locking nuts.

WARNING

Only use GENUINE RUGGERINI SPARESGENUINE RUGGERINI SPARES

GENUINE RUGGERINI SPARESGENUINE RUGGERINI SPARES

GENUINE RUGGERINI SPARES to ensure a good result..

motori

4.0

00497R0990 - 15-07-2000

DIESEL

5.0

service

00497R0990 - 15-07-2000

SERIES RY DIESEL ENGINES

1. TECHNICAL SPECIFICATIONS

DIESEL

MODELMODEL

MODEL Ry85.0Ry85.0

Ry85.0Ry85.0

Ry85.0 Ry85.1Ry85.1

Ry85.1Ry85.1

Ry85.1 Ry100Ry100

Ry100Ry100

Ry100 Ry101Ry101

Ry101Ry101

Ry101 Ry120Ry120

Ry120Ry120

Ry120 Ry121Ry121

Ry121Ry121

Ry121

Cycle 4-stroke Diesel

Injection direct

Cooling forced air with fan flywheel

Lubrication forced with vane pump

Governor centrifugal with weights

Number of cylinders 1

Swept volume

cc.

382 382 431 431 505 505

Bore

80 80 85 85 87 87

Stroke

76 76 76 76 85 85

Rpm 3000 3600 3000 3600 3000 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 combustion

m³/h

31 37 35 42 41 49

Dry weight

45 45 46.5 46.5 48 48

Maximum non-continua-

PTO side

45°°

°°

°(35°°

°°

°)45

°°

°(35°°

°°

°)45

°°

°(35°°

°°

°)45

°°

°(35°°

°°

°)45

°°

°(35°°

°°

°)45

°°

°(35°°

°°

°)

tive slant

Pulley side

35°°

°°

°(30°°

°°

°)35

°°

°(30°°

°°

°)35

°°

°(30°°

°°

°)35

°°

°(30°°

°°

°)35

°°

°(30°°

°°

°)35

°°

°(30°°

°°

°)

(continuative)

Right side

40°°

°°

°(30°°

°°

°)40

°°

°(30°°

°°

°)40

°°

°(30°°

°°

°)40

°°

°(30°°

°°

°)40

°°

°(30°°

°°

°)40

°°

°(30°°

°°

°)

Lato sinistro

45°°

°°

°(30°°

°°

°)45

°°

°(30°°

°°

°)45

°°

°(30°°

°°

°)45

°°

°(30°°

°°

°)45

°°

°(30°°

°°

°)45

°°

°(30°°

°°

°)

Casing oil capacity

1.3

Diesel fuel tank capacity

Max axial load on drive

shaft (non continuative)

300

6.0

00497R0990 - 15-07-2000

DIESEL

2. POWER GRAPHS

N:N:

N: Power for automotive service (DIN 70020)

NB:NB:

NB: Non-overloadable power (DIN 6271)

NA:NA:

NA: Continuative overloadable power (DIN 6271)

U1:U1:

U1: Normal field of use, 3,000 rpm engine rate

U2:U2:

U2: Normal field of use, 3,600 rpm engine rate

Mt-N:Mt-N:

Mt-N: Torque rate corresponding to curve N

C-N:C-N:

C-N: Specific consumption with reference to curve N

With ambient temperatures exceeding 20°C (+68°F) or altitudes above sea level, the engine sustains a 2% power loss for every

5°C temperature increase and 1% for every 100 meters of increased altitude.

2000 2400 3600

CVkW

rpmg/min

g/CV-h

185

205

1.9

Kg m

Mt-N

1600

C-N

2800 3200

1.8

1.7

260

280

240

g/kW-h

N m

260

280

240

g/kW-h

N m

2.1

32002800

C-N

1600

Mt-N

Kg m

2.3

2.2

205

185

g/CV-h

g/min rpm

kW CV-HP

3600

2400

2000

250

270

230

g/kW-h

N m

2.4

2.5

320028001600

Kg m

2.7

2.6

195

175

g/CV-h

g/min rpm

kW CV-HP

360024002000

Mt-N

C-N

2.8

RY85.0 - RY85.1RY85.0 - RY85.1

RY85.0 - RY85.1 RY100 - RY101RY100 - RY101

RY100 - RY101RY100 - RY101

RY100 - RY101

RY120 - RY121RY120 - RY121

RY120 - RY121

7.0

service

00497R0990 - 15-07-2000

3. OVERALL DIMENSIONS

8.0

00497R0990 - 15-07-2000

DIESEL

4. SPECIAL TOOLS

TOOL CODE DESCRIPTION

Crankshaft gear puller

(also used for series RD engines)

Flywheel puller

(also used for RD series 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

9.0

service

00497R0990 - 15-07-2000

Air filter oil level (for engines with wet air filters)

Engine block oil level

Battery fluid level

Rocker arm valve play

Injector calibration

A ir filter

Cylinder and head fins

Fuel tank

Internal oil filter

Injectors

Air filter oil (for engines with wet oil filters) [*]

Engine block oil [*]

Air filter cartridge

Fuel filter

Dry air filter

General overhaul

5. MAINTENANCE SCHEDULE

CHECKING

[*] Use oil for Diesel engines according to MIL-L-2104D specifications 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(theairfilteroilmustbechangedevery4-5hours

in dusty places).

Overhauls include : grinding the valve housings and guides, overhauling the injector and

injection pump, inspection of the injector protrusion, cylinder and piston replacement,

replacement of the main bearings.

REPLACEMENT CLEANING

25002500

2500

500500

500

200200

200

100100

100

5050

OPERATION

10.0

00497R0990 - 15-07-2000

DIESEL

6. TROUBLESHOOTING TABLE

PROBABLE CAUSE

Fails to start

Starts and stops

Poor efficiency

Blocked

Noisy

Blue smoke

White smoke

Black smoke

Knocks cas.zone

Spark pings

Hunts

Consumes oil

Oil lev. inc.

Disch. oil/exhaust

Disch. oil/air fil.

Heats

Misfires

Does not accel.

DEFECT

Air filter clogged ●

●●

●

Con rod small end with excessive play ●

●●

●

Engine running in ●

●●

●

Unsuitable fuel ●

●●

●

Air intaken by injection pump ●

●●

●

Fuel filter clogged ●

●●

●

Fuel tank empty ●

●●

●

Worn main bearing ●

●●

●

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 defective ●

●●

●

Exhaust valve burnt out ●

●●

●

Worn main or big-end bearing ●

●●

●

Excessive load ●

●●

●

Regulator lever with too much play ●

●●

●

Tank plug hole blocked ●

●●

●

Too much oil in casing ●

●●

●

Hardened injection pump lever ●

●●

●

Worn piston rings ●

●●

●

Slack pump delivery union ●

●●

●

Engine cold ●

●●

●

Low idling rate ●

●●

●

Change rate insufficient ●

●●

●

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