Related Manuals for Ruggerini MD/3 Series
Summary of Contents for Ruggerini MD/3 Series
- Page 1 WORK SHOP MANUAL MD/3 series engines, p.no. 1-5302-612 MD350 MD351 MD358 Edition COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-612 50894 07-03 14.07.2003...
- Page 2 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.
- Page 3 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.
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Page 4: Table Of Contents
INDEX This manual contains pertinent information regarding the repair of RUGGERINI air-cooled, indirect injection Diesel engines type MD350 - MD351 - MD358: updated July 14, 2003. TROUBLE SHOOTING __________________________________________________________ Page SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS ____________________________ " MODEL NUMBER AND IDENTIFICATION _____________________________________________ "... - Page 5 INDEX INJECTION EQUIPMENT ________________________________________________________ Page 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 ....................................
- Page 6 INDEX ENGINE TESTING _____________________________________________________________ Page Checking for oil leaks ..............................39 Checking oil pressure ..............................39 Dyno testing of engine ..............................39 Speed adjustment ................................39 STORAGE ___________________________________________________________________ Page How to prepare the engine for operation ......................... 41 Permanent protection (over 6 months) ..........................41 Storage .....................................
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Page 7: Trouble Shooting
TROUBLE SHOOTING 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. TROUBLE POSSIBLE CAUSE Clogged pipes Clogged fuel filter Air inside fuel circuit Clogged tank breather hole Faulty fuel pump... -
Page 8: Safety And Warning Decals - Safety Instructions
SAFETY INSTRUCTIONS • 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. - Page 9 • 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.
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Page 10: Model Number And Identification
MODEL NUMBER AND IDENTIFICATION MODEL NUMBER ENGINE IDENTIFICATION Model Engine Serial Number Approval code Customer's code R.P.M. setting R.P.M. Displacement (cc) COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-612 50894 07-03 14.07.2003... -
Page 11: Technical Data
TECHNICAL DATA CHARACTERISTICS ENGINE TYPE MD350 MD351 MD358 Number of cylinders Bore Stroke Swept volume cm³ 1566 1566 1566 Compression ratio 18:1 18:1 18:1 @ 3000 RPM 26(35,4) — — N 80/1269/CEE-ISO 1585 @ 3600 RPM — 28(38) — @ 3000 RPM 23,5(32) —... -
Page 12: Vcharacteristics
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. COMPILER TECO/ATI REG. -
Page 13: Overall Dimensions
OVERALL DIMENSIONS Note: Dimensions in mm COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-612 50894 07-03 14.07.2003... -
Page 14: Special Tools
SPECIAL TOOLS TOOL CODE DESCRIPTION 00365R0010 Universal puller 00366R0060 Main bearing extractor 00365R0880 By-pass valve extractor 00365R0910 Central bearing assembly tool 00365R0930 Valve guide rubber fitting tool 00365R0770 Cylinder collar Ø 80/85 mm 00365R0940 Injection advance control tool 00365R0430 Injector test bench COMPILER TECO/ATI REG. - Page 15 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING VIII Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system MANUTENANCE INTERVAL (HOURS) OPERATION COMPONENT 500 2500 5000 OIL-BATH AIR CLEANER HEAD AND CYLINDER FINS CLEANING FUEL TANK INJECTOR...
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Page 16: Maintenance - Recommended Oil Type - Refilling
VIII 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. -
Page 17: Disassembly Of The Engine
Besides disassembly and reassembly operations this chapter also During repair operations, when includes checking and setting specifications, dimensions, repair using compressed air, wear eye and operating instructions. Always use original RUGGERINI spare protection. parts for repair operations. Extracting fuel injectors Unscrew the fuel feeding pipes. -
Page 18: Extracting Crankcase Bushes
DISASSEMBLY OF THE ENGINE Extraction of crankshaft gear The gear can be 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 code 00366R0060 Extracting the oil pressure indicator plug Remove the oil filter and extract the by-pass valve using the extractor... -
Page 19: Cylinders Heads
CHECKS AND OVERHAUL Cylinders heads Parts shown in figure 10. 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. -
Page 20: Xchecks And Overhaul
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 thus necessary to remove the hardened surface with a 45° cutter (fig. 13). Grinding of valve seats causes a widening of the valve seat face P (fig. -
Page 21: Cylinders
CHECKS AND OVERHAUL Valves and springs In order to check the springs for possible failure measure the lengths under load as shown in figure 17. The permissible tolerance for loads and lengths is ± 10%. If the figures measured do not fall within these values, the springs must be renewed. -
Page 22: Connecting Rods
CHECKS AND OVERHAUL Piston rings - Pistons - Piston pins Check the wear of piston rings by fitting them into the cylinder through the lower end and measuring the end gap (fig.21). The values should be: Fitting mm Max. wear mm Piston ring Compression 0,30... -
Page 23: Crankshaft
CHECKS AND OVERHAUL 2. Position the calibrated pin on two prisms arranged on a check surface. 3. Use a dial gauge to check that the discrepancy between readings at the ends of the calibrated pin is no more than 0.05 mm;... -
Page 24: Camshaft
CHECKS AND OVERHAUL During grinding take care not to remove the shim adjustment material from the main journal thrust face to avoid changing the crankshaft end float; also ensure that the grinding wheel radii are as specified in figure 29 so as not to create crack initiation sections on the crankshaft. -
Page 25: Fuel Pump Push-Rod
CHECKS AND OVERHAUL Tappets and push rods Make sure that the tappet surfaces (fig.33) are free from wear and present no signs of scoring or seizure, otherwise, renew. Assembly clearance between tappets and their housings should Fitting mm Max. wear mm 0,10 0,014 ÷... -
Page 26: Governor Lever And Spring
CHECKS AND OVERHAUL The clearance between the external rotor of the oil pump and the cover facing surface must be: Fitting mm Max. wear mm 0,60 0,27 ÷ 0,47 End float of rotors (fig.37): Fitting mm Max. wear mm 0,01 ÷... -
Page 27: Injection Equipment
INJECTION EQUIPMENT Fuel circuit Fuel feeding can be either gravity type or forced, with a mechanical double diaphragm pump operated a cam located on the camshaft. Fuel is filtered by a filter in the fuel tank or through an external filter cartridge. -
Page 28: Assembly Of Injection Pumps
INJECTION EQUIPMENT The difference between the deliveries of the two pumps when locked must not exceed 0.5 cc. Also check: 1. That the distance between the injection cams in the rest position (bottom dead centre) and the pump supporting face is between 52.8 and 54.4 mm as shown on the data plate;... -
Page 29: Checking And Setting The Injectors
INJECTION EQUIPMENT Injectors Details of fig.47: 1.Injector casing - 2.Adjusting shim - 3.Spring - 4.Rod - 5.Distance ring with locating pin - 6.Nozzle - 7.Ring nut Checking and setting the injectors 1. Clean the nozzle holes with 0.25mm gauge steel wire (fig.48). 2. -
Page 30: Electrical Equipment
ELECTRICAL EQUIPMENT Plant specifications Starter motor: Left rotation, 12V, power 2.2 kW Built-in alternator: 400W Voltage regulator: Electronic with controlled diodes and connection for battery charge indicator light External alternator: 12V - 400W Recommended battery: Refer to tables in chapters 4 Flywheel ring gear: Check teeth for wear or damage. -
Page 31: Engine Assembly
6. Fit the vent restrictor element (fig. 59). A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems. Use genuine oil retainers with the RUGGERINI. Camshaft Prepare the camshaft assembly (fig.60) as described below: 1. -
Page 32: Governor Tie Rod Adjustment
XIII ENGINE ASSEMBLY The speed governor is of the centrifugal type with flyweights keyed directly onto the end of the camshaft gear (fig. 60). Flyweights (A) impelled outward by centrifugal force, cause a moving plate (P) to shift axially. The plate operates a lever (R) which is connected, through tie rods (T) to the control sleeves (E) of the injection pumps. -
Page 33: Central Main Bearings
ENGINE ASSEMBLY XIII Central main bearings Fit the shells into their seats and coat with a thin film of oil. Fit the bearing with outside diameter of 141mm onto the central journal - timing-case side, and the 141.5mm diameter bearing onto the central journal - flywheel side. -
Page 34: Crankshaft End Float
XIII ENGINE ASSEMBLY Crankshaft end float Once the crankshaft has been inserted into the crankcase, fit the external clearance adjustment ring with the milled grooves facing toward the timing gear. Also fit the brass shims, the O-ring (fig. 71), the key, the timing gear - ensuring that the reference marks match those on the camshaft gear (fig. -
Page 35: Connecting Rods
ENGINE ASSEMBLY XIII Pistons Lubricate the following parts with oil before mounting: the piston pin, the piston, the cylinder and the big-end bearing Fit the oil rings onto the pistons (fig. 77) in the following order: 1. Chromed compression seal ring 2. -
Page 36: Checking Injector Protrusion
XIII ENGINE ASSEMBLY Checking injector protrusion Before mounting the heads to the cylinders fit the injectors into their housings and, after having secured them temporarily, check the protrusion of the nozzles from the head faces (fig.81). Protrusion S should be: 1,75 ÷... -
Page 37: Injection Check
ENGINE ASSEMBLY XIII 5. Release the control sleeves: - on the traditional pumps by loosening the pins (E, fig.84) and inserting the appropriate distance collars (F, fig.84). - on the BOSCH type PF30 pumps by removing the pins (H, fig.84) and closing the hole on the pump body using plug G. Important: injection pumps should be released only after they have been connected to the governor tie rod and secured to the crankcase. -
Page 38: Electric Shut Off
XIII ENGINE ASSEMBLY Injectors and injector pipes Mount injectors to heads placing copper gaskets in between (see pag. 36). Connect the injectors to the pumps by way of the injection lines. Important: always use two wrenches to loosen or tighten the unions on the injector pipes (fig.90) thereby ensuring that the position of the delivery valve holder on the pumps is not changed (see pag.27). -
Page 39: Engine Testing
ENGINE TESTING Speed adjustment (fig.94) When the engine is hot set idle speed at 1000 rpm and maximum no-load speed at: 3150 rpm for engines MD350 3750 rpm for engines MD351 Checking oil pressure 1. Remove the bolt from the hole in the crankcase and fit a pressure gauge with 0 to 10 kg/cm²... - Page 40 ENGINE TESTING Running-in table Time (min) Load 2000 3000/3600 3000/3600 3000/3600 3000/3600 3000/3600 100% Engine power curves are reported at page 12. 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.
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Page 41: Storage
STORAGE Storage Prepare engines as follows for storage over 30 days Temporary protection (1/6 months) • Let engine run at idling speed in no-load conditions for 15 minutes. • Fill crankcase with protection oil MIL-1-644-P9 and let engine run at 3/4 full speed for 5/10 minutes. •... -
Page 42: Quick Reference Charts
QUICK REFERENCE CHARTS Couplings Spiel (mm) Grezen (mm) Camshaft and central bearings 0,070 ÷ 0,105 Camshaft and flywheel side bearing 0,040 ÷ 0,074 End gap of compression rings 0,30 ÷ 0,45 End gap of oil scraper rings 0,25 ÷ 0,40 Connecting rod and wrist pin 0,023 ÷... -
Page 43: Standard Screw Tightening Torques
QUICK REFERENCE CHARTS (Nm) Tightening torques Big ends 3,6 ÷ 3,8 (35,3 ÷ 37,3) Timing cover 2,2 ÷ 2,4 (21,6 ÷ 23,5) Injector ring nut (34,3) Injectors 2 ÷ 2,3 (19,6 ÷ 22,6) Injection pump 2 ÷ 2,3 (19,6 ÷ 22,6) Oil pump 0,9 ÷... - Page 44 RUGGERINI MOTORI Via Cav. del Lavoro A. Lombardini, 2 42100 REGGIO EMILIA - Italia - ITALY Tel. (+39) 0522 3891 - Fax (+39) 0522 389433/465 http://www.ruggerini.it è un marchio della La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione.