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WORK SHOP MANUAL RY series engines, p.no. 1-5302-584 RY 50 RY 70 RY 75 RY 103 RY 110 Edition COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-584 50871 15-01-2004 17-04-2003...
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Lombardini. Information presented within this manual assumes the following: 1 - The person or persons performing service work on Ruggerini series engines is properly trained and equipped to safely and professionally perform the subject operation; 2 - The person or persons performing service work on Ruggerini series engines possesses adequate hand and Lombardini special tools to safely and professionally perform the subject service operation;...
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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.
INDEX This manual contains pertinent information regarding the repair of RUGGERINI water-cooled, indirect injection Diesel engines type RY 50-70-75-103-110: updated January 15, 2004. TABLE OF CONTENTS TROUBLESHOOTING Page SAFETY DECALS - SAFETY INSTRUCTIONS " MODEL NUMBER AND IDENTIFICATION " TECHNICAL DATA "...
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...
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.
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• 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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NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 15-01-2004 1-5302-584 50871 17-04-2003...
MODEL NUMBER AND IDENTIFICATION Giri/1’ Tipo motore Tours/mn Type moteur r/min Engine type Eingestellte Drehzahl MODEL NUMBER ENGINE IDENTIFICATION Motortype R.p.m. Tipo motor Displacement (cc) R.P.M. Diesel Customer's code LOMBARDINI Approval code Engine group number Engine Serial Number Codice cliente Matricola identificazione motore Code client Matricule d’identification moteur...
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TECHNICAL DATA CHARACTERISTICS RY 50-70-75 TIPO MOTORE RY 50 RY 70 RY 75 Number of cylinders Bore Stroke Swept volume Compression ratio 21:1 20,3:1 20,3:1 R.P.M. 3600 3600 3600 N 80/1269/EEC-ISO 1585 3,5(4,8) 5,0(6,8) 5,5(7,5) Power kW (HP) NB ISO 3046 - 1 IFN...
TECHNICAL DATA CHARACTERISTICS RY 103-110 TIPO MOTORE RY 103 RY 110 Number of cylinders Bore Stroke Swept volume Compression ratio 20,3:1 20,3:1 R.P.M. 3600 3600 N 80/1269/EEC-ISO 1585 7,0(9,5) 7,7(10,5) Power kW (HP) NB ISO 3046 - 1 IFN 6,4(8,7) 7,0(9,6) NA ISO 3046 - 1 ICXN 5,8(7,9)
RY 50 RY 75 RY 70 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.
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CHARACTERISTICS CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES RY 103 RY 110 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.
OVERALL DIMENSIONS RY 50 RY 70 RY 75 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 15-01-2004 1-5302-584 50871 17-04-2003...
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OVERALL DIMENSIONS RY 103 RY 110 COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 17-04-2003 1-5302-467 50707 15-01-2004...
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: RY 50 lt. 3,0 RY 70 lt. 4,3 RY 75 lt. 4,3 RY 103 lt.
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OIL SUPPLY ( liters ) RY 50 SAE 20W Standard oil sump SAE 30 filter included SAE 40 SAE 10W-30 OIL SUPPLY ( liters ) RY 70 SAE 10W-40 Standard oil sump SAE 10W-60 SAE 15W-40 base minerale filter included...
15 cm from the paper. Lightly and repeatedly tap the element on a hard surface to eliminate all excess dirt. Dry air cleaner for RY 70 and RY 75 Cartridge components: 1 Seal 2 Metallic body...
DISASSEMBLY/REASSEMBLY VIII Clean the filtering element with air blast. Air must be blown from inside to outside the cartridge at a distance of at least 15 cm from the paper. Lightly and repeatedly tap the element on a hard surface to eliminate all excess dirt.
VIII DISASSEMBLY/REASSEMBLY Never clean the filtering element 6 using solvents with a low flash point. This could cause an explosion ! Make sure that the retention rings 4 - 5 are in a good condition and replace them if they are damaged. Oil-bath air cleaner (optional) Components: 1 Upper shell...
VIII DISASSEMBLY/REASSEMBLY Always check the the spring and valve to make sure they are in a good conditions. Rocker arm cover - Breather ricirculation Crankcase vapor recirculation occurs through duct 4. If the air filter clogs, the increased intake vacuum could suck oil through duct 4 into the combustion chamber, causing the engine to operate at a runaway rate.
VIII DISASSEMBLY/REASSEMBLY Hydraulic tappets RY 103-110 Distribution uses hydraulic tappets for automatic adjustment of valve clearance. The figure shows the tappet used in 15 LD 400 engines. Caption 1- Lock ring 2- Upper collar 3- Oil inlet holes 4- Low-pressure chamber 5- Piston 6- Play-recovery spring 7- Case...
VIII DISASSEMBLY/REASSEMBLY 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.
VIII DISASSEMBLY/REASSEMBLY Re-coil starting Operation: When pulling handle 10, thanks to the action of friction spring 12, teeth 4 protrude from cap 3. After starting these teeth go back to the initial position because the cap rotates. Rope 9 is re-wound around pulley 6 by means of spring 7.
5th phase: tighten the 2 side bolts (5) to a 10 Nm torque value value Engine RY 70 For RY 103-110 engines 1st phase: tighten all the bolts to a 30 Nm torque value in a phase: tighten all screws crosswise to 20Nm.
VIII DISASSEMBLY/REASSEMBLY Valves - Disassembly Components: 1 Valve stem 2 Oil seal 3 Spring washer/set 4 Spring 5 Cap 6 Half collets Note: To remove half collets place a suitable plate under the valve head and press down firmly as indicated in the figure. Valves - Oil seal in valve guide To prevent seal 2 from being deformed when the valve guide is mounted, fit it into tool 1 serial N°...
α α α α α ° 5 ÷ Valves, guides and housings 1 Intake guide 2 Exhaust guide Dimensions (mm) for RY 70-75-103-110 A = 40 B = 31 C = 11.000-11.018 D = 11.040-11.055 Dimensions (mm) for RY 50...
DISASSEMBLY/REASSEMBLY VIII Cylinder Set a bore gauge to zero with a calibrated ring. Check diameter at 1, 2 and 3; repeat the operation at the same points after turning the bore gauge 90°. If wear exceeds the max. given value by 0.05, bore the cylinder and fit oversize piston and rings.
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VIII DISASSEMBLY/REASSEMBLY COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 15-01-2004 1-5302-584 50871 17-04-2003...
VIII DISASSEMBLY/REASSEMBLY Piston rings, distance between the tips (mm) Fit the piston ring into the top part of the cylinder and measure the distance between the tips. r t i ÷ ÷ ÷ l i o t i n ÷ ÷...
C = Head gasket The thickness of gasket C determines the clearance A, which must be 0.45-0.55 mm for RY 70 with injection pump serial N° 6590-259; it is 0.50-0.60 mm with injection pump serial N° 6590-281. The clearance is 0.45-0.55 mm for RY 50 in all cases.
DISASSEMBLY/REASSEMBLY VIII Piston protrusion check To calculate the right thickness for the gasket, the protrusion between the piston and the cylinder head surface must be measured. Use a dial indicator with base plate. Reset to zero while resting on a surface plate, then position against the cylinder head base plane as shown in the diagram, so that the dial indicator rod rests against the piston.
When remounting, mount the cap from the same side as in C of the figure. Tighten the RY 50 bolts to a 23 Nm torque value. Tighten the bolts to a 30 Nm torque value for RY 70-75-103-110. Connecting rod, piston pin ÷ 0 ÷...
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 logo (see B). Drive shaft oil seals Oil retainer 1 is located in the gear cover on the timing side while retainer 2 is located in the crankcase on the flywheel side.
VIII DISASSEMBLY/REASSEMBLY Crankshaft - journal diameter (mm) ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ The undersizes for the crankpin and main journal are 0.25, 0.50 and 1 mm. The gears must be mounted with the right tools so that they can be correctly timed.
DISASSEMBLY/REASSEMBLY VIII Camshaft Components: 1 Journal, gear cover on timing side 2 Gear 3 Exhaust lobe 4 Injection lobe 5 Fuel pump eccentric 6 Intake lobe 7 Journal, crankcase side Camshaft journals and bore Use a comparator for interiors Dimensions of camshaft journals and bore (mm) ÷...
VIII DISASSEMBLY/REASSEMBLY Camshaft timing Fit camshaft by aligning marks' A with mark D on the crankshaft. Camshaft – Antireverse system RY 103-110 it consists of a device on the camshaft which lifts the intake valve in case of a startup in reverse direction with respect to normal rotation.
DISASSEMBLY/REASSEMBLY VIII Automatic decompression With the engine at a standstill and up to a rate of about 300 RPM, spring 1, acting on weights 2 and 3 via lever 4 and pin 5, keeps the exhaust valve open during the compression phase also. Once the engine exceeds the 300 RPM rate, weights 1 and 2 keep pin 5 in the hold position owing to the action of the centrifugal force.
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NOTE VIII COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 15-01-2004 1-5302-584 50871 17-04-2003...
VIII DISASSEMBLY/REASSEMBLY Dinamic balancer timing Position crankshaft as shown in the figure. Introduce the dynamic balancer so that timing mark 1 engages between teeth 2 of the crankshaft gear. Valve timing check Remove the tank and conveyor to access the flywheel. Carry out the inspections on the drive shaft.
= 10° after A corresponding to 20 mm. Values measured on the circumference of the flywheel D = 230 (one degree corresponds to 2 mm). For RY 70-75 α α α α α = 10° before A corresponding to 20.09 mm β...
LUBRICATION SYSTEM The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed. Use suitable oil in order to protect the engine. Nothing more than lubrication oil can influence the performances and life of an engine.
LUBRICATION SYSTEM RY 103-110 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM Components: 1) Oil fill cap 6) Oil drain plug 11) Oil intake filter 2) Safety valve 7) Metal filter element 12) Pushrods 3) Rod journal 8) Main journal 13) Hydraulic tappets 4) Pressure control valve 9) Oil filter 14) Calibrated union...
Oil pump - Clearance between rotors Measure clearance as shown in the figure; the max. value is 0.13 mm; wear limit 0.25 mm. Oil pressure regulation valve Components for RY 70-75: 1 Spring 2 Valve 3 Plug Free length A of the spring is 27.50-27.75 mm.
LUBRICATION SYSTEM Oil filter Filter components: RY 70-75-103-110 1 Seal 2 Adhesive 3 End cap 4 Filtering material 5 Plate Dimension mm: A = 26.5 B = 18 C = 88.5 D = 67.5 E = 8.5 Characteristics: Useful filtering area = 75 cm Degree of filtration = 50 µm.
LUBRICATION SYSTEM Oil pressure curve at idle speed The curve is obtained at the oil filter port with engine running at a constant speed of 1200 r.p.m. in no-load conditions; pressure is given in bar and temperature in centigrades. The curve represents the minimum pressure value while the maximum value is 5 bar.
FUEL SYSTEM Fuelling/injection circuit for RY 70-75-103-110 Components: 1 Tank 2 Return tube 3 Fuel filter 4 Injection pump 5 Injector leak-off line 6 Injector 7 High pressure line 8 Return tube Fuelling/injection circuit for RY 50 1 Tank 2 Injector leak-off line...
FUEL SYSTEM Fuel filter RY 50-70-75-103-110 A = 7.3 B = 3.8 C = 1.5 D = 42 H = 75 Characteristics: Filtering area ≥ 390 cm² Filtration level ≤ 7 µm See page 18 for fuel filter replacement Fuel filter RY 50 (version with internal filter in tank) 1 Rubber retention ring 2 PRV cover 3 SCP radial unit...
Protrusion A of drive rod 3 is 1.5-1.9 mm; it is not adjustable. Drive rod length = 58-58.2 mm for RY 50 Drive rod length = 65.8-66.0 mm for RY 70-75 Drive rod length = 61,4÷61,6 mm for RY 103-110 Injection pump This is of the simplified QLC type;...
A = 5.50 (nominal diam.) RY 50-70-75 2 Barrel A = 7,00 (nominal diam.) RY 103-110 3 Plunger A = 6,00 (nominal diam.) RY 70-75 EPA 4 Right helix B = 2.00 / 2.03 5 Delay notch C = 1.50 /1.53...
This also ensures that the engine stops promptly as soon as the stopping device is activated by means of the solenoid valve. Outlet fitting components for RY 70-75 EPA and RY 103-110 15 LD engines 70-75 EPA...
FUEL SYSTEM Injection pump delivery check on test bench 1 Delivery control rack rod 2 Rack rod 1 in stop position 3 Rack rod 1 in max. delivery position A = 18-19 mm (max.rack rod stroke) α α α α α = 66° Static injection timing Disconnect pipe 1 from injection pump and close it, to avoid fuel leakages.
FUEL SYSTEM Static injection lead test on flywheel Fill the tank and make sure that the fuel is not more than 10-15 cm above the tester. Set the flow governor lever of the injection pump in the stop position and lock it there. Turn the flywheel in the engine rotation direction.
A, replace the pad with a thinner one (fig. 116). Note: When the thickness of the pad varies by 0.1mm under the pump, B is delayed or brought forward by 1° on the flywheel. Injector Components: RY 70 1 Body 2 Union 3 Adjusting shim 4 Spring...
FUEL SYSTEM Nozzles The set-up between the needle and the guide must leave the needle free to fall and merely as a result of its own weight, when lifted 7mm from its seat and rotated in different directions, with the nozzle kept at a 45°...
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NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 15-01-2004 1-5302-584 50871 17-04-2003...
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6 Oil pressure light 7 Key switch 8 Battery charging light Note: The battery, which is not supplied by RUGGERINI, should have 12V nominal voltage rating and a capacity of not less than 44 Ah / 210 Amp. of fast discharge intensity.
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ELECTRICAL SYSTEM 24V, 9A alternator battery recharging curve 12V, 30A alternator battery recharging curve The test was conducted after heat stabilizing at 20°C. The value of the current delivered in relation to the curve may be subjected to a variation of between +10 % and -5%. Voltage regulator 12V, 12A: for standard alternators with 3 output wires 12V, 30A: for 12V, 20A alternators with 2 output wires...
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5 Pressure switch 6 Solenoid valve 7 Ignition switch Note: The battery, which is not supplied by RUGGERINI, should have 12V nominal voltage rating and a capacity of not less than 44 Ah / 210 Amp. of fast discharge intensity.
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ELECTRICAL SYSTEM Diagram of electric starter motor protection with sole self- winding starter - without battery - (optional) Components: 1 Alternator 2 Solenoid valve 3 Pressure switch 4 Thermostat 5 A.c. motor stop device COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED...
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Keep regulator away from heat sources above 75°C. Do no electric welding on engine or application. Starting motor Bosch type DW (L) 12V, 1.1 KW for RY 70-75-103-110 Bosch type DW (L) 12V, 0.9 KW for RY 50 Anti-clockwise rotation direction (viewed from pinion side) A = 17.5-19.5 mm (distance from flywheel rim surface to starter...
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ELECTRICAL SYSTEM Characteristic curves of Bosch starter motor type DW (L) 12V, 0.9 kW The curves were measured at a temperature of -20°C with a 55 Ah battery. U = Voltage on motor terminals in Volts. n = Motor speed in rpm M = Torque in Nm I (A) = Power draw in Amperes.
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SETTINGS / ADJUSTMENTS ADJUSTMENTS - RY 70-75 Idling speed setting in no-load conditions (standard) After filling with oil and fuel, start the engine and let it warm up for 10 minutes. Adjust idling speed to 1000-1250 rpm by turning set screw 1; then tighten lock nut.
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SETTINGS / ADJUSTMENTS ADJUSTMENTS - RY 50-103-110 No-load idling adjustment (standard) After having filled the engine with oil and fuel, start it and allow it to warm up for 10 minutes. Using adjuster screw 1, regulate the idling rate at 1000-1250 rpm. Tighten the check nut.
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SETTINGS / ADJUSTMENT Injection pump delivery setting 1) Bring engine to idling speed 2) Unscrew delivery limiting device C ( see fig. 145) 3) Bring the engine to the power and rpm required by the manufacturer of the device. 4) Check that fuel consumption falls within the table specifications (see below).
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STORAGE XIII 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.
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TORQUE SPECIFICATIONS MAIN TORQUE SPECIFICATIONS Reference ( fig. Diam. and pitch Torque Torque ( Nm ) Torque ( Nm ) POSITION N° and page) ( mm ) ( Nm ) 50 70-75 103-110 Re-coil starting fig. 18 - p. 25 Connecting rod 8x1 (70-75) fig.
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TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS DESCRIPTION R ≥ ≥ ≥ ≥ ≥ 1000 N/mm R ≥ ≥ ≥ ≥ ≥ 1200 N/mm R ≥ ≥ ≥ ≥ ≥ 800 N/mm Diameter per pitch (mm) 4x0,70 0,37 0,52 0,62...
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COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 17-04-2003 1-5302-467 50707 15-01-2004...
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RUGGERINI MOTORI Via Cav. del Lavoro Adelmo Lombardini, 2 42100 Reggio Emilia – Italia - ITALY Tel. (+39) 0522 354444 - Fax (+39) 0522 343344 Telex 530321 MOTRUG-I Internet: 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.
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