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MD151
Workshop manual
Ruggerini MD151 Workshop Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
General Service Notes
Table of Contents
1 Trouble Shooting
Possible Causes and Trouble Shooting
Safety and Warning Decals - Safety Instructions
2 II Safety and Warning Decals - Safety Instructions ____________________________ " 8-9
Model Number and Identification
3 III Model Number and Identification _____________________________________________ " 10
4 Technical Data
5 Vcharacteristics
6 Overall Dimensions
7 Special Tools
VII Special Tools
8 Maintenance - Recommended Oil Type - Refilling
9 Disassembly of the Engine
Extracting Fuel Injectors
Extraction of Crankshaft Gear
Extraction of Flywheel Side Main Bearing
Removing the Flywheel
Extracting Crankcase Bushes
Extracting the Oil Pressure Indicator Plug
Extraction of the Camshaft Gear
IX Disassembly of the Engine
Cylinders Heads
Valves - Guides - Seats
10 Xchecks and Overhaul
Cylinders
Rocker Arms
Valves and Springs
Connecting Rods
Piston Rings - Pistons - Piston Pins
Crankshaft
Camshaft
Central Main Bearings
Oil Seal Rings
Fuel Pump Push-Rod
Injection Pump Plug Nuts and Control Rods
Oil Pump
Tappets and Push Rods
Governor Lever and Spring
11 Injection Equipment
Checking Injection Pumps
Fuel Circuit
Injection Pump Setting
Injection Pumps
Assembly of Injection Pumps
Testing Air Tightness
XI Injection Equipment
Checking and Setting the Injectors
Disassembly and Re-Assembly of Injectors
Injectors
12 Electrical Equipment
Checking Electrical Equipment
Checking the Alternator
Plant Specifications
XII Electrical Equipment
13 Engine Assembly
Central Main Bearings
Preparing the Crankcase
Crankshaft
Crankshaft End Float
Main Bearings - Flywheel Side
XIII Engine Assembly
Camshaft
Governor Tie Rod Adjustment
Oil Pump
Pulley and Flywheel
Timing Cover
Connecting Rods
Cylinders
Pistons
Checking Injector Protrusion
Cylinder Heads
Injection Pumps
Valve Clearance
Injection Check
Electric Shut off
Feed Pump
Injectors and Injector Pipes
Oil Filter
14 Engine Testing
Checking for Oil Leaks
Checking Oil Pressure
Dyno Testing of Engine
Speed Adjustment
XIV Engine Testing
15 Storage
How to Prepare the Engine for Operation
Permanent Protection (over 6 Months)
Temporary Protection (1/6 Months)
16 Quick Reference Charts
Adjustments
Couplings
Standard Screw Tightening Torques
Tightening Torques
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Technical Data
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Maintenance - Recommended Oil Type - Refilling
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WORK SHOP
MANUAL
MD/2 series engines, p.no. 1-5302-602
MD150
MD151
MD190
MD191
1
Edition
st
COMPILER TECO/ATI
REG. CODE
MODEL N°
DATE OF ISSUE
DATE
ENDORSED
00
1
REVISION
1-5302-602
50884
06-03
23.06.2003
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Summarization of Contents
INTRODUCTION AND SERVICE NOTES
Foreword
Provides an overview and context for the technical information in the manual.
General Service Notes
Outlines essential general guidelines for servicing the engines.
WARRANTY CERTIFICATE
TROUBLESHOOTING ENGINE PROBLEMS
Engine System Fault Diagnosis
Identifies common engine issues and their potential causes across fuel, lubrication, electric, and mechanical systems.
SAFETY AND OPERATIONAL GUIDELINES
Safety Decals and Instructions
Explains safety decals and provides critical instructions for safe engine operation and maintenance.
MODEL IDENTIFICATION
TECHNICAL DATA AND CHARACTERISTICS
Engine Specifications and Performance Metrics
Details engine type, specifications, power, torque, and fuel consumption.
ENGINE PERFORMANCE CURVES
Power, Torque, and Fuel Consumption Graphs
Graphical representation of engine performance at different operating conditions.
OVERALL DIMENSIONS AND SPECIFICATIONS
SPECIAL TOOLS FOR MAINTENANCE
MAINTENANCE SCHEDULE AND LUBRICATION
Maintenance Schedule and Oil Type Recommendation
Outlines maintenance tasks, intervals, and recommended engine oil.
RECOMMENDED OIL TYPE AND SPECIFICATIONS
Oil Specifications and ACEA Sequences
Details required oil quantities and ACEA sequence levels for engine lubrication.
ENGINE DISASSEMBLY PROCEDURES
Component Removal (Injectors, Flywheel, Bearings, Gears)
Step-by-step guides for removing key engine components like injectors, flywheel, bearings, and gears.
Camshaft Gear, Crankcase Bushing, and Oil Plug Removal
CHECKS AND OVERHAUL OF ENGINE COMPONENTS
Cylinder Head and Valve System Inspection
Procedures for inspecting and overhauling cylinder heads, valves, guides, and seats.
Valve Seat Grinding and Seal Verification
Valve Spring, Rocker Arm, and Cylinder Dimension Checks
Piston, Ring, and Connecting Rod Component Checks
Crankshaft Inspection and Oil Passage Cleaning
Main Bearing and Camshaft Component Inspection
Tappet, Push Rod, Oil Pump, and Injection Pump Control Checks
Governor Lever and Spring Inspection
INJECTION EQUIPMENT OPERATION
Fuel Circuit and Injection Pump Checks
Description of the fuel circuit and procedures for checking and setting injection pumps.
Injection Pump Assembly and Air Tightness Testing
Injector Checks, Settings, and Disassembly Procedures
ELECTRICAL EQUIPMENT AND SYSTEM CHECKS
System Specifications and Alternator Testing
Lists engine electrical specifications and procedures for checking the alternator and wiring.
ENGINE ASSEMBLY AND INSTALLATION
Crankcase Preparation and Main Bearing Installation
Instructions for preparing the crankcase and installing central main bearings.
Crankshaft, Flywheel Bearings, and End Float Measurement
Camshaft, Governor, and Timing Alignment Procedures
Oil Pump, Timing Cover, and Pulley/Flywheel Installation
Piston, Connecting Rod, and Cylinder Installation Procedures
Injector Protrusion, Valve Clearance, and Cylinder Head Installation
Injection Pump Installation and Static Timing Check
Injector Pipes, Oil Filter, Feed Pump, and Electric Shut-Off Installation
ENGINE TESTING AND PERFORMANCE EVALUATION
Speed Adjustment and Oil Pressure Testing
Procedures for adjusting engine speed and checking oil pressure.
Oil Leak Detection and Dyno Testing Procedures
Methods for checking oil leaks and performing engine dynamometer testing.
Engine Run-in and Exhaust Fume Analysis
ENGINE STORAGE AND POST-STORAGE PREPARATION
Engine Storage Procedures
Guidelines for both temporary and long-term engine storage and preparation for reuse.
QUICK REFERENCE CHARTS AND SPECIFICATIONS
Component Clearances and Adjustments
Tables listing component clearances, fitting specifications, and adjustment values.
Tightening Torques and Screw Specifications
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