Ruggerini RD210 Instruction manual

1
COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
RD210
RD211
RD270
RD278
1st Edition
WORK SHOP
MANUAL
RD series engines, p.no. 1-5302-620

2COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
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.
The information in this manual is the exclusive property of Ruggerini. Neither partial nor total duplications or reprints
are therefore permitted without the express authorization of Ruggerini.
The information in this manual is given on the assumption that:
1 - The persons who service Ruggerini engines 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 Ruggerini tools to safely
and professionally carry out the necessary tasks;
3 - The persons who service Ruggerini engines have read the specific information concerning the above mentioned
Service operations and that they have clearly understood the operations required.
GENERAL SERVICE NOTES
1 - Only use genuine Ruggerini spare parts. Use of spurious spares may lead to incorrect performance and shorten
the life of the engines.
2 - The metric system is used to express all data, i.e. the dimensions are given in millimeters (mm), torque is
expressed in Newton-meters (Nm), weight in kilograms (kg), volume in liters or cubic centimeters (cc) and
pressure in barometric units (bar).

3
COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
WARRANTY CERTIFICATE
WARRANTY CERTIFICATE
Products Ruggerini Motori manufactured by Lombardini Srl are warranted to be free from non-conformity defects for a
period of 24 months from the date of delivery to the first end user.
For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed
within the setting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned
period (24 months) is not expired.
If no hour-meter is fitted, 12 working hours per calendar day will be considered.
For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling
system, sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above-
mentioned period (24 months) is not expired.
For correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the
documentation supplied with each engine.
To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be
carried out by qualified personnel only.
The list of the Lombardini authorized dealers for Ruggerini Motori products is reported in the “World Service
Organisation” booklet, supplied with each engine.
Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump),
filtering system, turbo-charged models, will require 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 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.
Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine
use or from both the total or partial impossibility of use, is excluded.
The repair or replacement of any component will not extend or renew the warranty period.
Lombardini Srl warranty obligations here above described will be cancelled if:
- Engines are not correctly installed and as a consequence the correct functional parameters are not respected and
altered.
- Engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied with
each engine.
- Any seal affixed to the engine by the Manufacturer has been tampered with or removed.
- Spare parts used are not original from Manufacturer.
- Feeding and injection systems are damaged by unauthorized or poor quality fuel types.
- Electrical system failure is due to components, connected to this system, which are not supplied or installed by
the Manufacturer.
- Engines have been disassembled, repaired or altered by any part other than an authorized Ruggerini Motori agent.
Following expiration of the above stated warranty periods and working hours, Lombardini will have no further
responsibility for warranty and will consider its here above mentioned obligations for warranty complete.
Any warranty request related to non-conformity of the product must be addressed to the Ruggerini Motori service
agents.

4COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
INDEX
I TROUBLESHOOTING__________________________________________________________ Page 7
II SAFETYANDWARNINGDECALS- SAFETY INSTRUCTIONS ____________________________” 8-9
III MODELNUMBERAND IDENTIFICATION _____________________________________________ ” 10
IV TECHNICAL DATA ______________________________________________________________ ” 11
V CHARACTERISTICS _____________________________________________________________” 12
VI OVERALLDIMENSIONS __________________________________________________________” 13
VII SPECIAL TOOLS________________________________________________________________” 14
VIII MAINTENANCE-RECOMMENDED OIL TYPE -REFILLING_______________________________” 15-16
IX DISASSEMBLY OF THE ENGINE ___________________________________________________” 17
Camshaft gear extraction................................................................................................................................................ 17
Crankshaft gear extraction.............................................................................................................................................. 17
Flywheel extraction.......................................................................................................................................................... 17
Oil pressure register valve extraction ............................................................................................................................. 17
X CHECKSANDOVERHAUL ______________________________________________________ Page 18
Camshaft ........................................................................................................................................................................24
Connecting rods .............................................................................................................................................................22
Crankshaft....................................................................................................................................................................... 23
Cylinder heads................................................................................................................................................................ 18
Cylinders .........................................................................................................................................................................20
Governor lever and spring .............................................................................................................................................. 25
Oil pump checking .......................................................................................................................................................... 25
Oil seal rings...................................................................................................................................................................24
Piston rings - Pistons - Piston pins................................................................................................................................21
Rocker arms ...................................................................................................................................................................20
Tappet checking ..............................................................................................................................................................24
Valves - Guides - Seats................................................................................................................................................... 18
Valves and springs ......................................................................................................................................................... 20
This manual contains pertinent information regarding the repair of RUGGERINI air-cooled, indirect injection Diesel engines
type RD210 - RD211, RD270 - RD278: updated August 01, 2003.

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COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
INDEX
XI INJECTIONEQUIPMENT ________________________________________________________ Page 26
Checking injection pump................................................................................................................................................ 26
Fuel circuit ....................................................................................................................................................................... 26
Injection pump ................................................................................................................................................................ 26
Injection pump assembly ............................................................................................................................................... 27
Injection pump setting .................................................................................................................................................... 26
Injector checking and setting.......................................................................................................................................... 28
Injectors........................................................................................................................................................................... 28
Testing air tightness .......................................................................................................................................................28
XII ELECTRICALEQUIPMENT ______________________________________________________ Page 29
Alternator checking (stator) ............................................................................................................................................. 30
Circuit checking............................................................................................................................................................... 29
Electric starting with motor and alternator for battery re-charging ................................................................................. 29
Method of use.................................................................................................................................................................. 30
Wire checking.................................................................................................................................................................. 30
XIII ENGINEASSEMBLY ___________________________________________________________ Page 32
Camshaft preparation..................................................................................................................................................... 32
Checking injector protrusion .......................................................................................................................................... 38
Checking start of injection .............................................................................................................................................. 41
Checking T.D.C. ..............................................................................................................................................................40
Checking valve head face depth.....................................................................................................................................38
Connecting rod-crankshaft coupling .............................................................................................................................. 36
Crankshaft preparation................................................................................................................................................... 33
Cylinder height adjustement .......................................................................................................................................... 38
Cylinder mounting........................................................................................................................................................... 37
Feeding pump assembly................................................................................................................................................ 36
Fitting cylinder heads...................................................................................................................................................... 39
Fitting of oil seal rings..................................................................................................................................................... 35
Injection pump fitting.......................................................................................................................................................40
Injection pump tie rod connection .................................................................................................................................. 40
Oil pump assembly......................................................................................................................................................... 35
Piston ring fitting .............................................................................................................................................................37
Piston ring working position ...........................................................................................................................................37
Piston-connection rod couplings.................................................................................................................................... 36
Preparation of crankcase................................................................................................................................................ 32
Protective cap fitting ........................................................................................................................................................37
Timing cover assembly................................................................................................................................................... 34
Upper crankcase preparation......................................................................................................................................... 33
Valve clearance ............................................................................................................................................................... 39

6COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
INDEX
XIV ENGINETESTING _____________________________________________________________ Page 42
Checking for oil leaks ..................................................................................................................................................... 42
Checking oil pressure .................................................................................................................................................... 42
Speed adjustment........................................................................................................................................................... 42
Testing engine on brake .................................................................................................................................................43
XV STORAGE ___________________________________________________________________ Page 44
How to prepare the engine for operation........................................................................................................................ 44
Permanent protection (over 6 months)........................................................................................................................... 44
Storage ............................................................................................................................................................................ 44
Temporary protection (1/6 months) ................................................................................................................................44
XVI QUICKREFERENCECHARTS ____________________________________________________ Page 45
Adjustments....................................................................................................................................................................45
Couplings........................................................................................................................................................................ 45
End floats ........................................................................................................................................................................45
Standard screw tightening torques................................................................................................................................. 46
Tightening torques.......................................................................................................................................................... 46

7
COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
ITROUBLE SHOOTING
Clogged pipes
Clogged fuel filter
Air inside fuel circuit
Clogged tank breather hole
Faulty fuel pump
Injector jammed
Jammed injection pump delivery valve
Wrong injector setting
Excessive plunger blow-by
Jammed injection pump delivery control
Wrong injection pump setting
Oil level too high
Jammed pressure relief valve
Worn oil pump
Air inside oil suction pipe
Faulty pressure gauge or switch
Clogged oil suction pipe
Battery discharged
Wrong or inefficient cable connection
Defective ignition switch
Defective starter motor
Clogged air filter
Excessive 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 piston rings
Worn or scored cylinders
Worn valve guides
Jammed valves
Worn bearings
Governor linkage not free to slide
Drive shaft not free to slide
Damaged cylinder head gasket
TROUBLE
LUBRICATION
POSSIBLE CAUSE
FUEL CIRCUIT
ELECTRIC
SYSTEM
MAINTE-
NANCE
SETTINGS/REPAIRS
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.
Engine does not start
No acceleration Black smoke
Excessive oil consumption
Too low oil pressure
Engine starts but stops
Non-uniform speed
White smoke Oil and fuel dripping from exhaust
Increase oil level

8COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS
Failure to comply with the
instructions could result in
damage to persons and
property
Failure to comply with the
instructions could lead to
technical damage to the
machine and/or system
SAFETY AND WARNING DECALS
SAFETY INSTRUCTIONS
DANGER CAUTION
•RuggeriniEnginesare builttosupplytheir performancesin asafe andlong-lastingway.To obtainthese results,itis
essential for users to comply with the servicing instructions given in the relative manual along with the safety
recommendationslistedbelow.
•Theenginehasbeenmadeaccordingtoamachinemanufacturer'sspecificationsandallactionsrequiredtomeetthe
essentialsafety andhealth safeguardingrequisites have been taken,as prescribed by the current laws inmerit. All
uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use
definedby Ruggerini which thus declinesall liability forany accidents derivingfrom such operations.
•Thefollowingindicationsarededicatedtotheuserofthemachineinordertoreduceoreliminaterisksconcerningengine
operationinparticular,alongwiththerelativeroutinemaintenancework.
•Theusermustreadtheseinstructionscarefullyandbecomefamiliarwiththeoperationsdescribed.Failuretodothis
couldlead toserious danger for his personalsafety andhealth andthat ofany personswho maybe inthe vicinityof
themachine.
•Theenginemayonlybeusedorassembledonamachinebytechnicianswhoareadequatelytrainedaboutitsoperation
and the deriving dangers. This condition is also essential when it comes to routine and, above all, extraordinary
maintenanceoperationswhich,inthelattercase,mustonlybecarriedoutbypersonsspecificallytrainedbyRuggerini
and who work in compliance with the existing documentation.
•Variationstothefunctionalparametersoftheengine,adjustmentstothefuelflowrateandrotationspeed,removalof
seals, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized
personnelshallrelieveRuggerinifromallandeveryliabilityforderivingaccidentsorforfailuretocomplywiththelaws
in merit.
•On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the
caseofmanualstart-ups,makesurethattherelativeactionscantakeplacewithouttheriskofhittingwallsordangerous
objects, also considering the movements made by the operator. Pull-starting with a free cord (thus excluding self-
windingstarting only), is not permittedeven in an emergency.
•Make sure that the machine is stable to prevent the risk of overturning.
•Become familiar with how to adjust the rotation speed and stop the engine.
•Neverstarttheengineinaclosedplaceorwherethereisinsufficientventilation.Combustioncreatescarbonmonoxide,
anodourlessandhighlypoisonousgas.Lengthystays inplaceswheretheenginefreelyexhauststhis gascanlead
tounconsciousness and death.

9
COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
IISAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS
•Theenginemustnotoperateinplacescontaininginflammablematerials,inexplosiveatmospheres,wherethereisdust
that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been
certifiedforthemachine.
•Toprevent fire hazards,always keep the machineat least one meterfrom buildings orfrom other machinery.
•Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving
from their operation.
•Fuel is inflammable. The tank must only be filled when the engine is off. Thoroughly dry any spilt fuel and move the
fuel container away along with any rags soaked in fuel or oil. Make sure that no soundproofing panels made of
porous material are soaked in fuel or oil. Make sure that the ground or floor on which the machine is standing has
not soaked up any fuel or oil.
•Fully tighten the tank plug each time after refuelling. Do not fill the tank right to the top but leave an adequate space
for the fuel to expand.
•Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place.
•Do not smoke or use naked flames when refuelling.
•The engine must be started in compliance with the specific instructions in the operation manual of the engine and/or
machine itself. Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).
•Before starting, remove any tools that were used to service the engine and/or machine. Make sure that all guards
have been refitted.
•During operation, the surface of the engine can become dangerously hot. Avoid touching the exhaust system in
particular.
•Before proceeding with any operation on the engine, stop it and allow it to cool. Never 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 radiator plug or expansion chamber with the utmost caution, wearing protective garments
and goggles. If there is an electric fan, do not approach the engine whilst it is still hot as the fan could also start
operating when the engine is at a standstill. Only clean the coolant system when the engine is at a standstill.
•When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to
safeguard the environment. The spongy filtering material in oil-cooled air filters must not be soaked in oil. The
reservoir of the separator pre-filter must not be filled with oil.
•The oil must be drained whilst the engine is hot (oil T ~ 80°C). Particular care is required to prevent burns. Do not
allow the oil to come into contact with the skin.
•Make sure that the drained oil, the oil filter and the oil it contains are disposed of in the correct way in order to
safeguard the environment.
•Pay attention to the temperature of the oil filter when the filter itself is replaced.
•Only check, top up and change the coolant fluid when the engine is off and cold. Take care to prevent fluids
containing nitrites from being mixed with others that do not contain these substances since "Nitrosamine",
dangerous for the health, can form. The coolant fluid is polluting and must therefore be disposed of in the correct
way to safeguard the environment.
•During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect
and insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter motor from
being energized.
•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.

10 COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
III MODEL NUMBER AND IDENTIFICATION
ENGINE IDENTIFICATION
Engine Serial Number
Approval code
Customer's code
R.P.M. setting
R.P.M.
Displacement (cc)
MODEL NUMBER
Model

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COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
IV
N.
mm
mm
cm³
Nm
g/kW.h
g/kW.h
lt
Ah -A
kg
m³/h
m³/h
kg.
N 80/1269/CEE-ISO 1585
NB ISO 3046 - 1 IFN
NA ISO 3046 - 1 ICXN
2
90
75
954
19:1
15(20,5)
—
14(19)
—
12,9(17,6)
—
50@2400
236
0,8
3
66-300
78
76
800
100(350)
25°(35°)
25°(40°)
25°(40°)
RD210
2
90
75
954
19:1
—
17(23)
—
15,7(21,4)
—
14,5(19,8)
50@2400
236
0,8
3
66-300
78
90
950
100(350)
25°(35°)
25°(40°)
25°(40°)
RD211
2
95
85
1205
18:1
20(27,2)
—
18,6(25,3)
—
17,2(23,4)
—
66@2200
245
0,8
3
90-450
96
97
1100
100(350)
25°(35°)
25°(40°)
25°(40°)
RD270
2
95
85
1205
18:1
—
—
9,5(13)#
—
8,6(11,7)#
—
—
250
0,8
3
90-450
96
65
800
100(350)
25°(35°)
25°(40°)
25°(40°)
RD278
TECHNICAL DATA
CHARACTERISTICS
ENGINE TYPE
Number of cylinders
Bore
Stroke
Swept volume
Compression ratio @ 3000 RPM
@ 3600 RPM
@ 3000 RPM
@ 3600 RPM
@ 3000 RPM
@ 3600 RPM
Max. torque *
Fuel consumption **
Oil consumption
Capacity of standard oil sump
Recommended battery 12V
Dry weight
Combustion air volume
Cooling air volume
Max.permissible driving shaft axial: continuous (instantaneous)
Flywheel site: continuous (instantaneous)
Max. inclination Power take off site: continuous (instantaneous)
Lateral: continuous (instantaneous)
Power kW (HP)
* Referred to N power
** Consumption at max torque
# @ 1500 RPM

12 COMPILERTECO/ATI ENDORSEDDATE
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REG.CODE
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MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
V
RD270
RD210-211
CHARACTERISTICS
CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES
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.
Mt-N Torque at Npower.
CSpecific fuel consumption at N power.
U1: Standard utilization range of engines rated at 3000 rpm
U2: Standard utilization range of engines rated at 3600 rpm
The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of
20°C and 1 bar.
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.

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COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
VI
RD210
RD211
RD270
RD278
OVERALL DIMENSIONS
Note: Dimensions in mm

14 COMPILERTECO/ATI ENDORSEDDATE
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REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
VII SPECIAL TOOLS
TOOL CODE DESCRIPTION
00365R0010 Extractor
00365R0940 Injection advance control tool
00365R0020 Flywheel extractor
00365R0040 Oil seal insertion tool
00365R0260 Oil seal protection cone
00365R0210 Injection pump spanner
00365R0450 Valve guide gauge Ø 7 mm (0.27 inch.)
00365R0400 Valve guide gauge Ø 9 mm (0.35 inch.)
00365R0410 Valve guide gauge Ø 9 mm (0.35 inch.)
00365R0850 Valve guide grinder Ø 7 mm (0.27 inch.)
00365R0860 Valve guide grinder Ø 9 mm (0.35 inch.)
00365R0540 Tool for valve seat
00365R0500 Cutter Ø 38 mm (1.50 inch.)
00365R0510 Cutter Ø 40 mm (1.57 inch.)
00365R0430 Injector test bench
00365R0100 Bearing extractor
00365R0770 Cylinder collar Ø 80=85 mm (3.15=3.35 inch.)
00365R0800 Cylinder collar Ø 90=95 mm (3.54=3.74 inch.)
00365R0880 Valve extractor

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COMPILERTECO/ATI ENDORSEDDATE
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REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
VIII
(*)
(*)
(**)(***)
(x)
(xx)
8 50 200 300 500 2500 5000
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING
Failure to carry out the operations described in the table may lead to technical damage to the machine
and/or system
First replacement
(*) Under severe working conditions, clean daily.
(**) Under extremely dusty conditions, change every 4-5 hours.
(***) See recommended oil type.
(x) The partial overhaul includes the following operations: valve and seat lapping, injector and injection pump overhaul,
injector projection check, fuel injection spark advance check, check of the harmful area between head and piston,
camshaft and crankshaft end float check, tightening of bolts.
(xx) The general overhaul includes - in addition to all partial overhaul - the following procedures: 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 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. Dispose of fuel in the
correct way and do not litter as it is highly polluting.
FUEL
When refuelling, it is advisable to use a funnel to prevent fuel from spilling out. The fuel should also be filtered to prevent dust
or dirt from entering the tank.
Use the same type of diesel fuel as used in cars. Use of other types of fuel could damage the engine. 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: lt. 7.0
The maintenance operations listed above refer to an engine operating in normal conditions (temperature, degree of humidity,
dust in the working environment). They may vary significantly according to the type of use.
MANUTENANCE
INTERVAL (HOURS)
COMPONENT
OPERATION
CLEANING
CHECK
OVERALL
INSPECTION
REPLACEMENT
OIL-BATH AIR CLEANER
HEAD AND CYLINDER FINS
FUEL TANK
INJECTOR AIR CLEANER OIL
LEVEL OIL SUMP
BATTERY FLUID
VALVE/ROCKER ARM CLEARANCE
INJECTOR SETTING
AIR CLEANER
SUMP
EXTERNAL OIL FILTER CARTRIDGE
FUEL FILTER CARTRIDGE
DRY AIR CLEANER CARTRIDGE
PARTIAL
COMPLETE
OIL

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MODEL N°
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DATEOFISSUE
08-03 REVISION 00
VIII
-
30 - 25 - 20 -
15 - 10 - 50+
5+ 10 + 15 + 20 +
25 + 30 + 35 +
40 + 45
SAE 20W
SAE 10W
+
50
SAE 30SAE 40
SAE 10W-30
SAE 10W-40
SAE 10W-60
SAE 15W-40 base minerale
SAE 15W-40 base semi-sintetica
SAE 20W-60 base semi-sintetica
SAE 5W-30 base sintetica
SAE 0W-30 base sintetica
SAE 5W-40 base sintetica
-
35
-
40
CCMC G- 2
CF CE CD CC CB CA SA SB SC SD SE SF SG
DIESEL BENZINA - ESSENCE - PETROL
BENZIN - GASOLINA
CCMC G- 3 G- 5
CCMC PD - 1 / PD - 2
CCMC D- 2
D- 4 CCMC D- 3
D- 5
MIL - L - 2104 D
MIL - L - 2104 E
MIL - L -46152 C
MIL - L- 46152 D/E
MB 226.1 MB 226.5
MB 227.1 MB 227.5
228.3 MB 228.1
VW 501.01
VW 500.00
SHAPI
G- 4
SJ
VOLVO VDS
MAN QC 13-017
VW 505.00
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.
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 if the oil is not regularly
changed. All this notably reduces engine life.
Oil viscosity must suit the ambient temperature in which the engine operates.
Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the
oil is inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible.
Appropriate protective gloves etc should be wore during this operation.
Old oil is highly polluting and must be disposed of in the correct way. Do not litter.
GRADERECOMMENDED OIL
AGIP SINT 2000 5W40 specification API SJ/CF ACEA A3-96 B3-
96 MIL-L-46152 D/E.
ESSO ULTRA 10W40 specification API SJ/CF ACEA A3-96 MIL-L-
46152 D/E.
In countries where AGIP and ESSO products are not available,
use API SJ/CF oil for gasoline-fuelled engines or oil that
complies with military specification MIL-L-46152 D/E.
OIL SUPPLY ( liters )
Standard oil sump
filter included 3.0 l.
ACEA SEQUENCES
A = Gasoline (Petrol)
B = Light Diesel fuels
E = Heavy Diesel fuels
Required levels :
A1-96
A2-96
A3-96
B1-96
B2-96
B3-96
E1-96
E2-96
E3-96

17
COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
IX
1
2
3
4
DISASSEMBLY OF THE ENGINE
During repair operations, when using compressed air,
wear eye protection.
Flywheel extraction
Use extractor cod. 00365R0020, as shown in figure 1.
During the demounting phases, pay particular attention to
prevent the 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.
Crankshaft gear extraction
Use extractor cod. 00365R0010 and cod. 00365R0100 (fig. 2).
Camshaft gear extraction
Use extractor cod. 00365R0010 (fig. 3).
Oil pressure register valve extraction
Use extractor cod. 00365R0880 (fig. 4).
DISASSEMBLY AND REASSEMBLY
Besides disassembly and reassembly operations this chapter also
includes checking and setting specifications, dimensions, repair
and operating instructions. Always use original RUGGERINI spare
parts for repair operations.

18 COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
IX
5
6
7
8
7,000 ÷ 7,010 7,0797,000
9,020 ÷ 9,030
9,040 ÷ 9,055
9,020
9,040
9,100
9,130
RD210
RD211
RD270
RD278
RD210
RD211 40 x 12 mm
A x B
RD270
RD278
A x B
7 mm 38 x 12 mm 7 mm
38 x 12 mm 9 mm 38 x 12 mm 9 mm
Cylinder heads
Details of fig. 5:
1. Cylinder head - 2. Pipe - 3. O-Ring - 4. Rockerarms - 5. Rockers -
6. Cotters - 7. Plates - 8. Springs - 9. Guides - 10. Seats - 11. Valves
- 12. Tappets - 13. Camshaft.
The heads are of aluminium with inserted guides and valve seats in
cast iron. Make sure there are no cracks or imperfections. Should it
be so, replace according to the instructions given in the spare parts
catalogue.
Never remove head while still hot in order to avoid
deformation.
Fitting of new guides always requires grinding of the valve seats
(see page 19).
Valve guides with an external diameter increased by 0.10 mm are
available.
If the inlet clearance between valve and guide is lower than 0.08
mm and the outlet clearance is lower than, 0.10 mm, the wear on B
is less than 0.03 mm and A is more than 0.05 mm, recondition the
valve by grinding face P to 45° (fig. 7).
As a result of prolonged engine operation, the hammering of the
valves on their seats at high temperature causes the face of the
seats to harden and hand grinding is made difficult. It is thus
necessary to remove the hardened surface with a 45° cutter
mounted on a valve seat grinding tool (fig. 8). Final fitting can then
be carried out manually with the cutters listed below.
Cut dimensions for valve seats
CHECKS AND OVERHAUL
Valves - Guides - Seats
Clean the valves with a wire brush and renew them if the valve
heads are deformed, cracked or worn.
Check clearance between valve and guide with a micrometer on
stem B (fig. 7) and with a go/no go gauge as shown in fig. 6 (tool
cod. 00365R0450, 00365R0400, 00365R0410).
Change the guide if the maximum gauge diameter passes through
it, as it has passed the maximum permissible wear.
After having fitted the new guide, check exact diameter using the
“go” end of the gauge and if necessary grind it to the dimensions
indicated in the table using the adjustable grinder (tool cod.
00365R0850, 00365R0860).
Engine Guide Ø Guide
mm
Ø Gauge mm
go no go
Inlet
Outlet
Inlet
Outlet
Engine Inlet
Ø guide
Outlet
Ø guide

19
COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
X
9
10
11
12
0,7 ÷ 1,2 2
0,9 ÷ 1,1 1,8
CHECKS AND OVERHAUL
Fitting mm Max. wear mm
Fitting mm Max. wear mm
Cutting of the valve seats involves the widening of the valve seat
face P with a consequent reduction of seal of the valve itself, fig. 9
If face P is more than 2 mm wide, invert cutter and lower level Q of
the seat, fig. 10, so as to restore the P level to the value of:
Final lapping of the valve on the seat must be carried out by coating
the seat with a fire grinding paste and rotating the valve backwards
and forwards with a slight pressure until a perfect finish to the
surface is obtained (fig. 11).
Make sure the face of the valve head in relation to the face of the
cylinder head is:
If the distance is less, the valve will strike the piston.
If the distance is more than 1.8 mm the valve seat rings
need to be changed. Fitting of new valves or seats always
requires grinding.
After grinding, wash valve and seat carefully with petrol or paraffin to
eliminate any residual grinding paste or cuttings.
To check the worthiness of the seal between valve and seat, after
grinding has taken place, proceed as follows:
1.Fit valve on head with spring, plates and cotters (see fig. 5).
2.Invert head and pour a few drops of diesel or oil round the
outside of the valve head.
3.Blow compressed air into the inlet of the cylinder head, taking
care to seal the edges so that the air does not escape (fig. 12).
Should air bubbles form between the seat and the valve, remove the
valve and regrind the seat.
The fit can also be checked by pushing the valve upwards and
letting it fall freely down onto its seat. If the resulting bounce is
considerable and uniform, also when the valve is rotated, it means
that the fit is good. If not, continue grinding until the conditions
described above are achieved.
Valve seats with an external diameter increased by 0.2 mm for the
RD210 and 0.5 mm for the RD270, are available.

20 COMPILERTECO/ATI ENDORSEDDATE
01.08.2003
REG.CODE
1-5302-620
MODEL N°
50902
DATEOFISSUE
08-03 REVISION 00
X
13
14
15
16
0,030 ÷ 0,056 0,15
0,10 ÷ 0,50
RD210 RD 211
RD270 RD278
Ø 90 ÷ 90,015
Ø 95 ÷ 95,015
RD210 RD 211
RD270 RD278
35,6 mm 50,1 mm 25 mm 34,8 mm 17,5 mm 24,8 mm
14,6kg
16,3kg 25 kg
27 kg
Valves and springs
In order to check the springs for possible failure measure the
lengths under load as shown in figure 13.
The permissible tolerance for loads and lengths is ± 10%. If the
figures measured do not fall within these values, the springs must
be renewed.
Rocker arms
Make sure that the facing surfaces between rocker and pin are not
scored and show no signs of seizure. If such marks are
encountered, renew rocker and pin. Rocker / pin clearance (fig.14):
Cylinders
Air cooled with cylinder barrels in special cast iron with integral
liners.
Use a dial gauge to check internal diameters (C-D) at three different
heights (fig.15).
Maximum permitted taper (A-B) and ovality (C-D) is 0.06mm.
Diameter of cylinders (fig.15):
If the diameter of the cylinder does not exceed said values or if there
are slight 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 an angle of 90°÷120°; lines
should be uniform and clear in both directions (fig. 16).
Average roughness must range between 0.5 mm 1 µm.
The cylinder surface which comes into contact with piston rings
should be machined with the plateau method.
If the taper and ovality of the cylinder exceed the values indicated,
then the cylinder and piston must be renewed.
Fitting mm Max. wear mm
Rocker axial play (fig.14):
CHECKS AND OVERHAUL