Ruggerini RY125 Series Instruction manual

1
COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
RY125
1st Edition
WORK SHOP
MANUAL
RY 125 series engines, p.no. 1-5302-633

2COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 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
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 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
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
INDEX
I TROUBLESHOOTING__________________________________________________________ Page 7
II SAFETYANDWARNINGDECALS - SAFETYINSTRUCTIONS ____________________________ " 8
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
IX DISASSEMBLYOF THE ENGINE _________________________________________________ Page 17
Demounting and remounting the main bearings .......................................................................................................... 18
Demounting the piston ................................................................................................................................................... 18
Flywheel extraction.......................................................................................................................................................... 17
Removing the cover on the timing system side .............................................................................................................17
Removing the injection pump......................................................................................................................................... 17
Removing the injector ..................................................................................................................................................... 17
X CHECKSANDOVERHAUL ______________________________________________________ Page 19
Camshaft ........................................................................................................................................................................23
Checking the oil pump.................................................................................................................................................... 23
Connecting rod ............................................................................................................................................................... 21
Crankshaft....................................................................................................................................................................... 22
Cylinder ........................................................................................................................................................................... 20
Fuel pump (optional) ......................................................................................................................................................24
Head................................................................................................................................................................................19
Injection pump tappets and pads................................................................................................................................... 24
Lubrication circuit............................................................................................................................................................22
Oil retention rings............................................................................................................................................................22
Piston rings - Piston - Pin ............................................................................................................................................... 21
Rocker arms ...................................................................................................................................................................20
Tapets and rocker arms..................................................................................................................................................24
Valve springs...................................................................................................................................................................20
Valves - Guides - Housings ............................................................................................................................................19
This manual contains pertinent information regarding the repair of RUGGERINI air-cooled, indirect injection Diesel engines
type RY125: updated February 29, 2004.

5
COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
INDEX
XI INJECTIONEQUIPMENT ________________________________________________________ Page 25
Checking the injection pump.......................................................................................................................................... 26
Demounting and remounting ......................................................................................................................................... 28
Fuel circuit ....................................................................................................................................................................... 25
Injection pump ................................................................................................................................................................ 25
Injection pump assembly ............................................................................................................................................... 26
Injection pump calibration .............................................................................................................................................. 26
Injector............................................................................................................................................................................. 27
Injector inspection and calibration ................................................................................................................................. 27
Leak test..........................................................................................................................................................................27
XII ELECTRICALEQUIPMENT ______________________________________________________ Page 29
Characteristics of the system ......................................................................................................................................... 29
Checking the alternator................................................................................................................................................... 30
Checking the system ...................................................................................................................................................... 29
Ring gear ........................................................................................................................................................................ 30
XIII ENGINEASSEMBLY ___________________________________________________________ Page 31
Camshaft ........................................................................................................................................................................ 34
Connecting rod - drive shaft connection.........................................................................................................................33
Counter-shaft .................................................................................................................................................................. 33
Cover on timing system side.......................................................................................................................................... 35
Cylinder ........................................................................................................................................................................... 36
Drive shaft assembly ...................................................................................................................................................... 33
Flywheel ..........................................................................................................................................................................35
Head................................................................................................................................................................................ 36
Injection lead...................................................................................................................................................................37
Injection pump tappets ................................................................................................................................................... 31
Injector and injector tube ................................................................................................................................................ 38
Mounting the injection pump on the engine ...................................................................................................................38
Oil retention rings............................................................................................................................................................ 35
Piston .............................................................................................................................................................................. 36
Play adjustment ..............................................................................................................................................................34
Preparing the engine block............................................................................................................................................. 31
Removal and assembly of the drive shaft gear.............................................................................................................. 33
Timing system cover pre-assembly ...............................................................................................................................32
Valve clearance ............................................................................................................................................................... 37

6COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
INDEX
XIV ENGINETESTING _____________________________________________________________ Page 39
Braked engine test.......................................................................................................................................................... 39
Rpm regulation ............................................................................................................................................................... 39
XV STORAGE ___________________________________________________________________ Page 40
Setting at work................................................................................................................................................................. 40
Storage for up to 6 months ............................................................................................................................................. 40
Storage periods of more than 6 months ........................................................................................................................ 40
XVI QUICKREFERENCECHARTS ____________________________________________________ Page 41
Adjustments....................................................................................................................................................................41
Couplings........................................................................................................................................................................ 41
Standard screw tightening torques................................................................................................................................. 42
Tightening torques.......................................................................................................................................................... 42
XVII SERVICE ____________________________________________________________________ Page 43

7
COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 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
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 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 asafeandlong-lasting way. Toobtaintheseresults, itis
essential for users to comply with the servicing instructions given in the relative manual along with the safety
recommendationslistedbelow.
•Theenginehasbeenmadeaccordingtoamachinemanufacturer'sspecificationsandallactionsrequiredtomeetthe
essentialsafety andhealth safeguardingrequisiteshave beentaken,as prescribedby thecurrentlaws inmerit.All
uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use
definedby Ruggeriniwhichthus declinesallliability foranyaccidents derivingfromsuch operations.
•Thefollowingindicationsarededicatedtotheuserofthemachineinordertoreduceoreliminaterisksconcerningengine
operationinparticular,alongwiththerelativeroutinemaintenancework.
•Theusermustreadtheseinstructionscarefullyandbecomefamiliarwiththeoperationsdescribed.Failuretodothis
couldlead toserious dangerforhispersonal safetyandhealthand thatofanypersons whomaybein thevicinityof
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 notpermittedeven inan 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 inplaceswheretheengine freely exhauststhisgascanlead
tounconsciousness anddeath.

9
COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 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 firehazards,always keepthe machineatleast onemeterfrom buildingsor fromothermachinery.
•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
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 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

11
COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
IV
RY125
TECHNICAL DATA
CHARACTERISTICS
ENGINE TYPE
Number of cylinders N. 1
Bore mm 87
Stroke mm 85
Swept volume cm³ 505
Compression ratio 19:1
N 80/1269/CEE-ISO 1585 9 (12.24)
Power kW (HP) NB ISO 3046 - 1 IFN 8.4 (11.42)
NA ISO 3046 - 1 ICXN 7.6 (10.34)
Crankshaft PTO ratio rpm 3600
Camshaft PTO ratio rpm 3000
Crankshaft main PTO rotation left *
Camshaft main PTO rotation right*
Max. torque Nm (@ rpm) 31 (2000)
Fuel consumption (@ max. torque) g/kWh 250
Oil consumption kg/h 0.0055
Capacity of standard oil sump lt 1.5
Recommended battery 12V in standard start conditions Ah-A 50Ah -255A DIN
Recommended battery 12V in heavy-duty start conditions Ah-A 60Ah -300A DIN
Dry weight kg 48
Combustion air volume l/min 800
Cooling air volume l/min 8700
Max.permissible driving shaft axial: on crankshaft main PTO: continuous (instantaneous) kg 120(300)
Flywheel site: continuous (instantaneous) 30°(35°)
Max. inclination Power take off site: continuous (instantaneous) 35°(45°)
Bank angle right side: continuous (instantaneous) 30°(40°)
Bank angle left side: continuous (instantaneous) 30°(45°)
* Viewed the engine from main P.T.O.

12 COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
V
RY125
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.
MN Torque at Npower.
MB Torque at NB power.
MA Torque at NA power.
CSpecific fuel consumption at NB power.
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.

13
COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
VI
PRESADIFORZASUALBEROACAMMEOPZIONALECONSENSO
DIROTAZIONEDESTRO
OPTIONALP.T.O.ONCAMSHAFTWITHCLOCKWISEDIRECTIONOF
ROTATION
PRESADIFORZASTANDARDCONSENSODIROTAZIONE
SINISTRO
STANDARDP.T.O. WITH ANTICLOCKWISEDIRECTIONOF
ROTATION
OVERALL DIMENSIONS
Note: Dimensions in mm

14 COMPILERTECO/ATI ENDORSEDDATE
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REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
VII
00365R0020
00365R0900
00366R0220
00366R0230
00365R0770
00365R0100
00366R0210
00365R0430
00366R0240
00365R0940
SPECIAL TOOLS
TOOL CODE DESCRIPTION
Flywheelpuller
Tooltomountanddemountmainbearings
Plugto mountand demountmainbearings
Sleevetoinsertmainbearings
Piston mounting tool
Crankshaftgearpuller
PunchtoinsertBy-passvalve
Injectortest bench
Tooltostagger injectionlead
Capillarytubeforinjectionlead

15
COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
VIII
10 50(1) 250(2) 500(3) 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
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. 5.0
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)
OPERATION
SUMP OIL LEVEL CHECK
OILBATHAIRCLEANERCLEANING
DRYAIR CLEANER CHECKING
OIL CARTER REPLACEMENT (4)
OILFILTERREPLACEMENT
FUELFILTER REPLACEMENT
COOLINGFINSCLEANING
SETTINGROCKERARMS CLEARANCE
SETTINGAND INJECTORS CLEANING
OVERALL INSPECTION PARTIAL
OVERALL INSPECTION COMPLETE
(1) After the first 50 working hours
(2) In case of low use: every 6 months
(3) In case of low use: every 12 months
(4) If you are using oil of a quality lower than the recommended one then you will have to replace it every 150 hours

16 COMPILERTECO/ATI ENDORSEDDATE
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REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 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 1.5 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
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
IX
1
2
3
4
DISASSEMBLY OF THE ENGINE
During repair operations, when using compressed air,
wear eye protection.
Flywheel extraction
Remove the fuel tank, the air conveyor and flywheel nut.
Use extractor cod. 00365R0020, as shown in figure 3.
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.
Removing the injector
Slacken off the fuel delivery pipe, remove the fixing bracket and take
out the tube.
Remove the injector by levering it out with a screwdriver, as
indicated in fig. 1.
Removing the injection pump
Mark the position of the injection pump in relation to the engine
casing (if this has not already been done).
Remove the injection tube and take out the fuel pipes.
The pump can only be removed when the stop lever has been
turned to the stop position. To do this, the pump must be pressed
towards the housing as shown in fig. 2.
Removing the cover on the timing system side
Slacken off the screws around the perimeter of the cover on the
timing system side. Split the cover from the engine casing by
levering with a screwdriver in the points indicated in fig. 4.
Warning: to prevent damage to the main bearings, it is
advisable to demount the cover from the timing system
side with the engine cold.
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
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
IX
5
6
7
00365R0900
00366R0220
00366R0230 00366R0220
00365R0900
DISASSEMBLY OF THE ENGINE
Main bearing
Main bearing
Demounting the piston
Take out the piston pin as shown in fig. 5.
Warning: do not demount the head when hot or the
retention surfaces could be damaged.
Demounting and remounting the main bearings
Use tool code 00365R0900 and plug code 00366R0220 (fig. 6) to
demount the main bearings from the engine casing and cover on
the timing system side.
To fit the main bearing back into the engine casing, use tool code
00365R0900 with plug code 00366R0220 and sleeve code
00366R0230 side A (fig. 7).
To mount the main bearing on the cover on the timing system side,
use tool code 00365R0900 with plug code 00366R0220 and sleeve
code 00366R0230 side B (fig. 7).
During the assembly operations, make sure that the bearing holes
match the oil ducts by making reference marks with a felt-tip pen.
Make sure that the reference mark on the bearing edge points
towards:
- the casing interior
- the outer part of the timing system cover.
WARNING
Proceed with the following inspections after assembly:
Cover on timing system side
The main bearing must project 1.7 to 2 mm in relation to
the bearing surface of the bull ring (inner side of cover).
Engine casing
The main bearing must be flush with the bearing surface
of the shimming ring (inner side of casing).

19
COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
8
9
10
11
X
BB
C1C2
A
D1D2
G
F1
F2
A
EE
øA øB øC1 øC2 øD1 øD2 øE(*) øF1 øF2 G
13 13,025 40,13 35,13 40 35 7 6,96 6,945 0,8
÷ ÷ ÷ ÷ ÷ ÷ ÷÷÷÷
13,01 13,037 40,145 35,145 40,025 35,025 7,01 6,97 6,955 1
CHECKS AND OVERHAUL
Head
Parts indicated in fig. 8.
1. Nut - 2.Nut with ball - 3. Rocker arm - 4. Cotters - 5. Rocker arm
stud - 6. Upper cap - 7. Spring - 8. Air-relief valve - 9. Lower cap - 10.
Valve guide - 11. Rocker arm cover - 12. Head - 13. Valve housing
- 14. Exhaust valve - 15. Intake valve - 16. Rocker arm rod - 17.
Camshaft - 18. Tappets.
The head is made of aluminium with valve guides and housings in
faced cast iron. Remove any carbon deposits from the head and
check the cylinder bearing surface. Level it off to a depth of no more
than 0.3 mm if deformed.
The head must not be cracked or deformed. If such faults are
discovered, replace the part after consulting the spare parts
catalogue.
Do not demount the head when hot to avoid deformations.
Valves - Guides - Housings
Clean the valves with a metal brush and replace them if the tops are
deformed, cracked or worn (fig. 9).
(*) with guide mounted. measurements in mm
Check the dimensions of the valve stem (fig. 10) and the play
between the guide and valve. Ream the guide to the dimensions
indicated in the table. Change the guide and valve if the play
exceeds 0.1 mm.
The valve housings will always need to be ground when new
guides are mounted. Valve guides oversized on the outside by 0.10
mm are available.
After the engine has been used for a lengthy period of time, valve
knocking in their housings at high temperatures will harden the
housing tracks and make manual milling difficult to carry out.
When this happens, remove the hardened surface layer with a
grinder at 45° (Fig. 11).
The valve retention track will widen when the valve housing is
machined. Final adaptation of the valve in the housing must be
carried out by smearing fine grain lapping compound in the housing
and turning the valve with a light pressure and with an alternate
movement until the surfaces bed perfectly (fig. 12).
Comply with the valve embedding values as indicated in the table
(G, fig. 9).
Warning: when the valve embedding values are lower
than those prescribed, the valves could interfere with the
piston.
1 = intake
2 = exhaust

20 COMPILERTECO/ATI ENDORSEDDATE
29.02.2004
REG.CODE
1-5302-633
MODEL N°
51074
DATEOFISSUE
02-04 REVISION 00
X
12
13
14
15
42.3 ÷ 43.7
28.3 ÷ 28,5
18,7÷ 18,9
14,91
±5%
Kg
D
CA
2°
1°
3°
B
X
90° - 120°
Ra = 0,5 - 1 µ
24,72
±5%
Kg
Ø 87 ÷ 87,020
CHECKS AND OVERHAUL
Free length
Grinding-in must always be carried out when new valves or
housings are mounted. Valve housings oversized on the outside by
0.5 mm are available.
Thoroughly wash the valve and housing with petroleum or gasoline
to eliminate lapping paste residues or swarf.
Proceed in the following way to make sure that the valve and seat
are tight:
1. Mount the valve on the head with cap string and cotters (see fig.
8)
2. Overturn the head and pour a few drops of diesel fuel or oil on
to the edge of the valve top
3. Blow compressed air into the head duct. Plug the edges of the
duct itself to prevent air escaping.
If there are air leaks in the form of bubbles between the housing
and valve, demount the valve and grind-in again.
Valve springs
Check the length of the spring as indicated in fig. 13 to identify any
yielding.
Replace the springs if the values are different.
Rocker arms
Make sure that there are no evident signs of wear on the contacting
surfaces. Replace the parts if necessary.
Cylinder
In special cast iron with integral liner. Use a bore gauge to check
the two internal diameters (C-D) perpendicular to each other and at
different heights (fig. 14). Maximum tolerated taper error (A-B) and
ovality error (C-D): 0.06 mm.
Cylinder diameter:
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. 15).
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.
Replace the cylinder and piston if there is a ridge in zone "X" fig. 15
of the cylinder and if tapering and ovality exceed the previously given
values.