Ruggerini SERIES RY Operating instructions

Repair Manual
for Diesel engines series
RY
cod. 00497R0990

Ruggerini
FOREWORD
This instruction manual includes all the technical information needed to
make any of the repairs required for the engines in question.
It is very important to strictly comply with all the instructions given to
ensure that the repair work is carried out as quickly and safely as
possible.
WORKSHOP REGULATIONS
- Always use the right tools for the repairs. Use of makeshift equipment
could damage the engine components
- Lightly tap solidly joined parts with a plastic or wooden mallet in order
to split the assemblies
- To facilitate the re-assembly operations, mark any parts without
reference points
- Separate the various components into distinct groups; retighten the
nuts and bolts of each assembly
- Wash each component with Diesel fuel or petroleum before
proceeding with the dimensional inspections
- During the assembly operations, thoroughly clean all parts, spread
lubricating oil on the mobile engine components and replace pins,
retention rings, seals, washers and self-locking nuts.
WARNING
Only use GENUINE RUGGERINI SPARESGENUINE RUGGERINI SPARES
GENUINE RUGGERINI SPARESGENUINE RUGGERINI SPARES
GENUINE RUGGERINI SPARES to ensure a good result..
..
.
motori

4.0
00497R0990 - 15-07-2000
DIESEL

5.0
service
00497R0990 - 15-07-2000
SERIES RY DIESEL ENGINES
1. TECHNICAL SPECIFICATIONS
DIESEL
MODELMODEL
MODELMODEL
MODEL Ry85.0Ry85.0
Ry85.0Ry85.0
Ry85.0 Ry85.1Ry85.1
Ry85.1Ry85.1
Ry85.1 Ry100Ry100
Ry100Ry100
Ry100 Ry101Ry101
Ry101Ry101
Ry101 Ry120Ry120
Ry120Ry120
Ry120 Ry121Ry121
Ry121Ry121
Ry121
Cycle 4-stroke Diesel
Injection direct
Cooling forced air with fan flywheel
Lubrication forced with vane pump
Governor centrifugal with weights
Number of cylinders 1
Swept volume cc. 382 382 431 431 505 505
Bore mm 80 80 85 85 87 87
Stroke mm 76 76 76 76 85 85
Rpm 3000 3600 3000 3600 3000 3600
Compression ratio 19.5:1 19.5:1 18.5:1 18.5:1 18.5:1 18.5:1
PTO spinning
direction anti-clockwise
Maximum torque Nm(rpm) 19(2200) 19(2200) 22(2200) 22(2200) 27(2200) 27(2200)
Governor rpm error margin 5% 5% 5% 5% 5% 5%
Recommended battery Ah(Amp) 60(300) 60(300) 60(300) 60(300) 60(300) 60(300)
Max. intake vacuum KPa 4.5 5 5 5.5 5.5 6
Max. exhaust back pressure KPa 6.5 7.3 7 7.8 7.5 8.4
Quantity of air for combustion m³/h 31 37 35 42 41 49
Dry weight Kg 45 45 46.5 46.5 48 48
Maximum non-continua-
PTO side 45°°
°°
°(35°°
°°
°)45
°°
°°
°(35°°
°°
°)45
°°
°°
°(35°°
°°
°)45
°°
°°
°(35°°
°°
°)45
°°
°°
°(35°°
°°
°)45
°°
°°
°(35°°
°°
°)
tive slant
Pulley side 35°°
°°
°(30°°
°°
°)35
°°
°°
°(30°°
°°
°)35
°°
°°
°(30°°
°°
°)35
°°
°°
°(30°°
°°
°)35
°°
°°
°(30°°
°°
°)35
°°
°°
°(30°°
°°
°)
(continuative)
Right side 40°°
°°
°(30°°
°°
°)40
°°
°°
°(30°°
°°
°)40
°°
°°
°(30°°
°°
°)40
°°
°°
°(30°°
°°
°)40
°°
°°
°(30°°
°°
°)40
°°
°°
°(30°°
°°
°)
Lato sinistro 45°°
°°
°(30°°
°°
°)45
°°
°°
°(30°°
°°
°)45
°°
°°
°(30°°
°°
°)45
°°
°°
°(30°°
°°
°)45
°°
°°
°(30°°
°°
°)45
°°
°°
°(30°°
°°
°)
Casing oil capacity l. 1.3
Diesel fuel tank capacity l. 5
Max axial load on drive
shaft (non continuative)
Kg 300

6.0
00497R0990 - 15-07-2000
DIESEL
2. POWER GRAPHS
N:N:
N:N:
N: Power for automotive service (DIN 70020)
NB:NB:
NB:NB:
NB: Non-overloadable power (DIN 6271)
NA:NA:
NA:NA:
NA: Continuative overloadable power (DIN 6271)
U1:U1:
U1:U1:
U1: Normal field of use, 3,000 rpm engine rate
U2:U2:
U2:U2:
U2: Normal field of use, 3,600 rpm engine rate
Mt-N:Mt-N:
Mt-N:Mt-N:
Mt-N: Torque rate corresponding to curve N
C-N:C-N:
C-N:C-N:
C-N: Specific consumption with reference to curve N
With ambient temperatures exceeding 20°C (+68°F) or altitudes above sea level, the engine sustains a 2% power loss for every
5°C temperature increase and 1% for every 100 meters of increased altitude.
2000 2400 3600
2
4
6
NA
NB
N
CVkW
rpmg/min
U2
U1
g/CV-h
185
205
1.9
2
Kg m
Mt-N
1600
C-N
2800 3200
1
3
5
7
8
9
10
1
2
3
4
5
6
7
8
1.8
1.7
260
280
240
g/kW-h
N m
20
19
18
17
260
280
240
g/kW-h
N m
23
22
21
20
2
2.1
8
7
6
5
4
3
2
1
10
9
8
7
5
3
1
32002800
C-N
1600
Mt-N
Kg m
2.3
2.2
205
185
g/CV-h
1
U
2
U
g/min rpm
kW CV-HP
N
NB
NA
6
4
2
3600
2400
2000
250
270
230
g/kW-h
N m
27
26
25
24
2.4
2.5
8
7
6
5
4
3
2
1
10
9
8
7
5
3
1
320028001600
Kg m
2.7
2.6
195
175
g/CV-h
1
U
2
U
g/min rpm
kW CV-HP
6
4
2
360024002000
NA
NB
N
Mt-N
C-N
11
12
9
2.8
RY85.0 - RY85.1RY85.0 - RY85.1
RY85.0 - RY85.1RY85.0 - RY85.1
RY85.0 - RY85.1 RY100 - RY101RY100 - RY101
RY100 - RY101RY100 - RY101
RY100 - RY101
RY120 - RY121RY120 - RY121
RY120 - RY121RY120 - RY121
RY120 - RY121

7.0
service
00497R0990 - 15-07-2000
3. OVERALL DIMENSIONS

8.0
00497R0990 - 15-07-2000
DIESEL
4. SPECIAL TOOLS
TOOL CODE DESCRIPTION
Crankshaft gear puller
(also used for series RD engines)
Flywheel puller
(also used for RD series engines)
Tool to mount and demount main bearings
(also used for MD series engines)
Plug to mount and demount main bearings
Sleeve to insert main bearings
Injector test bench
Punch to insert By-pass valve
Tool to stagger injection lead
Piston mounting tool
366.23
366.22
365.90
365.02
365.77
365.10
366.21
365.43
366.24
Capillary tube for injection lead
365.94

9.0
service
00497R0990 - 15-07-2000
Air filter oil level (for engines with wet air filters)
Engine block oil level
Battery fluid level
Rocker arm valve play
Injector calibration
A ir filter
Cylinder and head fins
Fuel tank
Internal oil filter
Injectors
Air filter oil (for engines with wet oil filters) [*]
Engine block oil [*]
Air filter cartridge
Fuel filter
Dry air filter
General overhaul
5. MAINTENANCE SCHEDULE
CHECKING
[*] Use oil for Diesel engines according to MIL-L-2104D specifications with detergent
degree S.3 (MIL-L-45199B) type AGIP SUPERDIESEL MULTIGRADE 15W/40.
use SAE 5W/30 oil if the engine operates in places where the temperature is below
() First oil change.
The maintenance operations refer to engines that operate in normal environmental
conditions (temperature, degree of humidity, degree of dust in the environment) and can
sensiblyvary,dependingonthetypeofuse(theairfilteroilmustbechangedevery4-5hours
in dusty places).
Overhauls include : grinding the valve housings and guides, overhauling the injector and
injection pump, inspection of the injector protrusion, cylinder and piston replacement,
replacement of the main bearings.
REPLACEMENT CLEANING
25002500
25002500
2500
500500
500500
500
200200
200200
200
100100
100100
100
5050
5050
50
88
88
8
OPERATION

10.0
00497R0990 - 15-07-2000
DIESEL
6. TROUBLESHOOTING TABLE
PROBABLE CAUSE
Fails to start Starts and stops Poor efficiency Blocked Noisy Blue smoke White smoke Black smoke Knocks cas.zone Spark pings Hunts Consumes oil Oil lev. inc. Disch. oil/exhaust Disch. oil/air fil. Heats Misfires Does not accel.
DEFECT
Air filter clogged ●
●●
●●
●●
●
Con rod small end with excessive play ●
●●
●
Engine running in ●
●●
●
Unsuitable fuel ●
●●
●●
●●
●●
●●
●●
●●
●
Air intaken by injection pump ●
●●
●●
●●
●●
●●
●●
●●
●
Fuel filter clogged ●
●●
●●
●●
●
Fuel tank empty ●
●●
●
Worn main bearing ●
●●
●
Clearance insufficient ●
●●
●●
●●
●
Clearance excessive ●
●●
●●
●●
●●
●●
●●
●●
●
Timing system gears defective ●
●●
●
Head and cylinder fins clogged ●
●●
●
Valve guides worn ●
●●
●●
●●
●
Piston seized ●
●●
●●
●●
●●
●●
●●
●●
●
Cylinder worn ●
●●
●●
●●
●●
●●
●
Excessive rocker arm play ●
●●
●●
●●
●
Regulator spring defective ●
●●
●
Pipe clogged ●
●●
●●
●●
●
Incorrect injection lead ●
●●
●●
●●
●●
●●
●●
●●
●●
●●
●
Injection pump defective ●
●●
●●
●●
●
Injection pump valve defective ●
●●
●●
●●
●
Intake valve without play ●
●●
●
Injector defective ●
●●
●●
●●
●●
●●
●●
●●
●●
●●
●
Injector with clogged holes ●
●●
●●
●●
●
Oil splash guard seals defective ●
●●
●
Exhaust valve burnt out ●
●●
●●
●●
●
Worn main or big-end bearing ●
●●
●
Excessive load ●
●●
●●
●●
●
Regulator lever with too much play ●
●●
●
Tank plug hole blocked ●
●●
●
Too much oil in casing ●
●●
●●
●●
●
Hardened injection pump lever ●
●●
●●
●●
●
Worn piston rings ●
●●
●●
●●
●●
●●
●
Slack pump delivery union ●
●●
●●
●●
●●
●●
●
Engine cold ●
●●
●
Low idling rate ●
●●
●
Change rate insufficient ●
●●
●

11.0
service
00497R0990 - 15-07-2000
7. ENGINE IDENTIFICATION
The type of engine and serial number are stamped on the
crankcase and on the data plate affixed to the conveyor (fig.
1).
Always indicate these engine identification numbers when
ordering spare parts or making requests under guarantee.
8.3 Removing the flywheel
Remove the fuel tank, the air conveyor and flywheel nut.
Remove the flywheel using puller code 365.02 as indicated in
fig. 4.
WARNING: do not strike the puller in an axial direction during
this operation.
4
1
2
3
8. DEMOUNTING THE ENGINE
8.1 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. 2.
8.2 Removing the injection pump
Markthepositionoftheinjection 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. 3.

12.0
00497R0990 - 15-07-2000
DIESEL
8.5 Demounting the piston
Take out the piston pin as shown in fig. 6.
Warning:Warning:
Warning:Warning:
Warning: do not demount the head when hot or the retention
surfaces could be damaged.
8
7
5
6
8.6 Demounting and remounting the main bearings
Use tool code 365.90 and plug code 366.22 (fig. 7) to
demountthemainbearingsfrom the engine casing and cover
on the timing system side.
To fit the main bearing back into the engine casing, use tool
code 365.90 with plug code 366.22 and sleeve code 366.23
side A (fig. 8).
To mount the main bearing on the cover on the timing system
side, use tool code 365.90 with plug code 366.22 and sleeve
code 366.23 side B (fig. 8).
During the assembly operations, make sure that the bearing
holes match the oil ducts by making reference marks with a
felt-tip pen.
Makesurethatthereferencemarkonthebearingedgepoints
towards:
- the casing interior
- the outer part of the timing system cover.
WARNING
Proceed with the following inspections after assembly:
Cover on timing system sideCover on timing system side
Cover on timing system sideCover on timing system side
Cover on timing system side
The main bearing must project 1.7 to 2 mm1.7 to 2 mm
1.7 to 2 mm1.7 to 2 mm
1.7 to 2 mm in relation to the
bearing surface of the bull ring (inner side of cover).
Engine casingEngine casing
Engine casingEngine casing
Engine casing
The main bearing must be flush with the bearing surface of
the shimming ring (inner side of casing).
8.4 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. 5.
Warning:Warning:
Warning:Warning:
Warning: to prevent damage to the main bearings, it is
advisable to demount the cover from the timing system side
with the engine cold.
Main bearingMain bearing
Main bearingMain bearing
Main bearing
365.90365.90
365.90365.90
365.90
366.22366.22
366.22366.22
366.22
Main bearingMain bearing
Main bearingMain bearing
Main bearing
366.23366.23
366.23366.23
366.23 366.22366.22
366.22366.22
366.22
365.90365.90
365.90365.90
365.90

13.0
service
00497R0990 - 15-07-2000
9. INSPECTIONS AND OVERHAULS
9.1 Head
Parts indicated in fig. 9.
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.
Theheadismadeofaluminiumwith valve guidesandhousings
in faced cast iron.
Do not demount the head when hot to avoid deformations.
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.
9.2 Valves - Guides - Housings
Clean the valves with a metal brush and replace them if the
tops are deformed, cracked or worn.
(*) with guide mounted.
Check the dimensions of the valve stem (fig. 11) and the play
betweentheguideandvalve.Ream theguidetothedimensions
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
guidesaremounted.Valveguidesoversizedontheoutsideby
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. 12).
The valve retention track will widen when the valve housing is
machined.Finaladaptationofthevalveinthehousingmustbe
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. 13).
Comply with the valve embedding values as indicated in the
table (G, fig. 10).
Warning:Warning:
Warning:Warning:
Warning: when the valve embedding values are lower than
those prescribed, the valves could interfere with the piston.
12
11
9
10
BB
BB
B BB
BB
B
1 = intake1 = intake
1 = intake1 = intake
1 = intake
2 = exhaust2 = exhaust
2 = exhaust2 = exhaust
2 = exhaust
CC
CC
C11
11
1CC
CC
C22
22
2
AA
AA
A
DD
DD
D11
11
1DD
DD
D22
22
2
GG
GG
G
FF
FF
F11
11
1
FF
FF
F22
22
2
AA
AA
A
EE
EE
EEE
EE
E
measurements in mm
øAøA
øAøA
øAøBøB
øBøB
øBøC1øC1
øC1øC1
øC1 øC2øC2
øC2øC2
øC2 øD1øD1
øD1øD1
øD1 øD2øD2
øD2øD2
øD2 øE(*)øE(*)
øE(*)øE(*)
øE(*) øF1øF1
øF1øF1
øF1 øF2øF2
øF2øF2
øF2 GG
GG
G
13 13.025 36.630 33.630 36.5 33.5 7 6.96 6.945 0.8
to to to to to to to to to to
13.01 13.037 36.645 33.645 36.525 33.525 7.01 6.97 6.955 1
RY85.0 - RY85.1RY85.0 - RY85.1
RY85.0 - RY85.1RY85.0 - RY85.1
RY85.0 - RY85.1
øAøA
øAøA
øAøBøB
øBøB
øBøC1øC1
øC1øC1
øC1 øC2øC2
øC2øC2
øC2 øD1øD1
øD1øD1
øD1 øD2øD2
øD2øD2
øD2 øE(*)øE(*)
øE(*)øE(*)
øE(*) øF1øF1
øF1øF1
øF1 øF2øF2
øF2øF2
øF2 GG
GG
G
13 13.025 40.13 35.13 40 35 7 6.96 6.945 0.8
to to to to to to to to to to
13.01 13.037 40.145 35.145 40.025 35.025 7.01 6.97 6.955 1
RY100 - RY101 - RY120 - RY121RY100 - RY101 - RY120 - RY121
RY100 - RY101 - RY120 - RY121RY100 - RY101 - RY120 - RY121
RY100 - RY101 - RY120 - RY121

14.0
00497R0990 - 15-07-2000
DIESEL
9.4 Rocker arms
Make sure that there are no evident signs of wear on the
contacting surfaces. Replace the parts if necessary.
9.5 Cylinder
In special cast iron with integral liner. Use a bore gauge to
check the two internal diameters (C-D)(C-D)
(C-D)(C-D)
(C-D) perpendicular to each
other and at different heights (fig. 15). Maximum tolerated
taper error (A-B)(A-B)
(A-B)(A-B)
(A-B) and ovality error (C-D)(C-D)
(C-D)(C-D)
(C-D): 0.06 mm.
Just replace the piston rings if the cylinder diameter does not
exceed the values above or if the cylinder is slightly scored on
the surface. In this case, to ensure that the piston rings and
cylinder adapt to each other as soon as possible, restore liner
roughness by passing 80 to 100 grain emery cloth soaked in
diesel fuel and wound around the palm of the hand over its
innersurface (fig.16)untilthisappearscross-hatched.Follow
theseoperationsbythorough washingingasolineorpetroleum.
Replace the cylinder and piston if there is a ridge in zone "X"
fig. 16 of the cylinder and if tapering and ovality exceed the
previously given values.
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. 9)
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.
9.3 Valve springs
Check the length of the spring as indicated in fig. 14 to identify
any yielding.
Replace the springs if the values are different.
RY85.0 - RY85.1 Ø80 to 80.020
RY100 - RY101 Ø85 to 85.020
RY120 - RY121 Ø87 to 87.020
Cylinder diameter:Cylinder diameter:
Cylinder diameter:Cylinder diameter:
Cylinder diameter:
16
15
14
42.3 to 43.7
28.3 to 28,5
Free length
18.7 to 18.9
14.9114.91
14.9114.91
14.91
±5%
KgKg
KgKg
Kg
13
DD DD
D
CC
CC
CAA
AA
A
22
22
2°
11
11
1°
33
33
3°
BB
BB
B
XX
XX
X
9090
9090
90°- 12020
2020
20°
Ra = 0.5 - 1 µRa = 0.5 - 1 µ
Ra = 0.5 - 1 µRa = 0.5 - 1 µ
Ra = 0.5 - 1 µ
24.7224.72
24.7224.72
24.72
±5%
KgKg
KgKg
Kg

15.0
service
00497R0990 - 15-07-2000
9.6 Piston rings - Piston - Pin
To gauge the wear on the piston rings, put them into the
cylinder from the bottom side and measure the distance
between the free ends (fig. 17), which must be:
Piston ringPiston ring
Piston ringPiston ring
Piston ring Assembly mmAssembly mm
Assembly mmAssembly mm
Assembly mm Wear limit mmWear limit mm
Wear limit mmWear limit mm
Wear limit mm
Compression 0.30 to 0.50 0.80
Oil scraper 0.25 to 0.50 0.80
Make sure that the piston rings slide smoothly in the slots and
use a thickness gauge to check the play between the slot and
ring (fig. 18). Replace the piston and rings if the play exceeds:
Piston ringPiston ring
Piston ringPiston ring
Piston ring Limite di usura mmLimite di usura mm
Limite di usura mmLimite di usura mm
Limite di usura mm
1st Compression A = 0.22
2nd Compression B = 0.19
3rd Oil scraper C = 0.16
WARNING:WARNING:
WARNING:WARNING:
WARNING:itisadvisable to replace the piston ringswhenever
the piston is demounted.
Checking the piston diameter:
the diameter of the piston must be measured at a distance
from the base (fig. 19) of approximately:
10 mm (for RY85.0 - RY85.1 - RY100 - RY101 series engines
11 mm (for RY120 - RY121) series engines
20
19
18
AA AA
A
BB BB
B
CC CC
C
100100
100100
100 mmmm
mmmm
mm
- 0.02- 0.02
- 0.02- 0.02
- 0.02
++
++
+
0.020.02
0.020.02
0.02
- 0.02- 0.02
- 0.02- 0.02
- 0.02
00
00
0
++
++
+
0.020.02
0.020.02
0.02
00
00
0
++
++
+--
--
-++
++
+--
--
-
9.7 Connecting rod
Coupling between the small end hole of the connecting rod
and pin is made without a bearing.
Play between connecting rod small end and pin mm:
Check connecting rod axes parallelism in the following
way:
1) Insert the pin into the small end hole of the connecting rod
and a calibrated plug into the big end (with the bearing
mounted).
2) Rest the plug on two prisms arranged on a surface plate or
between two centers (fig. 20).
3) Use a centesimal comparator to check that the difference
between the readings made at the ends of the pin does not
exceed 0.02 mm0.02 mm
0.02 mm0.02 mm
0.02 mm. square up the connecting rod if the
deformation is greater (max. 0.05 mm)(max. 0.05 mm)
(max. 0.05 mm)(max. 0.05 mm)
(max. 0.05 mm).
Pin ØmmPin Ømm
Pin ØmmPin Ømm
Pin Ømm Play mmPlay mm
Play mmPlay mm
Play mm Wear limit mmWear limit mm
Wear limit mmWear limit mm
Wear limit mm
21.997 to 22.002 0.003 to 0.013 0.040
Check the play between cylinder and piston. Replace the
parts if play exceeds 0.150 mm.
Play between pin and piston mm:
EngineEngine
EngineEngine
Engine Diameter mmDiameter mm
Diameter mmDiameter mm
Diameter mm
RY85.0 - RY85.1 79.915 to 79.935
RY100 - RY101 84.915 to 84.935
RY120 - RY121 86.915 to 86.935
Pin ØmmPin Ømm
Pin ØmmPin Ømm
Pin Ømm Play mmPlay mm
Play mmPlay mm
Play mm Wear limit mmWear limit mm
Wear limit mmWear limit mm
Wear limit mm
21.997 to 22.002 0.023 to 0.038 0.070
17

16.0
00497R0990 - 15-07-2000
DIESEL
55
55
5
24
23
21
22
The operation is carried out by applying a calibrated pressure
to the convex side in the middle of the connecting rod stem set
on surface plates (fig. 21).
CC
CC
C
AA
AA
A
BB
BB
B
9.8 Crankshaft
Itis advisabletocheck theconditionof thecrankshaftwhenever
the engine is demounted and particularly when cylinders and
pistons must be replaced following wear due to dust having
been intaken.
Thoroughly clean inside the oil ducts using a shaped metal
point.
Ifthere areheavilycaked incrustations,immersethe crankshaft
intoabathofpetroleumorgasolinebeforeproceedingwiththe
scraping operation (fig. 22).
Whenthecrankshaftis perfectlyclean,check withamicrometer
to ascertain wear and main journal ovality in the two
perpendicular positions (fig. 23).
Grind the shaft if the wear exceeds the values in the table by
0.08 mm0.08 mm
0.08 mm0.08 mm
0.08 mm or more.
NOTE: crankshaft grinding operations of more than 0.25NOTE: crankshaft grinding operations of more than 0.25
NOTE: crankshaft grinding operations of more than 0.25NOTE: crankshaft grinding operations of more than 0.25
NOTE: crankshaft grinding operations of more than 0.25
mm should not be carried out.mm should not be carried out.
mm should not be carried out.mm should not be carried out.
mm should not be carried out.
Illustration in fig. 24:
1. Internal intake oil filter in casing - 2. Oil pump - 3. By-pass valve
- 4. Engine oil filter - 5. Pressure switch - 6. Main bearing - 7. Big end
bearing.
9.10 Lubrication circuit
Lubrication of the main bearings and connecting rod big end
is the forced type with a rotor oil pump.
Excessive pressure in the oil circuit is prevented by the by-
pass valve (3, fig. 24).
All the other parts are splash lubricated.
Oil vapours are eliminated from inside the casing by a
diaphragm mounted in the rocker arm cover.
9.9 Oil retention rings
Make sure that the rings have not hardened in the retention lip
and that there is no sign of breakage or wear.
DimensionDimension
DimensionDimension
Dimension STD mmSTD mm
STD mmSTD mm
STD mm -0,25 mm-0,25 mm
-0,25 mm-0,25 mm
-0,25 mm
A C 41.97 to 41.99 41.72 to 41.74
B 39.98 to 40 39.73 to 39.75
WARNING:WARNING:
WARNING:WARNING:
WARNING: do not remove material from the main journal
shims during the grinding operation as this would alter
crankshaft float. Also make sure that the grinder radii
correspond to those indicated in fig. 22 to prevent fracture
sections from initiating on the shaft.
Undersized bearings can be mounted without any reaming
work required.
R 1R 1
R 1R 1
R 1 R 0.5R 0.5
R 0.5R 0.5
R 0.5
R 3R 3
R 3R 3
R 3
33
33
3
22
22
2
11
11
1
44
44
4
77
77
766
66
6
66
66
6

17.0
service
00497R0990 - 15-07-2000
28
27
25
26
InjectionInjection
InjectionInjection
Injection
IntakeIntake
IntakeIntake
Intake
ExhaustExhaust
ExhaustExhaust
Exhaust
FF
FF
F
EE
EE
E
CC
CC
C
FF
FF
FDD
DD
D
Rotor ARotor A
Rotor ARotor A
Rotor A Rotor BRotor B
Rotor BRotor B
Rotor B
9.11 Checking the oil pump
Make sure that the oil pump cover is in a good condition.
Afterdemounting,examine the rotors and replace them iftheir
lobes or centerings are damaged. To check the degree of
pump wear, measure the dimensions of rotor AA
AA
Aand rotor BB
BB
B
(fig. 25) and compare them with the values in the following
table:
E 26.205 to 26.27 26,31
F 7.97 to 7.99 7.93
Assembly mmAssembly mm
Assembly mmAssembly mm
Assembly mm Limite usura mmLimite usura mm
Limite usura mmLimite usura mm
Limite usura mm
C Ø25.97 to 25.99 Ø25,92
D Ø34.96 to 34.99 Ø34,87
OIL PUMP ROTOR DIMENSIONS AND PLAY
The entire pump must be replaced if the wear is greater.
The coupling play between the external oil pump rotor and the
housing on the cover of the timing system is:
Assembly mmAssembly mm
Assembly mmAssembly mm
Assembly mm Limite di usura mmLimite di usura mm
Limite di usura mmLimite di usura mm
Limite di usura mm
0.16 to 0.215 0.345
Make sure that the oil pump recess in relation to the surface
of the timing system cover (fig. 26) is between :
Assembly mmAssembly mm
Assembly mmAssembly mm
Assembly mm Wear limit mmWear limit mm
Wear limit mmWear limit mm
Wear limit mm
0.03 to 0.07 0.11
Make sure that there are no impurities in the by-pass valve on
the cover on the timing system side by unscrewing the
inspection plug near the fuel flow limiter.
NOTE:NOTE:
NOTE:NOTE:
NOTE: make sure that the valve lifting mechanism (fig. 28, A)
isnotdamagedand thatthereis nothingtohinder itsmovement.
Check the dimensions of the camshaft pins (D, fig. 28) and the
corresponding housings in the casing and cover on the timing
system side. The max. xonstructional play is 0.032 to 0.061
mm.
WARNING:WARNING:
WARNING:WARNING:
WARNING: replace the shaft if the wear on the cams or pins
exceeds:
0.1 mm0.1 mm
0.1 mm0.1 mm
0.1 mm (injection cams and pins)
0.3 mm0.3 mm
0.3 mm0.3 mm
0.3 mm (intake and exhaust cams)
9.12 Camshaft
Make sure that the cams and bearing pins are not scored or
worn. Check the dimensions as indicated in fig. 27.
Ø17.973Ø17.973 Ø17.973Ø17.973
Ø17.973 to 17.98417.984
17.98417.984
17.984
DD DD
D
DD DD
D
AA
AA
A
Ø17.973Ø17.973 Ø17.973Ø17.973
Ø17.973 to 17.98417.984
17.98417.984
17.984
A.C. PUMP INTAKE INJECTION EXHAUST
34.334.3 34.334.3
34.3 to 34.3534.35
34.3534.35
34.35
28.7928.79 28.7928.79
28.79 to 28.8128.81
28.8128.81
28.81

18.0
00497R0990 - 15-07-2000
DIESEL
9.13 Tapets and rocker arms
Make sure that there is no wear, scoring or signs of seizure on
the surfaces of the tappets (fig. 29). Replace the parts if
necessary.
Tapet and housing coupling play:
The rods must be straight with ball shaped surfaces at the
ends and in good conditions (fig. 29).
9.14 Injection pump tappets and pads
Replace the parts if the wear on their surfaces exceeds 0.1
mm (fig. 30).
Coupling play between the tappet and relative housing in the
crankcase:
Assembly mmAssembly mm
Assembly mmAssembly mm
Assembly mm Limite di usura mmLimite di usura mm
Limite di usura mmLimite di usura mm
Limite di usura mm
0.005 to 0.029 0.10
Assembly mmAssembly mm
Assembly mmAssembly mm
Assembly mm Wear limit mmWear limit mm
Wear limit mmWear limit mm
Wear limit mm
0.021 to 0.059 0.10
10.2 Injection pump
Illustration in fig. 32:
1. Delivery union - 2. Filler - 3. Valve spring - 4. Delivery valve - 5.
Washers - 6. Monobloc pump casing - 7. Adjuster seal - 8. Flange
- 9. Pump seal - 10. Plunger - 11. Adjuster sleeve - 12. Plug - 13.
Adjuster block - 14. Spring - 15. Lower cap
10. INJECTION COMPONENTS
10.1 Fuel circuit
Fuel supply is the gravitational type. An AC pump can be
mounted on request. Air bleeding is automatic.
Illustration in fig. 31:
1. Fuel tank - 2. Fuel pipe - 3. Fuel filter - 4. Fuel pipe - 5. Injection
pump - 6. Injection pump tappet - 7. Bleed tubes - 8. Injection
pipe - 9. Injector - 10. Washer - 11. Fuel return pipe.
32
31
29
30
198.8198.8
198.8198.8
198.8 to 199.2199.2
199.2199.2
199.2
Ø7.986Ø7.986
Ø7.986Ø7.986
Ø7.986 to 7.9957.995
7.9957.995
7.995
Ø18.9Ø18.9 Ø18.9Ø18.9
Ø18.9 to 1919
1919
19
4.454.45
4.454.45
4.45 to 4.554.55
4.554.55
4.55
22
22
2
216.8216.8
216.8216.8
216.8 to 217.2217.2
217.2217.2
217.2
RY85.0 -RY85.1RY85.0 -RY85.1
RY85.0 -RY85.1RY85.0 -RY85.1
RY85.0 -RY85.1
RY100 - RY101RY100 - RY101
RY100 - RY101RY100 - RY101
RY100 - RY101 RY120 - RY121RY120 - RY121
RY120 - RY121RY120 - RY121
RY120 - RY121
Ø21.959Ø21.959 Ø21.959Ø21.959
Ø21.959 to 21.97921.979
21.97921.979
21.979
11
11
1
77
77
7
33
33
3
44
44
4
55
55
5
66
66
6
77
77
777
77
7
1010
1010
10
99
99
9
88
88
8
1111
1111
11
11
11
1
22
22
2
33
33
3
44
44
4
55
55
5
66
66
6
77
77
7
88
88
8
99
99
9
1010
1010
10
1111
1111
11
1212
1212
12
1313
1313
13
1414
1414
14
1515
1515
15
9.15 Fuel pump (optional)
Check the projection of the A.C. pump rod in relation to the
engine casing surface with the canshaft eccentric in the non-
operative position.
WARNING: the rod projection cannot be adjusted.
53.0 to 53.2 0.3 1.45 to 2.05
Wear limitWear limit
Wear limitWear limit
Wear limit
mmmm
mmmm
mm
Rod lengthRod length
Rod lengthRod length
Rod length
mmmm
mmmm
mm Rod projectionRod projection
Rod projectionRod projection
Rod projection
mmmm
mmmm
mm

19.0
service
00497R0990 - 15-07-2000
36
35
33
34
10.5 Injection pump assembly (fig. 37)
If the injection pump must be demounted, use an electric pen
tomarkthe adjuster block (M) with the enblocpump casing (A)
and loosen the plug (N) after having heated it to make the
Loctite easier to release.
Comply with the following instructions when remounting the
parts:
1) Fit the washer (B), the delivery valve (C), the washer (D),
the valve spring (E), the filler (F) into the enbloc pump
casing (A) and torque the delivery union (G) to a value of:
10.3 Checking the injection pump
before demounting the injection pump, make sure that the
plunger unit, enbloc pump casing and valve are pressure tight
by proceeding in the following way:
1) Connect a pressure gauge with scale up to 600 Kg/cm²600 Kg/cm²
600 Kg/cm²600 Kg/cm²
600 Kg/cm²to
the fuel delivery pipe (fig. 33).
2) Set the regulating sleeve (fig. 34) to the average delivery
position.
3) Slowly turn the flywheel to make the plunger make one
compression stroke.
4) Read the indication on the pressure gauge. If it is lower
than 300 Kg/cm²300 Kg/cm²
300 Kg/cm²300 Kg/cm²
300 Kg/cm², the complete pump must be changed.
During the test, the pressure gauge needle will show a
progressive pressure increase until reaching a maximum
value, after which it will drop sharply back and stop at a lower
pressure value. Replace the valve if the pressure drop is more
that 50 Kg/cm²50 Kg/cm²
50 Kg/cm²50 Kg/cm²
50 Kg/cm²and continues to slowly drop lower.
The pressure must drop from 200 Kg/cm²200 Kg/cm²
200 Kg/cm²200 Kg/cm²
200 Kg/cm²to 150 Kg/cm²150 Kg/cm²
150 Kg/cm²150 Kg/cm²
150 Kg/cm²in
not less than 7 sec.7 sec.
7 sec.7 sec.
7 sec.
10.4 Injection pump calibration (fig. 35)
When the adjuster sleeve is 10.5 mm10.5 mm
10.5 mm10.5 mm
10.5 mm from the stop position
and the pump spins at 1,500 rpm1,500 rpm
1,500 rpm1,500 rpm
1,500 rpm, the amount of fuel for 1,0001,000
1,0001,000
1,000
deliveries must be between:
WARNING:
Check to make sure that plunger travel with the injection cams
in the non-operative position (BDC) at the start of delivery is:
1.9 to 2.0 mm1.9 to 2.0 mm
1.9 to 2.0 mm1.9 to 2.0 mm
1.9 to 2.0 mm
2323
2323
23 toto
toto
to 25 cc25 cc
25 cc25 cc
25 cc
Replace the pump if the values differ.
2) Insert the adjuster seal (H).
3) Insert the flange (I).
4) Inserttheplungerwithhelical profile (A, fig. 36) into the iner
housing of the adjuster sleeve from the side opposite the
sleeve pin (B, fig. 36).
4.3 to 5.4 Kgm (42.5 to 52.5 Nm)4.3 to 5.4 Kgm (42.5 to 52.5 Nm)
4.3 to 5.4 Kgm (42.5 to 52.5 Nm)4.3 to 5.4 Kgm (42.5 to 52.5 Nm)
4.3 to 5.4 Kgm (42.5 to 52.5 Nm)
AA
AA
A
BB
BB
B

20.0
00497R0990 - 15-07-2000
DIESEL
40
39
37
38
DD
DD
D
5) Insert the adjuster sleeve unit and plunger (L) into the
pump casing (A), making sure that the helical profile is
directed on a level with the return union with ball.
6) Fit in the adjuster block (M), matching the reference marks
applied during the demounting phase.
7) Tighten the plug (N) to a 0.5 to 0.6 Nm0.5 to 0.6 Nm
0.5 to 0.6 Nm0.5 to 0.6 Nm
0.5 to 0.6 Nm torque, locking it in
place with Loctite 290.
8) Insert the spring (O) and lower cap (P).
9) Compress the tappets in the various operating positions to
check that the adjuster sleeve (L) slides perfectly.
Resistance or jamming will make the engine to hunt during
operation.
10.6 Leak test
Plug the fuel return union and let air in through the fuelling
union at a pressure of 6 Kg/cm²6 Kg/cm²
6 Kg/cm²6 Kg/cm²
6 Kg/cm². Fully immerse the pump in
a receptacle containing diesel fuel for about 50 - 60 seconds
(fig. 38) and make sure that no bubbles appear when the
tappet is compressed 53.6 mm, corresponding to the bottom
dead center point during work.
NOTE: the position of the pump adjuster sleeve is of no
importance for this test.
10.7 Injector
Details of fig. 39:
1. Filter - 2. Fuel inlet union - 3. Fuel return union - 4. Nozzle holder
- 5. Calibration washer - 6. Spring - 7. Pressure rod - 8. Spacer - 9.
Nozzle - 9. Ring nut.
10.8 Injector inspection and calibration
1) Clean the nozzle holes with a thin steel wire (fig. 40) with
the following diameters: 11
11
1
22
22
2
99
99
977
77
755
55
5
33
33
3
44
44
4
66
66
6
88
88
8
1010
1010
10
6 Kg/cm
air
GG
GG
G
FF
FF
F
EE
EE
E
BB
BB
B
CC
CC
C
AA
AA
A
HH
HH
H
LL
LL
L
IIIII
MM
MM
M
OO
OO
O
PP
PP
P
NN
NN
N
2) Mount the injector on the test bench (code 365.43, fig. 41).
Disconnect the pressure gauge and rapidly operate the
lever. The nozzle must make the characteristic "trilling"
sound and inject with a good atomizing action.
3) Connect the pressure gauge. Slowly depress the level in a
continuous way until injection occurs.
The injector needle must "open" at the pressure of 230 to
238 bar. Vary the washer shims (N°5 fig. 39) to calibrate
in the correct way.
4) Leak test:Leak test:
Leak test:Leak test:
Leak test: operate the test bench lever until the gauge
pointer is 20 Kg/cm²below the injection pressure value.
Nozzle tightness is good if no fuel comes out within 10 sec.
5) Checkingfor leaks on the nozzle return phase:Checkingfor leaks on the nozzle return phase:
Checkingfor leaks on the nozzle return phase:Checkingfor leaks on the nozzle return phase:
Checking for leaks on the nozzle return phase: operate
the test bench lever until the gauge pointer is 20 Kg/cm²
RY85.0
RY85.1
Diameter of steelDiameter of steel
Diameter of steelDiameter of steel
Diameter of steel
wire (mm)wire (mm)
wire (mm)wire (mm)
wire (mm)
EngineEngine
EngineEngine
Engine
seriesseries
seriesseries
series Number ofNumber of
Number ofNumber of
Number of
holesholes
holesholes
holes Diameter ofDiameter of
Diameter ofDiameter of
Diameter of
holes (mm)holes (mm)
holes (mm)holes (mm)
holes (mm)
RY100
RY101
RY120
RY121
0.210.21
0.210.21
0.21
0.240.24
0.240.24
0.24
4 0.22
5 0.25