Related Manuals for Ruggerini RD210
Summary of Contents for Ruggerini RD210
- Page 1 WORK SHOP MANUAL RD series engines, p.no. 1-5302-620 RD210 RD211 RD270 RD278 Edition COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-620 50902 08-03 01.08.2003...
-
Page 2: General Service Notes
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. - Page 3 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.
-
Page 4: Table Of Contents
INDEX 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. TROUBLE SHOOTING __________________________________________________________ Page SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS ____________________________ ”... - Page 5 INDEX INJECTION EQUIPMENT ________________________________________________________ Page 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 ELECTRICAL EQUIPMENT ______________________________________________________ Page Alternator checking (stator) .............................
- Page 6 INDEX ENGINE TESTING _____________________________________________________________ Page Checking for oil leaks ..............................42 Checking oil pressure ..............................42 Speed adjustment ................................42 Testing engine on brake ..............................43 STORAGE ___________________________________________________________________ Page How to prepare the engine for operation ........................44 Permanent protection (over 6 months) ........................... 44 Storage ....................................
-
Page 7: Trouble Shooting
TROUBLE SHOOTING POSSIBLE CAUSES AND TROUBLE SHOOTING The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before removing or replacing any part. TROUBLE POSSIBLE CAUSE Clogged pipes Clogged fuel filter Air inside fuel circuit Clogged tank breather hole Faulty fuel pump... -
Page 8: Safety And Warning Decals - Safety Instructions
SAFETY INSTRUCTIONS • Ruggerini Engines are built to supply their performances in a safe and long-lasting way. To obtain these results, it is essential for users to comply with the servicing instructions given in the relative manual along with the safety recommendations listed below. - Page 9 • 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.
-
Page 10: Model Number And Identification
MODEL NUMBER AND IDENTIFICATION MODEL NUMBER ENGINE IDENTIFICATION Model Engine Serial Number Approval code Customer's code R.P.M. setting R.P.M. Displacement (cc) COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-620 50902 08-03 01.08.2003... -
Page 11: Technical Data
TECHNICAL DATA CHARACTERISTICS ENGINE TYPE RD210 RD211 RD270 RD278 Number of cylinders Bore Stroke Swept volume cm³ 1205 1205 Compression ratio 19:1 19:1 18:1 18:1 @ 3000 RPM 15(20,5) — 20(27,2) — N 80/1269/CEE-ISO 1585 @ 3600 RPM — 17(23) —... -
Page 12: Vcharacteristics
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. COMPILER TECO/ATI REG. -
Page 13: Overall Dimensions
OVERALL DIMENSIONS RD210 RD211 RD270 RD278 Note: Dimensions in mm COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-620 50902 08-03 01.08.2003... -
Page 14: Special Tools
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... -
Page 15: Maintenance - Recommended Oil Type - Refilling
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING VIII Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system MANUTENANCE INTERVAL (HOURS) OPERATION COMPONENT 500 2500 5000 OIL-BATH AIR CLEANER HEAD AND CYLINDER FINS CLEANING FUEL TANK INJECTOR... -
Page 16: Viii Maintenance - Recommended Oil Type - Refilling
VIII 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. -
Page 17: Disassembly Of The Engine
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. Flywheel extraction Use extractor cod. 00365R0020, as shown in figure 1. -
Page 18: Cylinder Heads
“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). Ø Gauge mm Ø Guide Engine Guide no go RD210 Inlet 7,000 ÷ 7,010 7,000 7,079 RD211 Outlet 9,020... - Page 19 Valve seats with an external diameter increased by 0.2 mm for the RD210 and 0.5 mm for the RD270, are available. After grinding, wash valve and seat carefully with petrol or paraffin to eliminate any residual grinding paste or cuttings.
-
Page 20: Xchecks And Overhaul
25 kg be renewed. 27 kg RD210 RD 211 RD270 RD278 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. -
Page 21: Piston Rings - Pistons - Piston Pins
Piston diameter check: The diameter of the piston must be measured at approximately 18 mm from the base (fig.19). Engine Diameter mm RD210 RD 211 89,919 ÷ 89,930 RD270 RD278 94,920 ÷ 94,935 Check the clearance between cylinder and piston, if it is greater than 0.120 mm both cylinder and piston must be replaced. -
Page 22: Connecting Rods
÷ 0,08 If it is necessary to replace a complete connecting rod with bushes and bolts, make sure its weight is: Engine Weight RD210 RD 211 gr. 570 ± 10 RD270 RD278 gr. 760 ± 10 Check parallelism between connecting rod axies (fig. 21) as follows: 1. -
Page 23: Crankshaft
CHECKS AND OVERHAUL Crankshaft Whenever the engine is dismantled, particularly for the replacement of cylinders and pistons due to wear caused by the aspiration of dust, it is good practice to check the condition of the crankshaft. 1. Remove the plugs “A” from the oil passages (fig.23). 2. -
Page 24: Camshaft
27 and 28 and comparing to the figures of the tables hereunder: exhaust inlet Distribution cam dimensions (fig. 27). Fitting Max. wear Measurement Engine RD210-211 29,95 ÷ 30,00 29,70 RD270-278 30,52 ÷ 30,57 30,25 Injection cam dimensions (fig. 28) Fitting Max. -
Page 25: Governor Lever And Spring
CHECKS AND OVERHAUL Governor lever and spring Check that the shoes (S, fig. 30) are level and that the springs have not lost their elasticity. Renew any excessively worn parts after consulting the spare parts catalogue. Supplement and governor spring dimensions (fig. 30): Lenght Lenght under Load... -
Page 26: Injection Equipment
Details of fig. 33: 1.Tank - 2.Diesel filter - 3.Feeding pump - 4.Injection pump - 5.Injection pipes - 6.Injectors - 7.Diesel discharge pipe. RD210 RD 211 Injection pump The injection pump is of the single casing type with two, constant stroke, separate pumping elements. -
Page 27: Injection Pump Assembly
The quantity of diesel is in relation to 1000 deliveries with the rack bar at 8 mm from the stop position. Ø Pumping Valve Ø Capacity Pump Engine element mm valve RD210-211 24 ÷ 26 24 ÷ 26 1500 1500 RD270 31 ÷ 33 31 ÷ 33 1500... -
Page 28: Injector Checking And Setting
Type B injector for RD 270-278 1.Body - 2.Nozzle - 3.Ring nut - 4.Plate - 5.Rod - 6.Spring - 7.Adjustment shim. RD210 RD 211 RD270 RD278 Injector checking and setting 1. Clean out nozzle holes with a thin piece of wire (fig. 42) of the... -
Page 29: Electrical Equipment
ELECTRICAL EQUIPMENT Electric starting with motor and alternator for battery re-charging Characteristics: Starter motor: anticlockwise rotation. 12V - 1.5 HP (1.1 kW) for RD 210-211 12V - 2.5 HP (1.9 kW) for RD 270-278 12V - 3.4 HP (2.5 kW) for RD 270-278 Flywheel alternator: - For re-charging 12V/280W batteries giving 17A charge at 3000 RPM, for RD 210-211... -
Page 30: Alternator Checking (Stator)
6. Avoid sparks between cables, as the alternator could burn out. RD210 RD 211 7. With an imperfect earth between the negative battery terminal and regulator casing, the charging current is irregular and the regulator could be damaged. - Page 31 ELECTRICAL EQUIPMENT Diagram of electric starting wiring system with flywheel alternator RD210 RD 211 (fig. 47). 1.Battery - 2.Regulator - 3.Alternator - 4.Starter motor - 5.Pressure gauge - 6.Oil pressure warning light - 7.Starter key - 8.Battery charging light. Diagram of electric starting wiring system with external alternator (fig.
-
Page 32: Engine Assembly
ENGINE ASSEMBLY Notice: These instructions are valid for engines up-dated prior to the publication of this manual. Any modifications must be checked on the technical circulars. Before assembling the engine carefully clean all parts and dry them with compressed air. Lubricate moving parts to prevent seizing when starting up. -
Page 33: Crankshaft Preparation
ENGINE ASSEMBLY XIII Crankshaft preparation The insertion of the main distribution gear onto the crankshaft must be carried out while hot. Heat by means of dry heating or an oil bath at 70/80 °C (fig. 53). Upper crankcase preparation 1. Insert accelerator internal lever onto crankcase taking care not to damage the oil seal O-Ring. -
Page 34: Timing Cover Assembly
8. Insert oil seal rings on the drive side of the crankshaft (fig. 58). A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems. Use genuine oil retainers with the RUGGERINI. 9. Mount lower crankcase complete with studs, centering pins and bearings. -
Page 35: Fitting Of Oil Seal Rings
A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems. Use genuine oil retainers with the RUGGERINI. The oil seal rings are to be fitted with the arrow pointing in the same direction of the crankshaft rotation. -
Page 36: Connecting Rod-Crankshaft Coupling
After insertion of the bearings into the big end, attach connecting rods to crank pins, bearing in mind that an arrow, on the pistons for RD210-211 , indicates the rotation direction of the engine (fig. 66). The combustion chamber, which is eccentric with respect to the axis, should be turned to the nozzle side. -
Page 37: Cylinder Mounting
ENGINE ASSEMBLY XIII Piston ring fitting Fit rings onto pistons in the following order (fig. 68): RD210-211 1. Chromed compression seal ring. 2. Torsional compression seal ring (with internal notch turned upwards). 3. Expander oil scraper ring. RD270-278 1. Chromed compression seal ring. -
Page 38: Checking Injector Protrusion
Before mounting the heads on the cylinders, insert injectors in their housings and after having secured them temporarily, check protusion of nozzles from head surface (fig. 75). Protusion S should be: Engine RD210 RD 211 2,25 ÷ 2,75 RD270 RD278 3,75 ÷ 4,25 COMPILER TECO/ATI REG. -
Page 39: Fitting Cylinder Heads
Adjustment is effected by inserting copper washers between the injector and injector supporting faces on the heads (fig. 76). Washer thickness 1 mm (RD210-211) and 0.5 mm (RD270-278). Fitting cylinder heads Insert oil seal O-rings on rocker arm housing and fit the cylinder head in place. -
Page 40: Checking T.d.c
XIII ENGINE ASSEMBLY Injection pump fitting Fit injection pump into timing case inserting adjusting shim between supporting flange and crankcase (fig. 80). To facilitate the insertion of the pump, rotate the flywheel so as to bring the actuating cam to rest position and set the rack bar in a half way position. -
Page 41: Checking Start Of Injection
Should the flywheel need to be replaced, the top dead center compression position of the pistons is to be determined as per page 40 and the start of injection according to the following table: Engine I.P. Ø flywheel RD210-211 26° 53,5 mm 236 mm RD270 27°... -
Page 42: Engine Testing
ENGINE TESTING Speed adjustment 1. With engine hot set minimum speed at 1000 RPM (fig. 88) and maximum to idle (fig. 89) at: 2100 RPM for RD 278 engine 3150 RPM for RD 210 engines 3700 to 3750 RPM for RD 211 engines 2. -
Page 43: Testing Engine On Brake
ENGINE TESTING Testing engine on brake After having placed the engine on the brake (fig. 92), proceed with the following operations: 1. Check oil level (fig. 93). 2. Start engine and run at minimum speed. 3. Check oil pressure on pressure gauge (fig. 90). 4. -
Page 44: Storage
STORAGE Storage Prepare engines as follows for storage over 30 days Temporary protection (1/6 months) • Let engine run at idling speed in no-load conditions for 15 minutes. • Fill crankcase with protection oil MIL-1-644-P9 and let engine run at 3/4 full speed for 5/10 minutes. •... -
Page 45: Quick Reference Charts
Camshaft journal and housing in crankcase 0,015÷ 0,048 End gap of compression rings 0,30 ÷ 0,50 End gap of oil scraper rings 0,25 ÷ 0,40 Connecting rod and wrist pin RD210-211 0,023 ÷ 0,038 0,07 Connecting rod and wrist pin RD270-278 0,001 ÷ 0,007 0,05 Rockers and shaft 0,030 ÷... -
Page 46: Standard Screw Tightening Torques
QUICK REFERENCE CHARTS Tightening torques (Nm) Crankcase (12,8) Connecting rod 3,8 ÷ 4,0 (37,3 ÷ 39,3) Bolt on power take off end (245,5) Timing cover (9,8) Oil sump (12,8) Injectors (22,6) Injection pump (22,6) Oil pump cover (5,9) Cylinder head (49) Flywheel (274,9) - Page 47 NOTE COMPILER TECO/ATI REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED REVISION 1-5302-620 50902 08-03 01.08.2003...
- Page 48 RUGGERINI MOTORI Via Cav. del Lavoro A. Lombardini, 2 42100 REGGIO EMILIA - Italia - ITALY Tel. (+39) 0522 3891 - Fax (+39) 0522 389433/465 http://www.ruggerini.it è un marchio della La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione.
Need help?
Do you have a question about the RD210 and is the answer not in the manual?
Questions and answers