Lombardini Marine Engines RY 125 series engines Workshop Manual

1 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 02-04 REVISION 00 RY125 1 st Edition WORK SHOP MANUAL RY 125 series engines, p.no. 1-5302-633

2 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 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 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 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.

4 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 02-04 REVISION 00 INDEX I TROUBLE SHOOTING__________________________________________________________ Page 7 II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS ____________________________ " 8 III MODEL NUMBER AND IDENTIFICATION _____________________________________________ " 10 IV TECHNICAL DATA ______________________________________________________________" 11 V CHARACTERISTICS _____________________________________________________________ " 12 VI OVERALL DIMENSIONS __________________________________________________________ " 13 VII SPECIAL TOOLS________________________________________________________________ " 14 VIII MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING _______________________________ " 15 IX DISASSEMBLY OF 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 CHECKS AND OVERHAUL ______________________________________________________ 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 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 02-04 REVISION 00 INDEX XI INJECTION EQUIPMENT ________________________________________________________ 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 ELECTRICAL EQUIPMENT ______________________________________________________ Page 29 Characteristics of the system ......................................................................................................................................... 29 Checking the alternator ................................................................................................................................................... 30 Checking the system ...................................................................................................................................................... 29 Ring gear ........................................................................................................................................................................ 30 XIII ENGINE ASSEMBLY ___________________________________________________________ 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

6 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 02-04 REVISION 00 INDEX XIV ENGINE TESTING _____________________________________________________________ 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 QUICK REFERENCE CHARTS ____________________________________________________ Page 41 Adjustments .................................................................................................................................................................... 41 Couplings ........................................................................................................................................................................ 41 Standard screw tightening torques ................................................................................................................................. 42 Tightening torques .......................................................................................................................................................... 42 XVII SERVICE ____________________________________________________________________ Page 43

7 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 02-04 REVISION 00 I TROUBLE 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

8 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 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 W ARNING DECALS SAFETY INSTRUCTIONS DANGER CAUTION • 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. • The engine has been made according to a machine manufacturer's specifications and all actions required to meet the essential safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit. All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined by Ruggerini which thus declines all liability for any accidents deriving from such operations. • The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine operation in particular, along with the relative routine maintenance work. • The user must read these instructions carefully and become familiar with the operations described. Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of the machine. • The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and the deriving dangers. This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the latter case, must only be carried out by persons specifically trained by Ruggerini and who work in compliance with the existing documentation. • Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal of seals, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve Ruggerini from all and every liability for deriving accidents or for failure to comply with the laws in merit. • On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous objects, also considering the movements made by the operator. Pull-starting with a free cord (thus excluding self- winding starting only), is not permitted even 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. • Never start the engine in a closed place or where there is insufficient ventilation. Combustion creates carbon monoxide, an odourless and highly poisonous gas. Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death.

9 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 02-04 REVISION 00 II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS • The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is dust that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been certified for the machine. • To prevent fire hazards, always keep the machine at least one meter from buildings or from 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 COMPILER TECO/ATI ENDORSED DATE 29.02.2004 REG. CODE 1-5302-633 MODEL N° 51074 DATE OF ISSUE 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

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Lombardini Marine Engines RY 125 series engines Workshop Manual

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