WORK SHOP

MANUAL
RD 290 series Engine, code 1-5302-574

RD 290

1nd edition

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

REVISION 00 1
1-5302-574 50861 30.03.2003 30.03.2003
PREFACE

Every attempt has been made to present within this service manual, accurate and up to date
technical information. However, development on the Ruggerini series is continuos. Therefore, the
information within this manual is subject to change without notice and without obligation.
The information contained within this service manual is the sole property of Lombardini. As such,
no reproduction or replication in whole or part is allowed without the express written permission of
Lombardini.

Information presented within this manual assumes the following:

1 - The person or persons performing service work on Ruggerini series engines is properly trained
and equipped to safely and professionally perform the subject operation;
2 - The person or persons performing service work on Ruggerini series engines possesses
adequate hand and Lombardini special tools to safely and professionally perform the subject
service operation;
3 - The person or persons performing service work on Ruggerini series engines has read the
pertinent information regarding the subject service operations and fully understands the operation
at hand.

GENERAL SERVICE MANUAL NOTES:

1- Use only genuine Lombardini repair parts. Failure to use genuine Ruggerini parts could result in
sub-standard performance and low longevity.
2- All data presented are in metric format. That is, dimensions are presented in millimeters (mm),
torque is presented in Newton-meters (Nm), weight is presented in kilograms (Kg), volume is
presented in liters or cubic centimeters (cc) and pressure is presented in barometric units (bar).
 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.

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

REVISION 00 3
1-5302-574 50861 30.03.2003 30.03.2003
 INTRODUCTION

This manual contains pertinent information regarding the repair of RUGGERINI air-cooled, direct
injection Diesel engines type RD 290: updated March 30, 2003.

TABLE OF CONTENTS

I TROUBLESHOOTING Pag. 9

II SAFETY DECALS - SAFETY INSTRUCTIONS " 10-11

III MODEL NUMBER AND IDENTIFICATION " 12

IV TECHNICAL DATA " 13

V CHARACTERISTIC CURVES " 14

VI OVERALL DIMENSIONS " 15

VII MAINTENANCE- RECOMMENDED OIL TYPE - REFILLING " 18-19

VIII DISASSEMBLY / REASSEMBLY " 21-45

0il vapour separator ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

22
0il-bath air cleaner ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
21
Alternator ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
24
CAMSHAFT ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

39
Camshaft end play ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
40
Camshaft timing ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
40
Checking main journals and crank pins ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
36
Checks and cylinder roughness ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
30
Clearance between main journals/crank pins and connecting rod bearings (mm) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
37
Clogging indicator ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
22
Compression release (optional) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 25
CONNECTING ROD ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
32
Connecting rod alignment ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 33
Connecting rod big end bearing ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
33
Connecting rod small end bushing ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
32
Connecting rod weight ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
33
Cooling fan ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
23
CRANKSHAFT ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
35
Crankshaft center main bearing support ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
35
Crankshaft end play ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
38
Crankshaft journal radii ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
36
Crankshaft lubrication ducts ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
36
Crankshaft removal ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
35
Crankshaft timing gear ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 34
CYLINDER ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
30
CYLINDER HEAD ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
26
Dimensions and clearance between guides and valves (mm) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 28
Dimensions of camshaft journals and housings (mm) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
39
Dry air cleaner ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
21
ELECTRONIC SPEED GOVERNOR ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
44
Electronic speed governor ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
44
Electronic speed governor control box ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 45
Electronic speed governor layout ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
44
Engine running with electronic speed governor ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
45
Exhaust manifold ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
23
Flywheel ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
25
Governor springs with rocker arm ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 43

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

4 REVISION 00
1-5302-574 50861 30.03.2003 30.03.2003
 INTRODUCTION

Governor springs with rocker arm ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

43
How to measure intake/exhaust cam height ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 39
How to measure main bearing inside diameter ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 37
Hub ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 24
Hydraulic pump p.t.o. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 42
Hydraulic pump p.t.o. (1 P) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
42
Injector ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 26
Injector projection ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
26
Intake manifold ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
22
Main bearing and connecting rod big end bearing inside diameter ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 37
Main bearing housings ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 38
Main bearing support, flywheeI side ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 34
Main bearing support, gear side ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 34
Main bearíng supports ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 38
Main journal and crank pin diameter (mm) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 36
MECHANICAL SPEED GOVERNOR ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 42
Mechanical speed governor ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 42
PISTON ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 30
Piston - Refitting ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 32
Piston clearance ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 32
Piston rings - End gaps (mm) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 31
Piston rings - Fitting sequence ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
31
Piston weight ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 31
Pistons ringis - Clearance between grooves (mm) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 31
Pulley guard - Shroud - Side plates ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 23
Pushrod tube ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 29
Rocker arm assembly ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 25
Shroud support (Gear cover plate) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 24
Spring for extra fuel supply at starting ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 43
Starting with electronic speed governor ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
45
Tank ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 24
Valve / rocker arm clearance ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 25
Valve guide insertion ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 28
Valve guides and valve guide housings ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
28
Valve material ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
27
Valve seat grinding ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 29
Valve seats and housings ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 29
Valve springs ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 27
Valve timing check ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 41
Valve timing without considering timing marks ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
40
Valves ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 27

IX LUBRICATION SYSTEM 46-48

Lubrication system ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
46
OIL PUMP ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 47
Oil filter cartridge (internal) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 47
Oil pressure relief valve ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
47
Oil pressure check ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
47
Oil pressure curve at idling speed ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
48
Oil pressure curve at full speed ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
48

IX FUEL SYSTEM 49-55

(STATIC) INJECTION TIMING ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

53
Check window for injection timing reference mark ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
54
Fuel feeding pump ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
49
Fuel feeding pump drive rod protrusion ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
49
Fuel feeding/injection circuit ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
49
Fuel filter (inside fuel tank) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
49
How to check injection pump delivery valve sealing ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
51
How to check plunger and barrel for internal leakage ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
51
How to mount injection pump on the engine ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
52
How to reassemble injection pump components ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
52

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

REVISION 00 5
1-5302-574 50861 30.03.2003 30.03.2003
 INTRODUCTION

INJECTION PUMP ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
50
Injection pump ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 50
Injection pump/mechanical speed governor timing ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 52
Injection timing check ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 53
Injection timing check ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 54
Injection timing checking device ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
53
Injection timing correction ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 54
INJECTOR ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 55
Injector setting ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 55
Nozzle ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 55
Plunger and Barrel Assembly ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 50
Test data for injection pump delivery ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 51

XI ELECTRIC SYSTEM 56-63

12 V, 24 A special voltage regulator ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

60
12.5 V, 14 A Alternator ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 56
14 V, 33 A Bosch G1 alternator battery charger curve ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 61
Alternator battery charger curve (12 V, 18 A) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
60
Alternator battery charger curve (12.5 V, 14A) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 57
Alternator type Bosch G1 14 V, 33 A ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 61
Alternator type Bosch G1 14 V, 33 A layout ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
61
Bosch starting motor type GIF - 12 V, class 1.5 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
62
Characteristic curves for starting motor type Bosch DW (R), 12 V, 1.7 kW ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 63
Characteristic curves for starting motor type Bosch GF -12 V, class 1.5 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
63
Characteristic curves for starting motor type Magneti Marelli E100, 1.5/12 V ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
62
Checking for cable continuity ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
57
Electrical starting layout with battery charging light ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 56
How to check voltage regulator for proper operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 59
Magneti Marelli starting motor type E100, 1,5/12 V ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 62
Magnetization checking tool (Part No. 7000-9727-001) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
57
OPTIONAL ELECTRIC EQUIPMENT ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
60
STANDARD ELECTRIC EQUIPMENT ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 56
STARTING MOTOR ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
62
Starting motor type Bosch DW (R) 12 V, 1.7 kW ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
63
VOLTAGE REGULATOR ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
58

XII SETTINGS 64-66

SETTINGS 64
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Full speed setting in no-load conditions (standard) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

64
lnjection pump delivery setting ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
64
lnjection pump delivery limiting and extra fuel device ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
64
Injection pump delivery setting with engine at the torque dynamometer ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
65
Required settings (as most commonly applies) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 65
Stop setting ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
66

XIII STORAGE 67

STORAGE ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
67
Temporary protection (1÷6 months) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
67
Permanent protection (over 6 months) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
67
How to prepare the engine for operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 67

XIV TORQUE SPECIFICATIONS 68-69

MAIN TORQUE SPECIFICATIONS ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

68
STANDARD BOLT TORQUE SPECIFICATION ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
69

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

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 NOTE

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

REVISION 00 7
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 NOTE

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

8 REVISION 00
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 POSSIBLE CAUSES AND TROUBLE SHOOTING I

POSSIBLE CAUSES AND TROUBLE SHOOTING

The following table contains the possible cause of some failures which may occur during operation. Always
perform the simplest checks before removing or replacing any part.

TROUBLE

Non uniform speed

No acceleration
POSSIBLE CAUSE

Withe smoke
Black smoke
Engine starts
Engine does

Too low oil

but stops

pressure
not start
Clogged pipings
Clogged fuel filter
Air inside fuel circuit
FUEL CIRCUIT

Clogged tank breather

Faulty feed pump
Stuck injector
Stuck injection pump valve
Wrong injector setting
Sticking injection pump rack
Wrong injection pump setting

Too high oil level

LUBRICATION

Stuck pressure relief valve

Incorrect relief valve setting
Worn-oil pump
Air inside oil suction pipe
Faulty pressure gauge or switch
Clogged oil suction pipe
Battery dis-charged
Wrong or inefficient cable connection
ELECTRIC
SYSTEM

Defective starter switch

Defective starter

Clogged air filter

MAINTE-
NANCE

Excessive idle operation

Incomplete running-in
Engine overloaded

Advanced injection
Retarded injection
SETTINGS/REPAIRS

Incorrect governor linkage adjustment

Broken or loose governor spring
Too low idle-speed
Worn-out or stuck piston rings
Worn-out cylinders
Sticking valves
Worn-out bearings
Governor linkage not freely operating
Crankshaft not turning freely

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

REVISION 00 9
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 II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS

SAFETY AND WARNING DECALS

DANGER CAUTION

Failure to comply with the Failure to comply with the

instructions could result in instructions could lead to
damage to persons and technical damage to the
property machine and/or system

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.
• 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 Lombardini 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 Lombardini 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.
COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED
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 SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS II

• 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.

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

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 III MODEL NUMBER AND IDENTIFICATION

Tipo motore
Type moteur
Engine type
Motortype
Tipo motor

Matricola identificazione motore Codice cliente

Matricule d’identification moteur Code client
Serial number Customer code (‘K’ No.)
Motornummer Kundennummer
Matricula identificación motor Código cliente

COMPILER TECO/ATL REG. CODE MODEL N° DATE OF ISSUE DATE ENDORSED

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 TECHNICAL DATA IV

RD 290
ENGINE TYPE
Number of cylinders N° 2
Bore mm 95
Stroke mm 88
Displacement Cm³ 1248
Compression ratio 17.5:1
R.P.M. 3000
N DIN 70020 21/28.5
Power KW/CV NB DIN 6270 19.2/26.0
NA DIN 6270 17.7/24.0
Max. torque * Kgm 7.5
RPM @ 2200
Max. torque at 3rd p.t.o. Kgm 3.0
Specific fuel consumption* g/KWh 186
Tank capacity l. 10
Oil consumption *** Kg/h 0.058
Oil sump capacity l. 3.0
Dry weight Kg 110
Combustion air volume at 3000 r.p.m. l./1' 1500
Cooling air volume at 3000 r.p.m. l./1' 26300
Max. permissible driving shaft axial load in both directions Kg. 300
momentary α 35°
Max. inclination lasting up to 1 h. α 25°
permanent α ***
* Referred to max. NB power
** At 2200 r.p.m.
*** Depending on the application

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 V CHARACTERISTIC POWER, TORQUE AND SPECIFIC CONSUMPTION CURVES

CHARACTERISTIC POWER, TORQUE AND SPECIFIC CONSUMPTION CURVES

RD 290

N (DIN 70020)Automotive rating, intermittent operation with variable speed and variable load.
NB (DIN 6270)Rating with no overload capability, continuous light duty operation with constant speed and variable load.
NA (DIN 6270)Continuous rating with overload capability, continuous heavy duty with constant speed and constant load..

C (NB) : Specific fuel consumption at NB power

Mt : Torque at N (at NB power for 9LD561-2/L).
a : Range of application for continuous operation. In case of application outside this range please contact LOMBARDINI.

The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions
of 20°C and 1 bar.
Max. power tolerance is 5%.
Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C.

Note: Consult RUGGERINI for power, torque curves and specific consumptions at rates differing from those given above.

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 OVERALL DIMENSION VI

RD 290

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 VII 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

ENGINE MAINTENANCE RD 290

INTERVAL (HOURS)
OPERATION COMPONENT
8 100 300 2500 5000
(OIL BATH) AIR CLEANER (*)
FEED PUMP FILTER
CLEANING HEAD AND CYLINDER FINS (*)
FUEL TANK
INJECTORS
INTERNAL OIL FILTER
AIR CLEANER OIL
LEVEL CRANKCASE OIL
BATTERY FLUID
CHECK
DELIVERY VALVE TIGHTNESS
VALVE AND ROCKER ARM CLEARANCE
INJECTOR SPRAY PATTERN
AIR CLEANER (**) (***)
OIL CRANKCASE (***)
REPLACEMENT OIL FILTER CARTRIDGE
FUEL FILTER CARTRIDGE
DRY AIR CLEANER CARTRIDGE (O)
OVERHAUL PARTIAL (****)
INSPECTION COMPLETE

(*) Under special working conditions clean daily.

(**) Under extremely dusty conditions clean every 4-5 hours.
(***) See reccomended oil type.
(****) Includes checking cylinders, piston rings, guides, springs, grinding valve seats, scaling heads and cylinders as well
as checking injection pump and injectors.
(O) When clogging indicator shows the need for replacement.

CAPACITIES ( liters)

Standard fuel tank 10,0

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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.

RECOMMENDED OIL GRADE

AGIP SUPERDIESEL MULTIGRADE 15W40 specifications API CF-4/ - - - - - - - - + + + + + + + + + +
SG ACEA E2,B2 MIL-L-46152 D/E. 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50
In the countries where AGIP products are not available, use oil API SAE 10W
SJ/CF for Diesel engines or oil corresponding to the military SAE 20W
specification MIL-L-46152 D/E.
SAE 30
SAE 40
OIL SUPPLY ( liters ) RD 290
SAE 10W-30
SAE 10W-40
filter included 3.3 SAE 10W-60
filter escluded 3.0 SAE 15W-40 base minerale
SAE 15W-40 base semi-sintetica
Air cleaner oil tank 0.3
SAE 20W-60 base semi-sintetica
SAE 5W-30 base sintetica
SAE 5W-40 base sintetica
SAE 0W-30 base sintetica
ACEA SEQUENCES
BENZINA - ESSENCE - PETROL
DIESEL
A = Gasoline (Petrol) BENZIN - GASOLINA
B = Light Diesel fuels
API CF CE CD CC CB CA SA SB SC SD SE SF SG SH SJ
E = Heavy Diesel fuels
CCMC G- 2 G- 4
Required levels : CCMC G- 3 G- 5
CCMC PD - 1 / PD - 2
A1-96 D- 4 CCMC D- 2
A2-96 D- 5 CCMC D- 3
A3-96 MIL - L - 2104 D
MIL - L - 2104 E
B1-96 MIL - L -46152 C
B2-96 MIL - L- 46152 D/E
B3-96 MB 226.1 MB 226.5
MB 227.1 MB 227.5
E1-96 228.3 MB 228.1
E2-96
VW 500.00
E3-96
VW 501.01
VW 505.00
VOLVO VDS
MAN QC 13-017

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 DISASSEMBLY/REASSEMBLY VIII

DISASSEMBLY AND REASSEMBLY

WARNINGS!
Besides disassembly and reassembly operations this chapter also
During repair operations, when includes checking and setting specifications, dimensions, repair and
using compressed air, wear eye operating instructions. Always use original RUGGERINI spare parts
protection. for proper repair operations.

0il-bath air cleaner

Check gaskets and replace if necessary.

Check that flange weld is free of porosity or defective spots.
Carefully clean bowl and filtering element with Diesel oil and blow
through with compressed air.
Top up with engine oil to the mark. When refitting tighten nuts at 2.5
Kgm.
See page 18 for periodic maintenance details.

Components:

1 Bowl
2 Oil level mark
3 Filtering element
4 Seal ring
5 Internal seal ring
6 Cover
7 Clamp
8 Prefilter

2
Dry air cleaner

1 Hand wheel
2 Cover
3 Cartridge
4 Seal ring
5 Bracket
6 Clogging indicator

Note: Replace cartridge immediately when indicator shows that is

clogged.

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Clogging indicator

Components:
1 Reset button
2 Transparent indicator

Note: Indicator is calibrated at 600÷650 mm. column of water.

Oil vapour separator

Fitted to engines with dry air cleaner.

Screw it out of the shroud bracket, carefully wash with gasoline inside
and blow out with compressed air.
When refitting connect with intake manifold by means of the special
rubber hose.

5 6

Intake manifold

Check flange surface for warpage and correct if necessary. Before

refitting check that heads are in line. Replace gaskets. Tighten nuts at
2.5 Kgm.

Note: In case of low temperature starting we can supply a manifold

with possibility of fitting a glow plug with air preheating.

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Exhaust manifold

Check that the inside is clean.

To avoid flange breakage check that heads are in line before tightening
nuts. Replace gaskets.
Tighten nuts at 2 Kgm.

Pulley guard - Shroud - Side plates

Components:
1 Pulley guard
2 Shroud
3 Side plates

The pulley guard is made of sound deadening material: it reduces the

noise that both the pulley and the fan tend to amplify.
Shroud and side plates are made of ANTIFON, an elastic Iayer which
absorbs the noise caused by the plate vibrations.

Cooling fan

Carefully clean and check all blades: if any are damaged, replace the
whole fan.
See page 13 for cooling air volume.

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Hub

Components:
1 Hub
2 Alternator rotor
3 Fan
4 Bolt

The hub holds the alternator rotor and the cooling fan.
Unscrew the bolt clockwise and tighten at 16 Kgm when refitting.

16

Alternator

Remove stator and place it inside the rotor to prevent metal particles
from being attracted by the magnets.
When refitting tighten rotor screws and stator bolts at 1 Kgm.
See page 56-57 for alternator characteristics.

17

Shroud support (Gear cover plate)

Loosen screws and remove shroud support very carefully to avoid da-
mage to the oil seal ring.
When refitting check that gaskets A and oil seal ring B are well inside
their housings.
Tighten screws at 2.5 Kgm.

18

Tank

Remove fuel filter and loosen clamp screws.

Completely empty the tank and check that no impurities are found
inside.
Check that cap breather hole is not clogged.
When refitting tighten bracket screws at 4 Kgm.
See page 49 for refitting fuel filter.

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Flywheel

Remove flywhee] with puller 1 (part No. 7271-3595-048).

Check starter ring gear and tapered crankshaft mating surfaces.
When refitting tighten bolt al 30 Kgm.

Note: To replace starter ring gear heat it up lo 200÷250°C and rapidly

drive it onto the flywheel.

15

Valve / rocker arm clearance

Remove rocker arm cover and check gaskets for breakage.

Setting should be performed when the engine is cold: bring each
cylinder piston to top dead center on the compression stroke and set
clearance A al 0.15÷0.20 mm.
When refitting tighten cover screws by 2 Kgm.

16 17

Compression release (optional)

Bring piston to top dead center on the compression stroke.

Unscrew rocker arm cover side plug and measure clearance A. It
must be 0.30÷0.40 mm.
For setting purposes remove rocker arm cover, unscrew lock nut and
set clearance A, by adding or removing shims under steeI plate (point
B).

18

Rocker arm assembly

Components:
1 Bore
2 Lubrication tube

Dimensions (mm):
A = 18.032÷18.050
B = 17.989÷18.000
If clearance (A-B) exceeds 0. 135 mm. replace shaft and rocker arms.
When retitting check that lubrication tube perfectly matches with the
journal bore.
Tighten screws al 2.5 Kgm.
19 20

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Injector

Clean injector and cheek calibrated pressure as indicated on page 55.

When refitting cheek that it correctly protrudes from the cylinder head
plane.
Tighten the fixing nuts at 1 Kgm.

21

Injector projection

The end of nozzle A should project 3.0÷3.5 mm. from the cylinder head
plane.
Adjust injector projection by means of copper shims B measuring 0.5
and 1.00 mm. in thickness.

22

CYLINDER HEAD

Do not remove it when hot to avoid deformation. lf cylinder head is

deformed level it off by removing a maximum of 0.3 mm.
When refitting tighten only if sure that rocker arm lubrication tube is well
inside its holes and that both heads are well in line.
Always replace copper head gasket: see page 32 for choosing the
right thickness.
Progressively tighten nuts in the 1, 2, 3, 4 sequence at 5.5 Kgm.

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Valves

Components:
1 Intake valve
2 Spring seat
3 Valve stem oil seal
4 Spring
5 Retainer
6 Half collets
To remove half collets firmly press down as shown in the figure.

Note: Valve stem oil seal, 3 must be fitted to the intake valve only.

24 25

Valve springs

Measure free length with a gauge.

Using a dynamometer check that the spring length under two dìfferent
loads corresponds to the values below:

Free length A = 47 mm
Length B compressed by a 20.6 Kg weight = 36.4 mm
Length C compressed by a 40.6 Kg weight = 26.1 mm
Replace spring if length is 1 mm or more below the stated values.

26

Valve material

Intake valves A
Material: X 45 Cr Si 8 UNI 3992
1 Chromium-plated portion
a 45°15'÷45°25'

Exhaust valve B
Shaft and head are made of 2 different materials.
2 Welded portion
3 Chromium-plated portion
4 Portion made of X 45 Cr Si 8 UNI 3992
5 Portion made of X 70 Cr Mn Ni N 216 UNI 3992
27 28 a 45°15'÷45°25'

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Valve guides and valve guide housings

Starting from engine No. 2883619 intake and exhaust valve guides
are both made of phosphoric cast iron.
Components:
1= Exhaust valve guide
2= Intake valve guide
Dimensions (mm):
A= 42,0
B= 53,5
C= 14,000÷14,018
D= 14,050÷14,060
Valve guides with outside diameter increased by 0.5 mm. are also
available;in such cases valve guide bore C shouid also be increased
29
by 0.5 mm.

Valve guide insertion

Heat cylinder head up to 160÷180°C

Press guides considering the A and B distances from the head plane.
Dimensions (mm):
A = 30.80÷31.20
B = 20.3÷20.7

Note: lf guides are seated with stop ring C, first locate the ring in place
and then position guides without considering A and B.

30

Dimensions and clearance between guides and valves (mm)

A = 8.030÷8.045
B = 7.985÷8.000
(A-B) = 0.030÷0.060
(A-B)limit value = 0.15

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Valve seats and housings

Dimensions (mm.):
A = 40.000÷40.016 (intake valve housing dia.)
B = 40.120÷40.140 (intake valve seat dia.)
C = 34.000÷34.016 (exhaust valve housing dia.)
D = 34.120÷34.140 (exhaust valve seat dia.)
Press valve seats into the housings and cut ot at 45°

32

Valve seat grinding

After cutting grind valve seats with fine emery paste in oil suspension.
The sealing surface S should not exceed 2 mm.
Valve recess after grinding D = 0.75÷1.25 mm; maximum worn limit
1.65 mm.

33 34

Pushrod tube

When refitting cheek that gaskets A and rocker arm lubricatíon tube C
are well inside their seats.

35

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CYLINDER

Measure diameter size between two diametrically opposed points at

three different heights.

Ø = 95.00 ÷ 95.02 mm.

In case wear exceeds 0.10 mm, bore the cylinder and fit oversize
piston and rings.
In case of less wear replace piston rings only.

36 37

Checks and cylinder roughness

The cylinder should show no blowholes or porosities.

Seal both ends of cylinder and pressurize with compressed air at 4
Bar for 30 secs. Immerse in water and check for leakage.
Fins must be intact.
Cross hatch pattern must range between 115°÷140°: they must be
uniform and clear in both directions.
Average roughness should range between 0.5 and 1 µ.

38

PISTON

Remove circlips and remove piston pin.

Remove piston rings and clean grooves.
Measure diameter at 2 mm from the bottom of skirt.

Ø = 94.93 ÷ 94.95 mm

In case of diameter wear above 0.05 mm replace piston and piston

rings.

Note: Oversize pistons of 0.5 and 1 .0 mm are available.

39 40

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Piston weight

Weigh pistons when replacing them in order to avoid unbalance. The

difference in weight should not exceed 6 g.

41

Piston rings - End gaps (mm)

Place piston rings squarely into the unworn part of the lower cylinder
and measure the end gap.

1° Chromium-plated ring A = 0.40÷0.65

2° Torsional (internal tapered) ring A = 0.40÷0.65
3° Oil control ring A = 0.30÷0.60

42

Pistons rings - Clearance between grooves (mm)

A = 0.07÷0.11; limit value = 0.20

B = 0.05÷0.09; limit value = 0.16
C = 0.04÷0.08; limit value = 0.15

43 44

Piston rings - Fitting sequence

A = 1° Chromium-plated ring
B = 2° Torsional (internal tapered) ring
C = 3° oil control ring

Note: Before fitting the piston into the cylinder stagger the ring gaps at
120°.

45

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Piston - Refitting

Connect piston to connecting rod in a way that the combustion chamber

centre b is at right angle under nozzle tip a.
Lubricate piston pin and introduce it into the piston by exerting pressure
with your thumb.
Check that both circlips are well inside their seats.

46 47

Piston clearance

A = Piston clearance
B = Copper head gasket

A (0.65÷0.7 mm) is determined by placing the piston at top dead center

and measuring with a feeler gauge and straight edge, the distance the
piston is below or above the cylinder face. A copper gasket (available
in various thicknesses) is them selected to ensure the clearance is
correct.
Gaskets are available in the following thicknesses 0.45, 0.5, 0.55, 0.6,
0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, 1.00 mm.

48 49

CONNECTING ROD

Remove oil pan.

Remove connecting rods and check as follows.
Both connecting rod/piston units should be fitted back into the
corresponding cylinders; mark them to avoid mistakes.
See page 33 for specifications as to the tightening of the connecting
rod big end bearing.

50 51

Connecting rod small end bushing

Dimensions and clearance (mm):

C = 25.020÷25.030 (with machined bushing in place)
D = 24.995÷25.000
(C-D) = 0.020÷0.035
(C-D) maximum worn limit = 0.070

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Connecting rod alignment

Check alignment of small end and big end bearing bores using fitted
mandrels; axial mis-alignment A = 0.02 mm; maximum limit = 0.05
mm Moderate warpage may be corrected by gradually working with a
press.

53

Connecting rod weight

Weigh connecting rods when replacing them in order to avoid

unbalance.
The difference in weight should not exceed 10 g.

54

Connecting rod big end bearing

Both centering notches A and B must be on the same side when

refitting. Tighten bolts at 4 Kgm.
See page 32 for dimensions.

55 56

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 VIII DISASSEMBLY/REASSEMBLY

Crankshaft timing gear

Use tool 1 (Part No. 7560-4000-052) and puller 2 (Part No. 7271-
3595-048) to remove the gear.

57

Main bearing support, gear side

Remove main bearing by means of two M8x1.25 screws with fully

threaded length of 40 mm or a puller (Part No. 7271-3595-048).

Note: To avoid deformation it is not recomended to replace the bearing

bushing, complete assembly's of bushing and support are available
in standard, 0.25 mm and 0.50 mm undersize configurations as spare
parts.
See page 32 for dimensions.

58

Main bearing support, flywheeI side

Remove it by means of two M8x1.25 screws with fully threaded length

of 40 mm.
Check oil seal ring and replace if warped, hardened or worn-out. When
refitting, tighten nuts at 2.5 Kgm.
See end float on page 31 for gasket replacement detaiis.
See page 31 for dimensions.

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CRANKSHAFT

Center main bearing support, locating bolt.

Straighten plate 1 and unscrew bolt 2 before removing crankshaft.

60

Crankshaft removal

To pull out the crankshaft tap lightfy on the timing side end using a
copper-headed hammer.
When refitting align center main bearing support so that the locating
bolt hole coincides with the crankcase hole.

61

Crankshaft center main bearing support

When refitting, both centering notches A and B must be located on the

same side.
Tighten screws at 2.5 Kgm.
See page 31 for dimensions.

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Crankshaft lubrication ducts

Remove plugs, clean duct A with a pointed tool and blow in compressed
air.
Screw plugs again and check for sealing.

63 64

Crankshaft journal radius

The radius R connecting journals to shoulders is 2.8÷3.2 mm.

Note: When grinding main journals or crank pins restore the R value to
original specification.

65

Checking main journals and crank pins

Use an outside micrometer gauge.

66

Main journal and crank pin diameter (mm)

A = 71.981÷72.000
B = 45.500÷45.516
C = 55.331÷55.350
D = 54.931÷54.950

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How to measure main bearing inside diameter

Use an inside micrometer gauge.

68

Main bearing and connecting rod big end bearing inside diameter

Dimensions (mm):
E = 72.070÷72.090
F = 45.548÷45.578
G = 55.404÷55.435
H = 55.000÷55.020
The above dimensions refer to driven in or tightened bearings.

Note: Both main bearings and connecting rod big end bearings are
available with inside diameter size measuring 0.25 and 0.50 mm less
than the standard version.

69

Clearance between main journals/crank pins and connecting rod

bearings (mm)

(E-A) = 0.070÷0.109; limit value = 0.195

(F-B) = 0.032÷0.078; limit value = 0.150
(G-C) = 0.054÷0.104;limit value = 0.190
(H-D) = 0,050÷0.089;limit value = 0.180

70

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Main bearíng supports

1 Flywheel side
2 Central
3 Gear side

Dimensions (mm):
I = 149. 000÷149.020
L = 76.980÷77.020
M =147. 010÷147.020
N = 59.074÷59.092
0 = 75.990÷76.010
P =60.000÷60.020
71

Main bearing housings

Dimensions (mm):
A = 149.000÷149.020
B = 147.000÷147.020
C = 76.000÷76.020

72

Crankshaft end play

When refitting crankshaft check end play by means of a thickness

gauge; this value should be 0.08÷ 0.38 mm and can be set by changing
the thickness of gasket A which is located on the flywheel-side main
bearings.
Gaskets with thickness of 0.10, 0.20 and 0.4 mm can be supplied.

73

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CAMSHAFT

How to measure camshaft journals and housings

Use an inside micrometer gauge for housings and an outside
micrometer gauge for journals.

74 75

Dimensions of camshaft journals and housings (mm)

A = 41.940÷41.960
B = 27.940÷27.960
C = 42.000÷42.025
D = 28.000÷28.020

Clearance (mm)
(C-A) = 0.040÷0.085;(C-A) limit value = 0.160
(D-B) = 0.040÷0.080;(D-B) limit value = 0.150

76

How to measure intake/exhaust cam height

A1 = 1 st cylinder intake cam

S1 = 1 st cylinder exhaust cam
A2 = 2nd cylinder intake cam
S2 = 2nd cylinder exhaust cam
Exhaust and intake cams feature the same height H.

H = 33.55÷33.65 mm

Replace camshaft if H is 0.1 mm below the given value.

77 78

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Camshaft end play

End play should be 0.10÷0.26 mm; check by means of a dial gauge

pushing or pulling camshaft as required.

79

Camshaft timing

Fit camshaft gear by making timing mark 1 coincide with timing -mark
2 on the crankshaft timing gear.
Tighten camshaft boll at 6 Kgm.

80

Valve timing without considering timing marks

Locate piston 1 (on flywheel side) at the top dead centre.

Position two small cylinders A of the same height onto the tappets.
Rotate camshaft stopping when cylinder 1 tappets are in overlap
position (intake open, exhaust closed).
By means of ruler B check that tappets are at the same height.
Engage camshaft gear with crankshaft gear.

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 DISASSEMBLY/REASSEMBLY VIII

Valve timing check

Check valve timing at the crankshaft.

The values shown are checked at the flywheel circumference (with
flywheel of 291 mm. diameter each degree corresponds to 2.5 mm).
Set valve clearance at 0.65÷0.70 mm (after checking restore the value
at 0. 15÷0.20 mm). Set dial gauge on intake valve to a zero value; by
rotating the driving shaft according to its direction of rotation you can
measure a (intake valve opening advance referred to top dead centre
S) and ß (intake valve closing delay referred to bottom (I) dead centre).
Follow the same procedure for exhaust valves checking y (exhaust
valve opening advance) and γ (exhaust valve closing delay): in the
case of RD 290 γ is advanced by 1° compared to S.
82

α = 1°
β = 21°
γ = 23°
δ = 1°

83

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 VIII DISASSEMBLY/REASSEMBLY

Hydraulic pump p.t.o.

A hydraulic pump of group 1 (1 P) or 2 (2P) can be installed on the gear

side, 3rd p.t.o.

84

Hydraulic pump p.t.o. (1 P)

Components:
1 Seal ring
2 Centering ring
3 Coupling
4 Half coupling
5 Flange
6 Gear
7 Bracket
8 Thrust washer
9 Stop ring
10 Cover
The maximum total torque is thus 3 Kgm corresponding to 12.5 HP at
85
3000 r.p.m. Reduction ratio 1:1

MECHANICAL SPEED GOVERNOR

Weight-type governor housed inside the camshaft drive gear.

86

Mechanical speed governor

Components:
1 Gear 2 Weight
3 Mobile bell 4 Stop ring
5 Thrust washer 6 Yoke
7 Lever 8 Drive rod
9 Governor spring 10 Rack control lever

Weights are moved to the periphery by the centrifugal force and thus
axially shift a mobile bell connected to the injection pump rack control
lever by a linkage. A spring placed under tension by the accelerator
control offset the weight centrifugal force. Balance between the two
forces keeps speed at an almost constant level in spite of load
87
variations. See page 44 for timing.

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 DISASSEMBLY/REASSEMBLY VIII

Governor springs with rocker arm

The system features two springs anchored to a rocker arm and allows
for minimal r.p.m. changes at low speed levels.

88

Governor springs with rocker arm

Components:
1 Rocker arm for spring anchoring
2 Governor springs
3 Plate
4 Link
5 Lever

89
Spring for extra fuel supply at starting

Components:
1 Extra fuel spring
2 lnjection pump control yoke
3 Governor spring.

The device is operated automatically: when the engine is stopped

spring 1 acts on injection pump control yoke 2 providing maximum
fuel delivery, until the engine starts and the governor controls the iniection
pump rack.

90

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 VIII DISASSEMBLY/REASSEMBLY

ELECTRONIC SPEED GOVERNOR

(optional)

A = Actuator
S = r.p.m. sensor

The crankcase features a hole for sensor S introduction.

91

Electronic speed governor

Components:
1 Injection pump
2 Delivery control lever
3 Actuator A mounting flange
4 Mobile retainer
5 Actuator magnet
6 Stator coils
7 Stator
8 Cable ends for connection to control box E
9 Electromagnet

92

Electronic speed governor layout

Components: A = actuator; C = key; P = potentiometer; T

=electromagnet; S = sensor
The device consists of an actuator A controlling injection pump rack,
an r.p.m. sensor S and an electromagnet T controlling fuel delivery
and supplying extra fuel at starting. Control box E (see page 35)
controls fuel delivery as a function of the load and of the speed set
through potentiometer P.
The potentiometer can be fìtted on the control box or on the control
panel P1 (see page 35).
The whole system makes it possible to keep the engine speed
constant independently of the load conditions. It detects speed through
the r.p.m. sensor mounted on the crankcase at the ring gear level. As
93
the number of revolutions changes the device immediately performs
the required corrections by means of the actuator acting on the injection
pump. Electromagnet T responds to max. fuel delivery (fuel flow setting)
and (when energized) enables the injection pump rack rod to reach its
maximum stroke (extra fuel supplied at starting).

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 DISASSEMBLY/REASSEMBLY VIII

Starting with electronic speed governor

(see lay-out on page 44)

In position O the engine is not working and no part is energized. The

rack rod is in stop position (retained by two springs 10 inside actuator
A). By rotating key C to position 2 the electromagnet with draws
allowing the rack rod to reach its highest delivery being connected to
the actuator at its max. level of energization. When the engine,
immediately after starting, reaches 1000 r.p.m. the controller reduces
the actuator position, after 1 second swìtches off the electromagnet T
and after more 0.5 seconds returns at his normal position with the
engine speed set as per position of potentiometer P1.

94

Engine running with electronic speed governor

The engine starts running at the pre-set speed.

Potentiometer P is located either inside the control box E or on control
panel P1.
In case of an external potentiometer P1 the engine speed can be set at
any point between the idling and full speed in on-load conditions
(setting performed on the control box in the test room).
The electronic control box E controls actuator A (by sending or cutting
off the power supply) to keep the speed set through P1 constant
independently of the absorbed load.
Control box E prevents the engine from starting (or stops it) in case of
no power supply or in case connection with r.p.m. sensor S is broken
(or short-circuited).

95

Electronic speed governor control box

Control box E features four setscrews which must be positioned on

the test bed (torque dynamometer) along with the engine.
a) Setscrew for speed control (r.p.m.)
b) Setscrew for sensitivity adjustment when the engine is running
at full speed.
c) Setscrew for sensitivity adjustment at low speed.
d) Setscrew for extra fuel release; once correctly positioned, this
set-screw is generally sealed.

96

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 IX LUBRICATION SYSTEM

The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because
its combustion may lead to a sharp increase in the rotation speed.
Use suitable oil in order to protect the engine.
Nothing more than lubrication oil can influence the performances and life of an engine.
Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, will cause the
piston rings to jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine life will
also be notably reduced.
The oil viscosity must suit the ambient temperature in which the engine operates.

Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. Wear protective
gloves to avoid touching used oil. If contact with the oil is unavoidable, you are advised to wash your hands with soap and
water as soon as possible. Dispose of old oil in the correct way as it is highly polluting.

LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM

97

Components:

1) Oil pressure switch - 2) Breather - 3) Connecting rod big end bearing - 4) Crankshaft main bearing on gear side - 5) Oíl
pressure relief valve - 6) Fitting tor pressure gauge connecl:Ion - 7) Cartridge filter , 8) Oil pump - 9) Oil fill plug - 10)
Rocker arm shafts 11) Pushrod protection tube - 12) Hydraulic pump gear - 13) Camshaft joumal on fiywheel side - 1,~)
Oìl dipstick - 15) Drain plug . 16) Internal filter

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 LUBRICATION SYSTEM IX

OIL PUMP

Check that gear teeth are intact and that clearance between gear edge
and pump body does not exceed 0.15 mm.
Further more check that control shaft is free to rotate with end float not
exceeding 0.15 mm.
Oil pump delivery al 3000 r.p.m. is 9 liters/min.

98 99

Oil filter cartridge (internal)

Components:
1 Plug
2 Seal ring
3 Spring
4 Cartridge
Features:
Type of filtration: 70 µ
By-pass valve opening pressure: 0.60÷0.75 bar.
Max. working pressure: 4.5 bar.

100

Oil pressure relief valve

Components:
1 Plug
2 Gasket
3 Spring
4 Valve
A = 37 mm
Carefully clean all components and check spring A length.

101 102

Oil pressure check

Once the engine is fitted fill with oil and fuel; connect a 10 bar pressure
gauge to the oil filter fitting.
Start the engine and check pressure as a function of the oil temperature
(see page 48)

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 IX LUBRICATION SYSTEM

Oil pressure curve at idling speed

The curve is obtained at the oil filter lever with constant engine speed
of 1200 r.p.m. in no-load conditions and at a room temperature of +
25°C.
Pressure is given in bar and temperature in centigrades.

104

Oil pressure curve at full speed

The curve is obtained at the oil filter level with engine working at 3000
r.p.m. and 25.84 HP at + 25°C room temperature.
Pressure is given in bar and temperature in centigrades.

105

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 FUEL SYSTEM X

Fuel feeding/injection circuit

Components:
1 Tank
2 Filter
3 Fuel feeding tube
4 Fuel feeding pump
5 lnjection pump
6 Injection line
7 Injector
8 Injector leak off line and self bleeding system

106

Fuel filter (inside fuel tank)

Components:
1 Spring
2 Disc
3 Ring
4 Cartridge
5 Gasket
6 Gasket
7 Cap
8 Ring
9 Bolt

107

Fuel feeding pump

The fuel feeding pump is of the diaphgragm type operated by a

camshaft eccentric through a drive rod. It features an external lever for
manual operation.
Characteristics: when the control eccentric rotates at 1500 r.p.m.
rninimum delivery is 64 l/h while self-regulation pressure is 4÷5 m
water column.

108

Fuel feeding pump drive rod protrusion

Components:
1 Drive rod
2 Gasket
3 Camshaft eccentric
Drive rod A protrudes 0.8-1.2 mm from the crankcase; it can be adjusted
by means of gaskets.
Gaskets are supplied in the following thicknesses: 0.50, 0.80 and 1.0
mm.

Note: This setting is performed when the rod is on the base of the cam
lobe (i.e. minimum protrusion).
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 X FUEL SYSTEM

INJECTION PUMP

The Bosch injection system consists of a single-body pump with

plungers featuring constant stroke and feeding one cylinder each. The
pump, mounted on the crankcase is directly operated by the camshaft.
Speed governor, extra fuel and stop device are separate from the pump
(see page 42, 43 and 66).

110

Injection pump

Components:
1 Pump body 2 Fitting
3 Seal ring 4 Filter
5 Shim 6 Spring
7 Delivery valve 8 Seat
9 Gasket 10 Plunger
11 Barrel 12 Rack rod
13 Sector gear 14 Spring
15 Upper retainer 16 Lower retainer
17 Tappet 18 Tappet roller

111

Plunger and Barrel Assembly

1 Barrel
2 Fuel feeding port
3 Control helix
4 Plunger
5 Retardation notch
Plunger diameter is 7.5 mm.

Note: Every plunger matches with its own barrel. For this reason they
are not interchangeable.

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 FUEL SYSTEM X

How to check plunger and barrel for internal leakage

This operation is only indicative since pressure changes depending

on the pumping speed.
Connect the delivery union with a 600 bar pressure gauge with safety
valve. Adjust rack rod at half-stroke. Turn flywheel according to its
direction of rotation so that the plunger puts the circuit under pressure.
Replace plunger if the displayed pressure is below 300 bar. Repeat
the same operation for the other plunger.

113

How to check injection pump delivery valve sealing

Components:
1 Valves
2 Seat
Adjust pump rack at half-stroke. Turn flywheel according to its direction
of rotation so that the plunger puts the circuit under pressure.
During this operation the displayed pressure will gradually reach a
peak followed by a sudden drop which corresponds to valve closing.
Pressure drop should be 30÷50 bar. Replace the valve if pressure
drop is below this value.
Repeat the same operation for the other plunger.

114 115

Test data for injection pump delivery

Rod stroke
Control rod Max. plunger
from max R.P.M. Delivery
max. force difference
deliv. point

Newton mm mm3/stroke mm3/stroke

10 1500 34÷37 3

13 500 7÷11 3
0,50
0 150 70÷78 --------

10 500 22÷26 3
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 X FUEL SYSTEM

How to reassemble injection pump components

After replacing the worn-out components, reassemble the pump as

follows:
Introduce sector gears into the pump body by making reference points
C match with the B points on the rack.
Fix barrels with the eccentric screws F on the pump body.
Fit valves with seats, springs, fillers and delivery unions tightening
them at 3.5÷4 Kgm.
Fit plungers by making reference points E match with the sector gear
D points.
Fix retainers and springs; lock tappet with special stop.
Check that both plungers have the same delivery by performing the
117 necessary measurements at the test bed; if delivery is not the same
set screw F.

How to mount injection pump on the engine

Tighten screws at 2.5 Kgm

Check that rack rod slides smoothly: if not, the engine may fail to start
or hunt.

118

Injection pump/mechanical speed governor timing

Loosen screw 1
Move injection pump lever 2 to maximum delivery (to the right).
Check that drive rod 3 closes the speed governor; keeping lever 2
pressed to the right the drive rod should have no clearance.
Tighten screw 1.

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 FUEL SYSTEM X

(STATIC) INJECTION TIMING

Disconnect injection line on cylinder 1 making sure not to loosen the

pump delivery union. Attach the timing tool shown below.

120

Injection timing checking device

Components:
1 Union
2 Tube
3 Sleeve
4 Transparent body, seria] No. 7271-9727-003.
This device allows for immediate monitoring of the fuel flow through
its transparent portion.
Dimensìons (mm):
Ø1 = 10.00; Ø2 = 0.60; Ø3 = 2.00; Ø4 = 6.50.
A = 29.00; B = 20.00; C = 25.00; D = 45.00

121 122

Injection timing check

Top up the tank checking that fuel level is at least 10 cm above cheeking
device.
Adjust injection pump rack rod at half-stroke.
Turn the flywheel according to the engine direction of rotation and
check that fuel reaches the checking device.
Repeat this last operation; during compression proceed slowly and
stop immediately when the fuel is seen to pass through the checking
device hole; bring flywheel back by 5 mm: this is the so-called static
injection timing.

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 X FUEL SYSTEM

Injection timing reference marks on crankcase and flywheeI

A = Piston reference mark at the top dead centre

B = Injection timing reference mark compared to A
A ÷ B = Distance in mm.
C = Piston reference mark in injection timing position.
a = Reference angle in degrees.

(A÷B) mm = 63,5÷68,5
α = 25°÷27°

124

Check window for injection timing reference mark

Components:
1) Window
2) Injection timing reference mark
A window is provided to identify the reference mark corresponding to
the above mark C.

125

Injection timing correction

lf reference mark C does not match with B follow examples 1 and 2.

1) Example of late injection timing: remove shims under the pump to
make C match with B.
2) Example of early injection timing add shim under the pump to make
C match with B.

Note: By adding or removing a 0.1 mm shim under the pump C is

delayed or advanced by approximately 3 mm.

126 127

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 FUEL SYSTEM X

INJECTOR

Components:
1 Intake fitting
2 Nozzle holder
3 Shim
4 Spring
5 Pressure rod
6 Intermediate flange
7 Nozzle
8 Needle valve
9 Fixing flange
10 Taper pin
11 Gasket
12 System duct
13 Sump

128

Nozzle

Features:
Hole number and diameter 4x0.28 mm.
Jet angles = 160°.
Needle valve elevation = 0.20 ÷ 0.22 mm
Hole length = 0.7 mm
Sump diameter and length = 1x1.5 mm

129

Injector setting

Conect injector to a hand pump and cheek that setting pressure is 210
÷220 bar; make the required adjustments, if any, by changing the shim
over the spring.
When replacing the spring, setting should be performed at a 10 bar
greater pressure (220÷230 bar) to allow for bedding during operation.
Check needle valve sealing by slowly moving hand pump until
approximately 180 bar.
Replace nozzle in case of dripping.

130

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 XI ELECTRIC SYSTEM

STANDARD ELECTRIC EQUIPMENT

Electric starting layout without battery charging light

Components:
1 Alternator
2 Starting motor
3 Voltage regulator
4 Battery
5 Pressure switch
6 Oil pressure warning light
7 Key switch

131

Electrical starting layout with battery charging light

Components:
1 Alternator
2 Starting motor
3 Voltage regulator
4 Battery
5 Pressure switch
6 Oil pressure warning light
7 Key switch
8 Battery charging light

Note: Battery, which is not supplied by Lombardini, should feature 12

V voltage and capacity not below 70 Ah.

132

12.5 V, 14 A Alternator
Features a fixed armature winding mounted on the air shroud bracket.
The rotating permanent magnet inductor is located in the fan spindle.
Dimensions (mm):
A = 158.80÷159.20
B = 27.50÷27.90

Note: Clearance between armature winding and inductor (air gap)

should be 0.48÷0.60 mm.

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 ELECTRIC SYSTEM XI

Alternator battery charger curve (12.5 V, 14A)

The curve was obtained at room temperature of + 25°C with 12.5 V

battery voltage

134

Magnetization checking tool (Part No. 7000-9727-001)

Components:
1 Casing
2 Slider
3 Casing reference line
4 Slider reference line
Rest the tool end horizontally onto the magnetic poles. Hold slider so
that its reference line coincides with the casing reference line. Release
slider: if no attraction occurs the rotor is demagnetized; therefore replace
alternator.

135

Checking for cable continuity

Check that stator windings have no unsoldered connections, burnt

areas or grounded wìres.
Using an ohmmeter check for continuity between the red cable and
the two yellow ones.
Furthermore, check that they are insulated from the ground.

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 XI ELECTRIC SYSTEM

VOLTAGE REGULATOR
Type RUGGERINI, supplied by SAPRISA and DUCATI: Voltage 12 V,
max. current 26A. References for SAPRISA connections with the
corresponding DUCATI connections

SAPRISA DUCATI

~ G

R R

+ B

LE L
137
o o C

To avoid wrong connections 3 different sizes are supplied.

CONNECTION SIZE mm
SAPRISA DUCATI
WIDTH THICKNESS

~ G 6.25 0.8

R R 9.50 1.2

+ B 9.50 1.2

LE L 4.75 0.5

138 o o C 6.25 0.8

The voltage regulator fits to both circuits with and without battery
charging light; in the latter case connections LE (SAPRISA) and L
(DUCATI) are not used.

139

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 ELECTRIC SYSTEM XI

How to check voltage regulator for proper operation

Check that connections correspond to the layout.

Disconnect the terminal from the battery positive pole.
Connect a d.c. voltmeter between the two battery poles.
Fit an ammeter between the positive pole and the corresponding cable
1 terminal.
Start a couple of times until battery voltage drops below 13 V.
When battery voltage reaches 14.5 V the ammeter current suddenly
drops down to almost zero.
Replace regulator if recharge current is zero with voltage below 14 V.

Warning: When the engine is running do not disconnect battery cables

or remove the key from the control panel.
Keep regulator away from heat sources since temperatures above
75°C might damage it.
No electric welding on engine or application.

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 XI ELECTRIC SYSTEM

OPTIONAL ELECTRIC EQUIPMENT

12 V, 18A Alternator
Only two yellow cables are at output.
Dimensions (mm):
A = 158.80÷159.20
B = 27.50÷27.90

Note: Clearance between armature wìnding and inductor (air gap)

must be 0.48÷0.60 m m.

142

Alternator battery charger curve (12 V, 18 A)

This curve is obtained at +25°C with 12.5 V battery voltage.

143

12 V, 24 A special voltage regulator

The special LOMBARDINI SAPRISA voltage regulator is of the bridge

type.
See page 48 for tag dimensions.

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 ELECTRIC SYSTEM XI

Alternator type Bosch G1 14 V, 33 A

The alternator is of the claw-pole rotor type with built-in voltage regulator.
The rotating motion is conveyed by the engine through a "V" belt and
sheave.
Features: 12 V rated voltage. Max. current 33 A at 7000 alternator
r.p.m.. RH direction of rotation

145

Alternator type Bosch G1 14 V, 33 A layout

Components:
1 Alternator
2 Starting motor
3 Battery
4 Key switch
5 Pressure switch
6 Oil pressure warning light
7 Battery charging light

146

14 V, 33 A Bosch G1 alternator battery charger curve

The curve was obtained at room temperature of + 25°C. Battery

terminal voltage is 12.5 V.
The r.p.m. shown on the table reters to the engine.

147

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 XI ELECTRIC SYSTEM

STARTING MOTOR
Made by MARELLI and BOSCH.
Apply to their distributors for any type of repair.

1) Magneti Marelli starting motor type E100, 1,5/12 V

RH direction of rotation
A = 29.5÷31.5 mm
B = Ring gear plane
C = Flange plane

Warning: The fiywheel should not project from ring gear plane B.

148

Characteristic curves for starting motor type Magneti Marelli E100,

1.5/12 V

Curves were obtained at room temperature of + 20°C with 88 Ah

batteries.
V = Motor terminal voltage in Volt
P = Power in kW
C = Torque in N/m
N = Motor speed in r.p.m.
I (A) = Absorbed current in Ampere

149

2) Bosch starting motor type GIF - 12 V, class 1.5

RH direction of rotation.
A = 29.5÷31.5 mm
B = Ring gear plane
C = Flange plane

Warning: Flywheel should not project from ring gear plane B.

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 ELECTRIC SYSTEM XI

Characteristic curves for starting motor type Bosch GF -12 V, class

1.5

Curves are obtained at room temperature of + 20°C with 66 Ah battery.

V = Motor terminal voltage in Volt
P = Power in kW
C = Torque in N/m
N = Motor speed in r.p.m6.
J (A) = Absorbed current in Ampere.

151

3) Starting motor type Bosch DW (R) 12 V, 1.7 kW

RH direction of rotation.
Note: This motor is of the epicyclic type with reduction ratio of 3.3:1
between rotor and pinion gear.

A = 29.5÷31.5 mm
B = Ring gear plane
C = Flange plane

Warning: Flywheel should not project from ring gear plane B.

152

Characteristic curves for starting motor type Bosch DW (R), 12 V,

1.7 kW

Curves were obtained at the temperature of + 20°C with 88 Ah battery.

V = Motor terminal voltage in Volt

P = Power in kW
C = Torque in N/m
N = Motor speed in r.p.m.
J (A) = Absorbed current in Ampere.

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 XII SETTINGS

SETTINGS

1) ldling speed setting in no-load conditions

After filling with oil and fuel, start the engine and let it warm up for 10
minutes.
Adjust idling speed at 1200÷1300 r.p.m. by turning setscrew 1; then
tighten lock nut.

154

2) Full speed setting in no-load conditions (standard)

After setting idle speed turn screw 2 and set full speed in no-load
conditions at 3200 r.p.m.; then tighten lock nut.

Note: When the engine reaches the pre-set power full speed stabilizes
at 3000 r. p. m.

155

lnjection pump delivery setting

This setting should be performed at the torque dynamometer. lf not,

setting is oniy approximate.
The following steps are required:
Loosen delivery limiting device C by 5 turns.
Bring engine to full speed in no-load conditions i.e. 3200 r.p.m.. Tighten
limiting device until the engine shows a drop in r.p.m..
Unscrew limiting device C by 1/½ turn. Tighten lock nut.

Note: lf the engine, under full load, generates too much smoke tighten
C; if no smoke is observed at the exhaust and the engine cannot reach
its full power unscrew C.
156

lnjection pump delivery limiting and extra fuel device

Limiting device C limits the injection pump maximum delivery. It also

acts as a torque setting device since spring N opposes the resistence
of spring M inside the cylinder through lever L.
The torque setting device allows lever L to move over stroke H
corresponding to 0.15÷0.25 mm.
This consequently increases injection pump delivery with torque
reaching its peak value.

Note: In generator sets and power welders, the torque setting device
acts as a delivery limiter only. It therefore does not feature spring M or
stroke H.
157
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 SETTINGS XII

Injection pump delivery setting with engine at the torque

dynamometer
1) Bring engine to idling speed
2) Unscrew delivery limiting device C (see page 64)
3) Bring engine to the power and r.p.m. required by the manufacturer
of the device.
4) Check that consumption falls within the table specifications (see
below). lf consumption is not as indicated change balance conditions
at the torque dynamometer by varying the load and adjusting the
governor. Under stable engine conditions check consumption again.
5) Tighten limiting device C until the engine r.p.m. decreases.
Lock the limiting device by means of lock nut.
In versions with manually-operated mechanical extra fuel feeding D
perform this operation keeping drive rod E as shown in the figure.
6) Release brake completely and check at what speed the engine
becomes stable.
Speed governor should comply with the requirements of the class
indicated by the manufacturer of the device.
7) Stop the engine
8) Check valve clearance when the engine has cooled down.

Required settings (as most commonly applies)

Power Specific fuel consumption*

Engine R.P.M. HP
(kW) Time (sec) rev/HP h
per 100 cmc (g/kW h)

N 28 197÷207
RD 290 3000 53÷56
(20,59) (268÷282)
158
NB 26 190÷200
RD 290 3000 60÷63
(19,12) (258÷272)

NB 18,5 171÷181
RD 290 1800 90÷95
(13,6) (233÷246)

NA 16,5 163÷173
RD 290 1800 104÷110
(12,13) (223÷235)

NB 14,8 175÷185
RD 290 1500 110÷116
(10,88) (239÷252)

NA 13,3 169÷178
RD 290 1500 125÷132
(9,78) (230÷243)

Theindicatedspecificfuelconsumptionreferstotheperiodfollowing
approximately 30 working hours.

159

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 XII SETTINGS

Stop setting

1) Completely turn lever C counterclockwise and keep it in this position.

Retainer F should not be in contact with lever C.
2) Unscrew nut G and bring retainer F in contact with lever C
3) Push retainer F so that lever C is moved backwards clockwise by
1.0÷1.5 mm.
4) Lock retainer F by screwing nut G

Note: Under these conditions no damage can be caused to the injection

pump rack rod stops by sudden impacts due to the available electric
stops.

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 STORAGE XIII

STORAGE

Prepare engines as follows for storage over 30 days:

Temporary protection (1÷6 months).

• Let engine work 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 f ull speed for 5 ÷ 10 minutes.
-When engine is warm empty oil pan and fill with standard new oil. ---
Remove fuel tube and empty the tank.
Remove fuel filter, replace cartridge if dirty and refit. Carefully clean
cylinder fins, heads and fan.
161 Seal all openings with tape.
Remove injectors, pour a spoonful of oil type SAE 30 into the cylinders
and rotate manually to distribute the oil. Refit injectors.
Spray oil type SAE 10W into exhaust and intake manifolds, rocker
arms, valves, tappet etc. Grease all unpainted parts.
Loosen belt.
Wrap the engine in a plastic film.
Store in a dry place, if possible not directly on the soil and far from high
voltage electric lines.

Permanent protection (over 6 months)

The following is recommended apart from the above instructions:

• For the lubrication and injection system as well as for moving
parts use rustproof oil type MiL-L-21260 P10, grade 2, SAE 30 (Ex.
ESSO RUST - BAN 623 - AGIP, RUSTIA C. SAE 30). Let the engine run
with rustproof oil and drain any excess.
• Coat external unpainted surfaces with antirust type MIL-C-
162
16173D,grade 3 (Ex. ESSO RUST BAN 398 - AGIP, RUSTIA 1001F).

How to prepare the engine for operation

• Clean engine outside

• Remove protections and covers.
• Remove antirust by an appropriate solvent or degreaser.
• Remove injectors, fili with standard oil, turn crankshaft by a few
revolutions, remove oil pan and drain the protective oil.
• Check injectors, valve clearance, belt tension, head tightening, oil
fìlter and air cleaner for proper setting. lf the engine is stored over a
long period of time (over 6 months) check one of the bushings for
corrosion.

163

164

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 XIV TORQUE SPECIFICATIONS

MAIN TORQUE SPECIFICATIONS

Diam. and pitch Torque
POSITION
( mm ) ( Nm )
Connecting rod 8x1.25 4.0
Injection pump delivery valve union 18x1.5 4.0
Rocker arm cover 8x1.25 2.0
Center main bearing support 8x1.25 2.5
Intake manifold 8x1.25 2.5
Exhaust manifold 8x1.25 2.0
Air shroud 6x1.0 0.6
Accelerator cover 6x1.0 1.0
Oil filter housing 6x1.0 1.25
Internal oil filter cover 6x1.0 1.0
Hydraulic pump flange 8x1.25 2.5
Camshaft gear 10x1.5 6.0
Oil pump gear 10x1.5 3.5
Starting motor 10x1.5 4.5
Blower hub 14x1.5 16
Rocker arm shaft 8x1.25 2.5
Gear cover plate 8x1.25 2.5
Engine mounting foot 10x1.5 4.0
Fuel feeding pump 8x1.25 2.5
Injection pump 8x1.25 2.5
Oil pump 8x1.25 2
Nozzle holder 6x1.0 1
Oil pan 8x1.25 2.5
Starting pulley 10x1.5 4.5
Main bearing support, gear case side 8x1.25 2.5
Main bearing support, flywheel side 8x1.25 2.5
Center main bearing support 10x1.5 3.0
Hydraulic pump gear support 8x1.25 2.5
Governor fork support 8x1.25 2.5
Fuel tank bracket 8x1.25 4.0
Cylinder head 10x1.5 5.5
Blower 6x1.0 1.0
Flywheel 20x1.5 30.0

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 TORQUE SPECIFICATIONS XIV

STANDARD BOLT TORQUE SPECIFICATIONS

DESCRIPTION

Diameter per Pitch R ≥ 800 N/mm2 R ≥ 1000 N/mm2 R ≥ 1200 N/mm2

(mm)
Nm Kgm Nm Kgm Nm Kgm

4x0,70 3,6 0,37 5,1 0,52 6 0,62

5x0,80 7 0,72 9,9 1,01 11,9 1,22

6x1,00 12 1,23 17 1,73 20,4 2,08

7x1,00 19,8 2,02 27,8 2,84 33 3,40

8x1,25 29,6 3,02 41,6 4,25 50 5,10

9x1,25 38 3,88 53,4 5,45 64,2 6,55

10x1,50 52,5 5,36 73,8 7,54 88,7 9,05

12x1,75 89 9,09 125 12,80 150 15,30

14x2,00 135 13,80 190 19,40 228 23,30

16x2,00 205 21,00 289 29,50 347 35,40

18x2,50 257 26,30 362 37,00 435 44,40

20x2,50 358 36,60 504 51,50 605 61,80

22x2,50 435 44,40 611 62,40 734 74,90

24x3,00 557 56,90 784 80,00 940 96,00

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 RUGGERINI MOTORI
Via Cav. del Lavoro Adelmo Lombardini, 2
42100 Reggio Emilia – Italia - ITALY
Tel. (+39) 0522 354444 - Fax (+39) 0522 343344
Telex 530321 MOTRUG-I
Internet: http://www.ruggerini.it

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Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication.
Data reported in this issue can be modified at any time by Lombardini.
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La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación.

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REVISION 00 30.03.2003