Sisu Diesel 320 Workshop Manual
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Sisu Diesel 320 Workshop Manual

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WORKSHOP MANUAL
SISUDIESEL
8366 40634
320
420
620
634

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Summary of Contents for Sisu Diesel 320

  • Page 1 WORKSHOP MANUAL SISUDIESEL 8366 40634...
  • Page 2 Sisu Diesel Inc. FIN–37240 Nokia, Finland Telephone: +358 3 341 7111 E–mail: info.sisudiesel@sisudiesel.com www.sisudiesel.com Diesel Engines, After Sales Telefax: +358 3 341 7333 Sisu Diesel Inc. takes no responsibility for any damages caused because of incorrect information in this manual...

  • Page 3: Table Of Contents

    0---11 Coolant pump (320, 420 separate ball bearings) ........
  • Page 4 ......... . . 11---1 C. Reconditioning coolant pump (320, 420, 620, 634 separate ball bearings) ....
  • Page 5 Contents 0---0 H. Removing fuel injection pump ........... . 13---10 I.

  • Page 6: To The User

    This Workshop Manual is intended to facilitate workshop operations and repair work. 320, 420, 620 and 634---engines are mainly the same in construction, so the same repair instructions usually apply to different engine types. The differences between the various engine types which affect repair work have been mentioned in technical data and repair instructions.

  • Page 7: Safety Instructions

    Safety Instructions 0---2 SAFETY INSTRUCTIONS When you are operating the engine or working near it, use hearing protectors to avoid noise injuries. In the service --- and repair work of the engine there is al- ways the possibility of injury. Before starting the work Stop the engine always before service --- or repair work.

  • Page 8: Engine Specification

    Engine Specifications 0---3 ENGINE SPECIFICATIONS 320D 320DS 420D 420DS 420DW 420DWI 620D 620DS 634DS Engine type Number of cylinders Displacement (dm Cylinder bore (mm) Stroke (mm) Compression ratio 16,5/18,5:1 Combustion direct injection Firing order 1---2---3 1---2---4---3 1---5---3---6---2---4 Compression pressure bar Weight kg Direction of rotation from the engine front...

  • Page 9: Special Tools

    Fitting tool for coolant pump shaft 320, 420 9052 47800 Pressure valve testing gauge 9052 48900 Extractor for injection pump gear 9025 99100 Injection timing check pin (320, 420, 620, 634/Valtra Valmet---tractors) 8366 62022 Electronic timing kit 9025 99000 Control rod locking bush 9051 71300...
  • Page 10 Special Tools 0---5 20--- 6...

  • Page 11: Technical Data

    ............13,250...13,320 mm Main bearing housing diameter .

  • Page 12: Valves, Rocker Arms And Tappets

    Technical Data 0---7 Valves, rockers and tappets With a valve clearance of 1,0 mm: --- inlet valve opens ............0˚±2˚...

  • Page 13: Crankshaft

    Technical Data 0---8 Camshaft clearance in bearing bushes (others than no 1) ......0,090...0,140 mm Camshaft clearance in bearing bushes nos 2, 3 and 4 (620/634---engines) .

  • Page 14: Balancing Unit

    Technical Data 0---9 Balancing unit (420---engines) Tooth backlash: --- crankshaft ring gear ---balancer weight gear wheel ......0,1...0,3 mm --- between the balancer weights gear wheels .

  • Page 15: Piston, Piston Rings And Pin

    Piston diameter: --- 17 mm from lower edge (320, 420, 620---engines) ......

  • Page 16: Oil Pump (620/634

    15...20 mm Coolant pump (with separate ball bearings 320 --- and 420 ---engines) Outside diameter of bearing ..........

  • Page 17: Coolant Pump (620/634

    95˚C Turbocharger Schwitzer S1A (320 DS) Shaft end float .............

  • Page 18: Tightening Torques

    Use a washer with the aluminium parts. The bolts of a self carrying oil sump 12.9 30 Nm 12.9 90 Nm 12.9 150 Nm 10.9 200 Nm 10.9 700 Nm 10.9 300 Nm 10.9 700 Nm 10.9 700 Nm ) 320 and 420...

  • Page 19: Construction

    Construction 0---14 CONSTRUCTION General The Sisudiesel 20/34---series engines (3---, 4---, or 6---cylin- The flywheel housing are delivered according to the require- ders) are water ---cooled, four stroke, direct---injection in ---line ments set, by the engine application and differet flywheel diesel engines. All engines are produced as naturally aspir- housings can be mounted on all engine types.

  • Page 20: Cylinder Head

    320---engine. Each cylinder has its own inlet and ex- haust ports located on either side of the head. Between hot ex- haust valves a cool inlet valve is fitted to balance the thermal On the turbocharged engines the upper ring location is load.

  • Page 21: Timing Gears

    Construction 0---16 20--- 9 Timing gears The timing gear train consists of hardened, helically cut gear wheels. The gears are encased by the timing gear casing which is fitted to the front of the engine. The timing gear drives the camshaft, fuel injection pump and oil pump. If the engine is equipped with a hydraulic pump, it is driven via a gear or a separate drive unit.

  • Page 22: Lubricating System

    Construction 0---17 Lubricating system (620/634-- engines) 1. Lubricating oil pump 2. Pressure ---relief valve 20--- 10 3. Oil filter 4. Turbocharger 5. Main oil gallery 6. Piston cooling nozzle 7. Oil pressure sensor Lubricating system The engine has a pressure lubricating system in which the oil pump (gear pump) is attached to the cylinder block lower face.
  • Page 23 The coolant pump has separate ball bearings or the pump shaft and the bearings are built together to form one unit (320--- and 420 engines). The thermostat opens at 79˚C. During a cold season, a ther- mostat with the opening temperature of 83˚C can be use.
  • Page 24 The compressed air is cooled by the air to water basis. The air with o---rings in 420---engines and with level seals in coming from the turbocharger has a temperature about 320/620/634---engines. 150˚C which is cooled by the cooling water of the engine down to about 95˚C.
  • Page 25 Construction 0---20 20--- 14 Electronic Engine Management sys- tem (EEM) The Sisudiesel EEM system is a microprocessor based diesel engine control system to replace the traditional mechanical speed governor on the engine. This system significantly im- proves the properties of the engine and adds several func- tions and operational features that could not be realised with mechanical governors.
  • Page 26 Cylinder Block 1---1 WORK INSTRUCTIONS 1. CYLINDER BLOCK A. Measuring cylinder liner wear 9051 73100 1. Using a micrometer set the dial gauge to zero using a new cylinder liner indicating the initial dimension of the bore: 108,00 mm. 2. Clean the inner surface of the cylinder liner thoroughly be- fore measurement.
  • Page 27 Observe the position of the bushing oil holes. It is unnecess- 21--- 5 ary to ream the bushings after fitting. Oversize camshaft bushings for 320---engines. Numbering begins from the front end of the engine. Order no. Hole diameter 1.
  • Page 28 Cylinder Block 1---3 134 mm 272 mm 6...7 mm Order no. Hole diameter 1. 8363 24661 56,02...56,05 21--- 6 2. 8368 52460 55,42...55,45 3. 8368 52460 55,42...55,45 4. 8368 52461 55,64...55,67 Camshaft oversize bearing bushings for 420---engines. Numbering begins from the front end of the engine. 266 mm 272 mm 134 mm...
  • Page 29 Cylinder Block 1---4 G. Fitting guide pipe for oil dipstick 3. If the recess is damaged, or the cylinder liner height (see point 5) needs to be adjusted, use milling cutter 9101 65600. If necessary, a light lapping can be executed after milling with 1.
  • Page 30 Cylinder Block 1---5 6. If the cylinder liner height is too low, a liner with a higher flange is fitted. 21--- 14 Order no Markinggrooves +0,02 8366 47420 9,03 --- (std.) 21--- 16 +0,02 8366 47933 9,08 +0,02 8366 47934 9,13 +0,02 8366 47935...
  • Page 31 Flywheel Housing 2---1 2. FLYWHEEL HOUSING A. Fitting flywheel housing The flywheel housing is centred on the cylinder block by two tension pins. Even the flywheel housings which are delivered as spare parts have ready ---made holes for the pins. 1.
  • Page 32 Flywheel Housing 2---2 5. Fit the seal as follows: --- Do not remove the plastic sleeve in before hand. --- NOTE! FIT THE SEAL DRY, NOT OILED! 22--- 4 O = Sleeve T = Seal --- Put the sleeve against the crankshaft rear end so that the sleeve is on the shaft bevelling.
  • Page 33 9101 66000. 1. Install the counter screw 9052 47200 for the valve spring in- stalling tool in the rocker arm cover bolt. On the 320--- and 620/634---engines there is not a screw stud at the valves for the centre cylinder.
  • Page 34 Cylinder Head 3---2 9101 65900 23--- 6 23--- 4 5. Measure the clearance between the valve stem and the valve guide with a dial gauge. Lift the valve so that the valve head is 15 mm from the face of the cylinder head, and measure the clearance.
  • Page 35 Cylinder Head 3---3 F. Changing valve seat rings G. Grinding valves Exhaust valves are fitted with separate valve seat rings. If the In order to ensure that there is a proper seal around the valves, sealing surface is damaged so badly that it cannot be repaired there is a difference in the sealing surface angles.
  • Page 36 1. Measure the length of the cylinder head bolts. Compare with dimensions shown in figure below. Change too long bolts. max. 142 320, 620, 634 23--- 12 max. 188,5 23--- 11 2. Screw the cylinder head stud bolts in to the cylinder block to a torque of 30 Nm.
  • Page 37 Valve Mechanism 4---1 4. VALVE MECHANISM 60˚ A. Reconditioning valve mechanism 1. Check the valve tappets, especially the contact surface against the camshaft. Worn or damaged tappets should be discarded. 24--- 4 5. Fit the plug to the other end of the rocker arm shaft. Lubri- cate the shaft and fit various parts in a correct order.
  • Page 38 Valve Mechanism 4---2 B. Changing camshaft/camshaft gear Modification of the cam shaft From engine no L 13188 all 620/ 634--- engines are equipped 1. Remove the inlet pipe between the turbocharger and the with a cam shaft where the front end bearing location has no induction manifold.
  • Page 39 0,35 mm feeler gauge is slightly tight---fitted between the rocker arm and the valve stem end. Adjust clear- ance by rotating the adjusting screw. --- tighten the locking nut and check the clearance 320, 620, 634 24--- 8 I = Inlet P = Exhaust...
  • Page 40 Crankshaft 5---1 5. CRANKSHAFT A. Removing crankshaft 1. Remove the oil sump. 2. Disconnect the balancing unit lubricating oil pipe from the cylinder block and unscrew the balancing unit fixing bolts. Re- move the balancing unit and the lubricating oil pipe (only 420 ---engines).
  • Page 41 Crankshaft 5---2 D. Changing crankshaft gear rim 2. Assembly the bearing with oilholes/groove (A) to the cylin- der block and the bearing with no hole (B) to the bearing cap. (420---engines only) Ensure that the bearing shell clamping claws fit into their notches and that the shells to be fitted in the cylinder block have a hole coinciding with the oil port.
  • Page 42 Crankshaft 5---3 Note! 320---engines. Tightening torque of screws of crank- 3. Fix the new vibration damper/pulley on the crankshaft. Tap shaft counterweight is 160 Nm. Apply locking fluid Loctite the timing indicator in its place and tighten the fixing screws 2701 on the screw threads.
  • Page 43 Crankshaft 5---4 H. Checking element of the rubber I. Viscose type vibration damper damper (620/420) 25--- 12 1. Housing 2. Damper mass 30 Nm 3. Liquid cavity 4. Bushing In the 634---engines and some 620---engine versions there is 25--- 10 a vibration damper of so---called viscose type.
  • Page 44 Connecting Rods and Pistons 6---1 6. CONNECTING RODS AND PISTONS A. Removing pistons together with 40,025... connecting rods 40,040 1. Remove the oil sump and the oil inlet and pressure pipes. 2. Remove the cylinder head. 3. Scrape off the possible soot in the cylinder liner. If the turn- ing edge is clearly marked, smooth it down carefully with a scraper.
  • Page 45 Connecting Rods and Pistons 6---2 Earlier used connecting rod New connecting rod from engine number L 11212 40 Nm + 90˚ Torx E18 max. 86,50 40 Nm + 90˚ Measure the length of the connecting rod screws. The length Note! Always change the screws when opened. should be max 86,50 mm.
  • Page 46 Measure the diameter of the piston at the point shown in the figure below. Renew a piston if needed. 320, 420, 634: 620: 26--- 12 26--- 10 3.
  • Page 47 Connecting Rods and Pistons 6---4 F. Fitting piston pin G. Fitting piston together with con- necting rod. 1. Place the connecting rod inside the piston and push the pis- ton pin into place. 1. Check that the bearing locations are clean and place the bearing shells in the connecting rod and bearing cap.
  • Page 48 Counterbalance 7---1 7. COUNTERBALANCE (420) A. Removing and disassembling counterbalance unit 1. Remove the oil sump 2. Disconnect the lubricating oil pipe of the counterbalance unit. 3. Remove the counterbalance unit. Take care of any shims. 4. Loosen the locking screws and press out the shafts in the direction of the locking screws.
  • Page 49 Flywheel 8---1 8. FLYWHEEL Note! E ---engine’s flywheel delivered as spare parts do not have injection register mark. Make the marking on the new flywheel in connection with installation. A. Changing starter ring gear on fly- --- Rotate the crankshaft until the piston of the 1st cylinder re- wheel aches its top dead centre.
  • Page 50 0,1...0,25 mm inside the gear wheel rear edge (see picture on next page). 9101 65700 29--- 1 3. Loosen the crankshaft nut (special tool 9101 65700 for 320, 420, 620---engines and tool 9024 55800 for 634 engines) and remove the belt pulley/hub. 29--- 2 Note! On 620---engines the belt pulley must be removed be- 1.
  • Page 51 Timing Gear Assembly 9---2 29--- 4 4. Fit the idler gear with shaft stud and ensure that the mark- ings are in the correct position. Fit the washer and tighten the bolts to the correct torque. 29--- 3 C. Fitting timing gear casing 29--- 5 The position of the timing gear casing and cover is deter- mined by two tension pins.
  • Page 52 9. Lubricate both the seal and sealing surfaces and fit the crankshaft V ---belt pulley with hub. 10. Lubricate the crankshaft nut threads. Tighten the nut to 600 Nm on 320--- and 420---engines and 1000 Nm on 620 and 634 engines. 11. Fit the other detached parts.
  • Page 53 Timing Gear Assembly 9---4 D. Idler gear with bevelled ball bear- ings 1. Camshaft gear 2. Idler gear 3. Injection pump gear 4. Hydraulic pump gear 5. Crankshaft gears 6. Oil pump gear 7. Idler gear of compressor 8. Compressor gear 29--- 10 In some 620/634---engines versions bevelled ball bearings are need in the idler gear.
  • Page 54 Timing Gear Assembly 9---5 E. Power take---off In the 20/34---series engines is used a transmission that can be equipped with a P .T.O. run from the camshaft gear. The P .T.O. can run e.g. a hydraulic pump. 29--- 14 Note when assembling the P .T.O. the front bearing seal posi- tion.
  • Page 55 Lubrication System 10---1 10. LUBRICATION SYSTEM Loctite 638 A. Reconditioning of oil relief valve for lubricating oil pressure If the engine lubricating oil pressure is insufficient or if it varies, the relief valve should be checked after first checking the oil level.
  • Page 56 Lubrication System 10---2 Note! 320---engines from engine number C 1474 420---engines from engine number C 1328 620---engines from engine number C 1133 The connection between the gear and shaft in the lubrication oil pump has been modified to a conical connection without key.
  • Page 57 Lubrication System 10---3 D. Fitting oil sump gasket F. Piston cooling nozzles (620/634) The cooling nozzles can be removed after removing the oil Fit the oil sump gasket with the silicone stripes against the cyl- sump. The nozzles have a ball valve with an opening pressure inder block (self carrying and casted oil sumps).
  • Page 58 Lubrication System 10---4 G. Lubricating oil quality requirements --- Naturally aspirated and turbocharged engines API CF ---4, CG ---4, CH---4 ACEA E2/E3 ---96, E4 ---98, E5 ---99 API CG ---4, CH---4 ACEA E3 ---96, E4 ---98, E5 ---99 --- Low emission (E) engines TEMPERATURE ˚C ---40 ---30...

  • Page 59: Cooling System

    211--- 4 Note! Modification of the by ---pass pipe. 4. Remove the fan hub using puller 9052 48900. Remove the 320/420---engines from engine number D 3056 circlip from the pump body. 620---engines from engine number D 3532...
  • Page 60 C. Reconditioning coolant pump 7. Press the shaft into its location in the body using special tool 9051 64900 and fit the circlip. (Separate ball bearings 320, 420, 620, 634) 1. Drain the coolant. Remove the thermostat housing, fan and the v ---belt.
  • Page 61 Note! If the pump bearings have to be changed, use a re- conditioning kit. This kit also contains all seals (see Parts Cata- Note! Some 320/420---engines are equipped with a new type logue). of coolant pump, where the diameter of impeller has changed 87 >...
  • Page 62 Cooling System 11---4 D. Coolant pumps with heavy---duty bearings (620, 634) Some versions of 620/634---engines have a heavy ---duty bearings in the coolant pump. The reconditioning of this pump is done according to the instruction in part C. Note specially the position of the front bearing as assembling. 0,8...1,2 mm 120 Nm 211--- 11...

  • Page 63: Inlet And Exhaust System

    Inlet and Exhaust System 12---1 12. INLET AND EXHAUST SYS- C. Checking turbocharger If a fault is suspected in the turbocharger it can be located in the following way: An engine that is equipped with a turbocharger is a great deal 1.
  • Page 64 Inlet and Exhaust System 12---2 If any defects or wear are confirmed, the turbocharger should be reconditioned. If the engine does not work correctly and the turbocharger is not defective or too worn, the fault could be traced to one of the following items: --- Blocked air filter --- Leakage in the inlet or exhaust systems.
  • Page 65 Injection order: --- 320 ..............
  • Page 66 Fuel System 13---2 1. Fuel tank 213--- 1 2. Prefilter 3. Fuel feed pump 4. Fuel filter Fuel system, description 5. Fuel injection pump 6. Injector 7a. Thermostart fuel reservoir Fuel feed pump (3) draws fuel from tank (1) through pre- 7b.
  • Page 67 Fuel System 13---3 Bosch ---P injection pump 1. Boost control 2. Cold start solenoid 3. Speed lever 4. Injection timing indicator 5. Lube oil into the injection pump 6. Hand pump 7. O ---ring seal 8. Return of lube oil to engine 9.
  • Page 68 Fuel System 13---4 The pump element consists of one plunger and one cylinder which are a matched pair and because of the fine tolerances the whole element should be changed as a complete unit. The cylinder has two passages: inlet passage and release passage.
  • Page 69 Fuel System 13---5 Governor Fuel injection pump type plate The injection pump type plate shows one particular letter indi- cating the user application, see figure below. This letter should always be quoted when ordering a replacement pump or when looking for setting values. 213--- 8 213--- 7 1.
  • Page 70 Fuel System 13---6 A. Bleeding fuel system B. Bleeding Thermostart system Always remove air from the glow plug fuel pipe when the pipe or reservoir has been emptied during repair work etc. This prevents damages to the glow plug caused by lack of fuel dur- ing starting.
  • Page 71 Fuel System 13---7 C. Measuring fuel feed pressure E. Changing fuel feed pump valves 1. Clean the fuel injection pump and the filter and the pipes be- 1. Clean the feed pump. Disconnect fuel pipes to the feed tween them. pump.
  • Page 72 Fuel System 13---8 F. Checking injection timing 213--- 16 4. Turn the crankshaft to a position where the 1st cylinder pis- ton reaches its compression stroke top dead centre. Then turn the crankshaft backwards until the timing mark on the pulley (flywheel) passes the timing indicator.
  • Page 73 Fuel System 13---9 2nd way of checking Note! In some types of injection pumps the injection starting 0 986 612 174 point in the 1st cylinder has been positioned with aid of an indicator pin in the pump governor housing. Do the inspection of injection timing as follows: 1.

  • Page 74: Removing Fuel Injection Pump

    213--- 20/1 on the governor housing and pour in oil. Note! When removing the Bosch ---P injection pump, open Filling quantity: 320---engines 0,3 l bottom mounting screws on the both side of injection pump. 420---engines 0,4 l 620/634---engines 0,6 l Note! If the engine is not to be disturbed while the pump is re- moved, there is no need to secure the pump gear.
  • Page 75 Fuel System 13---11 Bosch ---P injection pump Note! In some types of injection pumps the injection starting point in the 1st cylinder has been positioned with aid of an 1. Check the condition of the o---rings between the pump and indicator pin in the pump governor housing.

  • Page 76: Checking And Changing Pressure Valve

    Fuel System 13---12 J. Checking and changing pressure Note! Replace the sealing ring and o---ring. valve 8. Tighten the holder as follows: --- Tighten first to 30 Nm. 1. Clean the injection pump, injectors and surrounding parts. --- Open the holder about ½ a turn and tighten to 40 Nm. Disconnect the delivery pipes.

  • Page 77: Removing Injectors

    Fuel System 13---13 6. Tighten the adjusting screw of the additional spring until the idling speed rises to the rated value. Lock the adjusting screw M. Inspecting injectors in this position. 7. Fix the safety caps of the adjusting screws. Note! When pressure testing the injectors, it is important to avoid the nozzle end as the fuel jetting out easily pen- Note! Other adjustments (output and max.

  • Page 78: Reconditioning Injectors

    Fuel System 13---14 Chattering sound properties Testing with a hand powered pump does not create the same circumstances as when the injector is fitted in the engine. Only with new nozzles are the test results reliable. With used nozzles, there is no chattering (creaking) sound when the tester is pumped at a certain rate.

  • Page 79: Fitting Injector In Engine

    Fuel System 13---15 O. Fitting injector in engine P . Fitting delivery pipes 1. Clean the injector sealing surface in the cylinder head. If 1. Check the state of the pipes. If there are kinks, damage by necessary use a reamer 9101 66000. chafing, or if the tapered sealing end is damaged, the pipes should be changed.

  • Page 80: Cav Distributor Pump

    Fuel System 13---16 CAV DISTRIBUTOR PUMP Some 420--- and 620---engines are having a CAV made DPA ---type distributor pump. The pump is equipped with an electrical solenoid (ignition key starting and stopping) and automatic bleeding system. The internal lubrication of the injection pump is done by the fuel it is pumping.

  • Page 81: Dismounting And Mounting Injection Pump

    Fuel System 13---17 A. Dismounting and mounting in- B. Injection pump gear jection pump The engines equipped with a rotary injection pump have a different timing mark on the gear in 420--- and 620---en- 1. Clean the pump and the surrounding parts carefully. gines.

  • Page 82: Feed Pump

    Fuel System 13---18 Bleed the thermostart system Always remove air from the glow plug fuel pipe when the pipe or reservoir has been emptied during repair work etc. This prevents damages to the glow plug caused by lack of fuel during starting. 1.

  • Page 83: Stanadyne Distributor Pump

    Injection order: --- 320 ...............
  • Page 84 Fuel System 13---20 Fuel system with distributor pump 1. Fuel tank 2. Prefilter 213--- 40 3. Fuel feed pump 4. Fuel filter 5. Distributor pump 6. Injector 7a,b,c. Return fuel to tank 8. Thermostart reservoir 9. Glow plug 10a,b. Bleeding screws 11.
  • Page 85 Fuel System 13---21 Stanadyne---distributor pump 213--- 40/1 1. Type plate with pump order number 2. Timing marks under the cover 3. Fuel inlet 4. Return fuel/overflow valve 5. Revolution lever 6. Connector for wire to electric stop solenoid Eventual injector pump equipment (e.g. E-- engines) A.
  • Page 86 Fuel System 13---22 Stanadyne distributor pump 1. Drive shaft 2. Governor weights 3. Governor spring 4. Stop solenoid 5. Overflow valve 6. Metering valve 7. Cam ring rollers 8. Hydraulic head 9. Pressure regulator valve 10. Transfer pump blades 11. Distributor rotor 12.
  • Page 87 Fuel System 13---23 Stanadyne distributor pump Housing pressure 213--- 42 Transfer pump pressure Injection pressure 1. Fuel tank 10. Regulator spring 2. Water trap 11. Centrifugal weights 3. Fuel feed pump 12. Overflow valve 4. Fuel filter 13. Hydraulic head connecting passage 5.

  • Page 88: Removing Pump

    Fuel System 13---24 A. Removing pump 1. Clean the pump and the surrounding parts carefully. Remove the delivery pipes, the throttle cable wire from the revolution lever and the stop solenoid wire from the pump. Fit protective caps on the delivery pipe unions. 2.

  • Page 89: Bleeding Fuel System

    Fuel System 13---25 C. Bleeding fuel system D. Fuel feed pump Note! This fuel system removes automatically small For the membrane type fuel feed pump no spare parts are amounts of air bubbles from the filter and the pump when supplied.

  • Page 90: Adjusting Low Idling Speed

    Fuel System 13---26 F. Adjusting low idling speed H. Wiring diagram of electrical ad- vance (CCA) Ignition switch Alternator Red 1,5 mm Control unit Green 1,5 mm 213--- 47 Blue 1,5 mm 1. Low idling speed 2. Revolution lever Brown 1,5 mm 3.

  • Page 91: Checking Injection Timing (Dynamic)

    ENTER leaving the trigger point at 30%. Setting values are available through Service Department of 6. Display shows ”Offset 20.0˚”. Press ENTER leaving the Sisu Diesel Inc. offset at 20,0˚. Read also manufacturer service manual. 7. Display shows ”Calibrate?”. Start the engine and run it at...

  • Page 92: Trouble Shooting

    Fuel System 13---28 Trouble shooting If the timing deviates remarkably from given, check the fol- lowing: 1. Vibrating delivery pipe, hold the pipe with hand. 2. Distance of magnetic probe from flywheel not correct, re --- set the magnetic probe. 3.

  • Page 93: Fuel Quality Requirement

    Fuel System 13---29 Fuel quality requirement Requirement Test method Density, +15˚C 0,82...0,86 kg/dm ASTM D 4052, EN ISO 12185 Viskosity, +40˚C 1,2...4,5 mm ASTM D 445, ISO 3104 Sulphur content max. 0,2 % m/m ASTM D 4294, ISO 8754 Cetane index min.

  • Page 94: Equipment And Feeding Tables

    Equipment and Feeding Table 14---1...
  • Page 95 Equipment and Feeding Table 14---2...
  • Page 96 Equipment and Feeding Table 14---3...
  • Page 97 Equipment and Feeding Table 14---4...
  • Page 98 Equipment and Feeding Table 14---5...
  • Page 99 Equipment and Feeding Table 14---6...
  • Page 100 Equipment and Feeding Table 14---7...
  • Page 101 Equipment and Feeding Table 14---8...
  • Page 102 Equipment and Feeding Table 14---9...
  • Page 103 Equipment and Feeding Table 14---10...

  • Page 104: Electrical System

    15---1 15. ELECTRICAL SYSTEM A. Alternators Magneti Marelli A 127 45 A/65 A (Sisu Diesel no. 8366 40127 45 A) (Lucas) (Sisu Diesel no. 8366 40128 65 A) Nominal voltage ............. . .
  • Page 105 15---2 Bosch N1 28 V 10/80 A (Sisu Diesel no. 8353 39751) Nominal voltage ............. .
  • Page 106 Electrical System 15---3 Iskra AAK 5118 14 V 95 A (Sisu Diesel no. 8366 40927) (Sisu Diesel no. 8366 66225) Nominal voltage ............. .

  • Page 107: Starters

    Electrical System 15---4 B. Starters Magneti Marelli M 127/2,8 12 V (Sisu Diesel no. 8353 31592) (Lucas) Values, unloaded Running speed .............
  • Page 108 Electrical System 15---5 Iskra AZJ3234 12 V 3,1 kW z11 (Sisu Diesel no. 8366 40949) Values, unloaded Running speed ............
  • Page 109 Electrical System 15---6 Iskra AZJ3319 12 V 3 kW z10 (Sisu Diesel no. 8366 40949) Values, unloaded Running speed ............

  • Page 110: Electric Stop Device

    Electrical System 15---7 C. Electric stop device FASTENING TO INJECTION PUMP Loctite 242 Assembly 1. Solenoid Loctite 242 2. Thread sleeve 3. Rubber bad 4. O ---ring 5. Screw 6. O ---ring 7. Parts to be removed Electrical connection 1. Solenoid 2.
  • Page 111 Electrical System 15---8 FASTENING TO BRACKET A. Connect a voltmeter or a suitable lamp between the sole- noid positive pole and AUX---pole. When the current is Checking the solenoid operation (Synchro start) switched on and the solenoid moves to the end of its motion range, the voltmeter reading should indicate approximately battery voltage or the light should be on.

  • Page 112: Installation Of Magnetic Pick Up

    Electrical System 15---9 D. Installation of magnetic pick up 1. Rotate the flywheel to a position so that one of the flywheel ring gears teeth are in front of the pick up installation hole. 0,75 215--- 8 2.Turn the pick up in, until it comes in contact with the tooth. 3.Turn the pick up out ½...

  • Page 113: Optional Equipment

    Optional Equipment 16---1 16. OPTIONAL EQUIPMENT A. Compressor (Bendix) 140 Nm 216--- 1 1. Inlet valve heads A. Cylinder head retaining screws 2. Spring B. Cylinder head 3. Valve guide C. Valve plate 4. Gasket D. Ventil plate retaining screws 5.

  • Page 114: Compressor (Knorr)

    Optional Equipment 16---2 B. Compressor (Knorr) INSPECTION 1. Thoroughly clean all removed parts. Ensure that all air and water passages are clear. Clean off any carbon from the pis- ton heads and the cylinder top parts. 12 Nm 2. Check the condition of the inlet and delivery valve seats. Only slight, even wear is permitted.

  • Page 115: Industrial Clutch (A.p . Borg & Beck)

    Optional Equipment 16---3 C. Industrial clutch (A.P . Borg & ADJUSTMENT Beck) The clutch is correctly adjusted when the engagement load at the end of the operating lever is 34...41 kg (operating lever length 63,5 cm). SERVICE Note! Never service or adjust the clutch with the engine Adjusting rings of the clutch running.
  • Page 116 Optional Equipment 16---4 Adjusting the main bearing The tapered roller bearings on the drive shaft must be ad- justed when the shaft end play exceeds 0,25 mm. max. A 0,25 " 1. Lock plate 2. Tapered roller bearings 3. Adjusting ring 216--- 6 1.

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