Руководство по эксплуатации sisu

Sisu Diesel Engines owner’s, service and maintenance manuals, error codes list, DTC, spare parts manuals & catalogues, wiring diagrams, schematics free download PDF

SISU diesel engine Manuals PDF

SISU diesel engines are part of a new generation of engines that are quiet, fuel-efficient, and have optimum torque and power characteristics. The concentration of service points on one side of the motor and up to 500-hour service intervals will enable fast maintenance at a low cost. Major components are warranted for 5000 hours, and the engine for 3000 hours. Before the first overhaul, a diesel engine has a service life of 15,000 hours. To guarantee that the engine stays in good functioning condition throughout its lifespan, all important components are designed to be repairable repeatedly. SISU motors are lighter and more compact than equivalent motors from other manufacturers due to their standard displacement.

Diesel engines of the SISU Diesel brand are available in a variety of types, allowing the user to select the engine with the required horsepower. Many engine components and replacement parts are standardized: the cylinder liner, flywheel, and flywheel housing, among others, are interchangeable across three-, four-, and six-cylinder engines. This substantially facilitates the maintenance of motors and enables the optimization of spare parts inventory. Effective cooling of the upper portion of the cylinder liners enables perfect thermal equilibrium and prevents deformations caused by overheating.

SISU motors are completely compliant with TIER 2 (STAGE 2) and TIER 3 environmental standards (STAGE 3). The specific fuel usage is lower than other manufacturers’ equivalents. The option to utilize biodiesel fuel (100% biofuel – for TIER 2, TIER 3) not only makes the engine more eco-friendly but also more cost-effective for agricultural applications. Rapeseed oil, which may be used as a basis or component of biofuels, is an ideal fuel for the engine based on cost, availability, and physical and chemical properties.

SISU engines are placed on the major agricultural, industrial, and municipal equipment manufacturers’ machines: AGCO, Valtra, Challenger, STEYR, Laverda, Massey Ferguson, Sampo Rosenlew, Valmet, Logman, Kalmar Industries, AJ Power, Logset, and Lannen Eng.

Sisu Trucks operator’s, electrical wiring diagrams, workshop, service and repair manuals, spare parts catalogues, error codes in PDF download 

Schuller drove SISU trucks in Germany at the Mengkofen location in Lower Bavaria from 2006 to 2010. Windlin, based in Kriens, Switzerland, was the Swiss distributor for SISU trucks.

Sisu Citius Series 44, 49, 66, 74 and 84 Engines Workshop Manual PDF. This Workshop Manual is intended to assist with workshop operations and repair work. This Workshop Manual does not cover the regular service procedure as this is explained in the Citius series Instruction Manual.

Citius series engines (types 44, 49, 66, 74 and 84) are generally of the same construction, so the same repair instructions will usually apply to various engine types. The differences between the various engine types, which affect repair work, are mentioned in the technical data and repair instructions. All measurements are in millimetres and valid when the temperature of the parts is +20°C, unless otherwise stated.

Before starting any repair work, please read the safety instructions at the beginning of this book. Make sure that you have all the necessary tools, parts and accessories to hand. The special tools mentioned in the work instructions are not all essential, but they speed up and facilitate the work and contribute to successful execution of the work. An engine which has undergone repairs must be run in just like a new one.

Should the engine require work not described in this manual, please consult your local agent or the Service Department of Sisu Diesel Inc., Linnavuori, Finland. To facilitate consulting, find out the following facts about the engine before contacting us:

• engine type
• engine number
• model or equipment
• hours operated or kilometres driven.

As Sisu Diesel Inc. is continuously developing the products, all rights are reserved to alter the specifications, accessories and the service and repair procedure without separate notice.

CONTENTS

• TO THE USER
• SAFETY INSTRUCTIONS
• ENGINE TYPE DESIGNATIONS
• LOCATION OF THE ENGINE SERIAL NO
• MARKING OF THE EEM 3 CONTROL UNIT
• LIFTING THE ENGINE
• CONSTRUCTION
  • Technical Data
  • General
  • Cylinder Block
  • Flywheel Housing
  • Valve Mechanism
  • Cylinder Head, 2V Engines
  • Cylinder Head, 4V Engines
  • Crank Mechanism
  • Timing Gears
  • Lubricating System
  • Cooling System
  • Inlet and Exhaust System
• TECHNICAL DATA
  • Cylinder Block
  • Cylinder Liners
  • Cylinder Head
  • Valves and Rockers
  • Tappets and Push Rods
  • Camshaft
  • Crankshaft
  • Flywheel
  • Balancing Unit
  • Timing Gears
  • Connecting Rod
  • Piston, Rings and Pin
  • Lubricating System
  • Oil Pump
  • Coolant Pump
  • Thermostat
  • Turbocharger
• TIGHTENING TORQUES
• SPECIAL TOOLS
  • Cylinder Block
  • Timing Gear- and Flywheel Housing
  • Cylinder Head and Valve Mechanism
  • Crank Mechanism
  • Coolant Pump
  • Fuel System

WORK INSTRUCTIONS

• 1. CYLINDER BLOCK
  • 1.1. Measuring cylinder liner wear
  • 1.2. Removing cylinder liner
  • 1.3. Checking cylinder block
  • 1.4. Changing camshaft bushing
  • 1.5. Fitting plug at camshaft rear end
  • 1.6. Oversize bushings for camshaft
  • 1.7. Fitting plug at camshaft rear end (oversize bushings)
  • 1.8. Fitting cylinder liner
• 2. FLYWHEEL HOUSING
  • 2.1. Fitting flywheel housing
  • 2.2. Changing crankshaft rear oil seal
• 3. CYLINDER HEAD, 2V ENGINES
  • 3.1. Removing cylinder head
  • 3.2. Removing valves
  • 3.3. Checking cylinder head
  • 3.4. Changing valve guides
  • 3.5. Machining valve seat
  • 3.6. Changing valve seat rings
  • 3.7. Grinding valves
  • 3.8. Fitting valves
  • 3.9. Fitting cylinder head
• 4. CYLINDER HEAD, 4V ENGINES
  • 4.1. Reconditioning
  • 4.2. Fitting Cylinder Head
• 5. VALVE MECHANISM, 2V ENGINES
  • 5.1. Reconditioning valve mechanism
  • 5.2. Changing camshaft / camshaft gear
  • 5.3. Adjusting valves
• 6. VALVE MECHANISM, 4V ENGINES
  • 6.1. Reconditioning valve mechanism
  • 6.2. Checking and Adjusting Valve Clearances
• 7. CRANKSHAFT
  • 7.1. Removing crankshaft
  • 7.2. Checking crankshaft
  • 7.3. Changing crankshaft gears
  • 7.4. Fitting crankshaft
  • 7.5. Crankshaft hub piece
  • 7.6. Checking element of the rubber damper
  • 7.7. Viscose type Vibration Damper
• 8. CONNECTING RODS AND PISTONS
  • 8.1. Removing Pistons Together with Connecting Rods
  • 8.2. Changing Connecting Rod Bearings
  • 8.3. Checking Connecting Rod
  • 8.4. Changing Piston Rings
  • 8.5. Checking Pistons
  • 8.6. Fitting Piston Pin
  • 8.7. Fitting Piston Together with Connecting Rod
• 9. COUNTERBALANCE (44- and 49-Engines)
  • 9.1. Removing and Disassembling Counterbalance Unit
  • 9.2. Reconditioning Counterbalance Unit
  • 9.3. Fitting Counterbalance Unit
  • 9.4. Changing Crankshaft Gear Rim
• 10. FLYWHEEL
  • 10.1. Changing Starter Ring Gear on Flywheel
  • 10.2. Fitting Flywheel
• 11. TIMING GEAR ASSEMBLY, 44-, 49-, 66- ENGINES
  • 11.1. Removing Timing Gear Casing
  • 11.2. Reconditioning Idler Gear
  • 11.3. Fitting Timing Gear Casing
  • 11.4. Power Take-off
• 12. TIMING GEAR ASSEMBLY, 74- AND 84-ENGINES
  • 12.1. Removing Timing Gear Casing
  • 12.2. Fitting Timing Gear Casing
  • 12.3. Fan Drive Device
• 13. LUBRICATION SYSTEM
  • 13.1. Oil Pressure Regulating Valve
  • 13.2. Removing and Dismantling Lubricating Oil Pump
  • 13.3. Assembling and Fitting Lubricating Oil Pump
  • 13.4. Piston Cooling Nozzles
  • 13.5. Fitting Oil Sump Gasket
  • 13.6. Lubricating Oil Cooler
  • 13.7. Lubricating Oil Quality Requirements
  • 13.8. Oil Capacities
• 14. COOLING SYSTEM
  • 14.1. Quality Requirements of Coolant
  • 14.2. Thermostat
  • 14.3. Reconditioning Coolant Pump
  • 14.4. Coolant Pumps with Heavy Duty Bearings
  • 14.5. Reconditioning the Coolant Pump
• 15. INLET AND EXHAUST SYSTEM
  • 15.1. Checking the Air Cleaner
  • 15.2. Checking the Inlet and Exhaust Pipes
  • 15.3. Checking the Turbocharger
  • 15.4. Fitting the Turbocharger
• 16. FUEL SYSTEM
  • 16.1. Technical Data
  • 16.2. Bleeding Fuel System
  • 16.3. Measuring Fuel Feed Pressure
  • 16.4. Inspecting Injectors
  • 16.5. High-Pressure Pump
  • 16.6. Rail
  • 16.7. Fuel Quality Requirements
• 17. EEM3 ENGINE CONTROL SYSTEM
  • 17.1. Construction of the EEM3
  • 17.2. EEM3 Engine Control System, Description
  • 17.3. Service Tool of the EEM3 System
  • 17.4. Changing the Control Unit (ECU)
  • 17.5. Changing the ID Module
  • 17.6. Wiring Sets
  • 17.7. Sensors of the Engine Control System
• 18. ELECTRICAL SYSTEM
  • 18.1. Alternators
  • 18.2. Starters

Language: English
Format: PDF
Pages: 118

Sisu Citius Series 44, 49, 66, 74 and 84 Engines Workshop Manual PDF free online

• 15, Technical Data 0 — 1 1 Piston, rings and pin Minimum distance between piston and cylinder head (measured with a piece of lead wire thought the injector loc at i on hole) 0,900…1,150 mm……………………………… Piston diameter: — 15 mm from lower edge 110,863…110,877 mm……………………………………………. Pin bore in piston 44,003…44,009 mm…………………………………….…

• 80, AB 415— 5 Electrical System 15—8 C. Fitting stop solenoid A Running position B Stop position For a correct use of the dual coil sole noid (pull coil and hold coil) the plunger should reach the end of its magnetic stroke at each pulse. In this way, it will press the internal switch which connects the continuous operation seco nd hold coil working without over— heating and with a minimum power absorption. 1. Fit the solenoid…

• 67, 413— 24 1 2 3 4 5 6 7 8 9 Fuel System 13—11 413— 22 2. Secure the injector in a test bench and check the following: — injector opening pressure — the properties of the chattering (creaking) sound and the form of the spray pattern — sealing of nozzle valve against its seat Opening pressure Pump a few times to fill the injector. Increase the pressure in the injector until the chattering (creaking) sound becomes audible. Read off the opening pres…

• 47, Sisu Diesel 645 Series Tensioning Device 9 — 1 9. TENSIONING DEVICE A. Tesioning device for ribbed belt 4 9 — 1 80 Nm 200 Nm 1. Assemble the tensioning device, as the picture shows. The bearing bushes o f the upper shaft do not have to be broached after fitting. 2. Fasten the tensioner to the mounting plate. Lubricate the grease nipple of the upper shaft of the tensioner. Use heat re- sistant grease, e.g. ISOFLEX TOPAS NB52 (NLGI 2). 4 9 — 2 15 29 3. Note, when tightening a new ribb…

• 24, Cylinder Block 1 — 1 WORK INSTRUCTIONS 1. CYLINDER BLOCK A. Measuring cylinder liner wear 1. Using a micrometer set the dial gauge to zero using a new cylinder liner indicating the initial dimension of the bore: 111,00 mm. 2. Clean the inner surface of the cylinder liner thoroughly before measurement. 4 1 — 1 3. Per form the measurement crosswise at the liner top end, lower end and middle. 4. Check the gauge reading for maximum wear and ovalness (compare with rated). B.…

• 16, Technical Data 0 — 1 2 Coolant pump Outside diameter of bearing 52 mm………………………………………….. Inside diameter of bearing housing in pump body 51,970…52,000 mm…………………………. Shaft diameter at bearing 24,996…25,009 mm……………………………………………. Shaft diameter at impeller 15,907…15,920 mm……………………………………….…

• 73, 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 12 V……………………………………………………… Max. voltage 6000 r/min A 127 45 A 45 A……………… ……………………… A 127 65 A 65 A……………………… Earthing ( — ) m i n u s……………………………………………………………. Max. allowed spee…

• 8, Special Tools 0 — 4 SPECIAL TOOLS Order no Description 1 9104 51500 Puller for cylinder liner 2 9104 52000 Milling cutter for cylinder liner seat 3 9104 52700 Centring tool for flywheel housing 4 9104 52600 Drift for fitting rear crankshaft seal 5 9103 94600 Drift for fitting front crankshaft seal 6 9052 46620 Drift for 40 mm cup plug 7 9052 46650 Drift for 16 mm cup plug 8 9025 87400 Drift for fitting camshaft cup plug 9 9101 66300 Press tool…

• 78, Electrical System 15—6 Iskra AZJ3234 12 V 3,1 kW z11 (Sisu Diesel no. 8366 40949) Values, unloaded Running speed £10 000 r/min…………………………………………………… Amperage £140 A……………………………………………………….. Voltage 11 V…………………………………………………………. V alues with armature locked Running speed 0 r/min (max.)………………………

• 55, 412— 3 1 2 3 4 5 6 7 8 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. Leaking flange seal. — Defective or wrongly adjusted injection pump. — Wrongly adjusted throttle linkage. — Def…

• 6, WARNING 4 0 — 2 A A To t h e U s e r 0 — 2 Location of the engine serial no. 4 0 — 1 Lifting the engine Safe lifting of the engine is done with a lifting device where the lifting force effects the lifting ears vertically. A = Engine lifting ears Engine weight (dry, without flywheel and electrical equipment). — self carrying and casted oil sump 826 kg — normal oil sump 690 kg
  …

• 3, Contents 0 — 0 CONTENTS TO THE USER 0 — 1………………………………………………………………. Engine type designations 0—1…………………………………………………. Location of the engine serial no. 0—2……………………………………………. Lifting the engine 0 — 2……………………………………………………….. SAFETY INSTRUCTIONS 0 — 3…………………………

• 61, Sisu Diesel 645 Series 3 4 5 6 7 1 2 8 9 413— 7 Fuel System 13—5 Governor 1. Governor weight 2. Control rod 3. Starting spring 4. Main lever 5. Idler screw 6. Governor spring 7. Additional spring, idling 8. Spring for equaliser 9. Governor control arm The governor is of the centrifugal type and is fitted at the r ear end of the injection pump. The governor controls the rota- tional speed of the engine throughout the whole speed range, and iden…

• 40, Connecting Rods and Pistons 6 — 2 Earlier used connecting rod 40 Nm + 90˚+90˚ max. 66,50 E Measure the length of the connecting rod screws. The length should be max 66,50 mm. If the screw is longer, change it with a new one. It is recommended that the screws are always changed when they are unscrewed. The connecting rods are divided into weight classes with in- tervals of 20 g. The weight class (a letter) is stamped on the side face of the connecting ro…

• 65, Fuel System 13—9 G. Adjusting fuel injection timing If the timing is incorrect, adjust as follows: 1. Loosen the retaining nuts and screw of the injection pump and the connection nuts of the injection pipes. A R 413— 16 2. If the injection timing is retarded, turn the injection pump anti— clockwise (viewed from the front end of the pump). If the timing is advanced, turn the pump clockwise. 3. Check the injection timing and turn the pump again, if necessary. 4. When the injection timing is …

• 22, Sisu Diesel 645 Series 4 0 — 8 1 2 3 4 5 6 Construction 0 — 1 8 The cooling system 1. Radiator 2. Coolant pump 3. By—pass pipe 4. Thermostats 5. Expansion tank 6. Oil cooler Cooling system The gear driven coolant pump is attached to the front face of the timing gear housing. The thermostat housing is mounted on front end of the cylinder head. The system has the internal liquid circulation via the by—pass pipe. The circulation is regulated by the 2 —way thermostat. This arrangeme…

• 57, Sisu Diesel 645 Series Fuel System 13—1 13. FUEL SYSTEM Note! This manual gives only general instructio ns for repair and service measures related to the fuel system. This applies particularly to the injection pump which can be repaired only by a specially trained person who has the necessary special tools and gauges. All service and repair work related to the fuel system requires special care and cleanliness! TECHNICAL DATA Injection pump Bosch ’’…

• 43, Flywheel 7 — 1 7. FLYWHEEL A. Changing starter ring gear on fly- wheel If the ring gear is worn, change it with a new one. The ring gear cannot be turned around because its teeth are cham- fered and hardened on the starter motor side. 1. Remove the old starter ring by tapping it at various points with a drift. Clean the flywheel contact face with a steel—wire brush. 4 7 — 1 2. Warm the ring gear to the temperature of 150…200˚C.Fit the ring gear with the inner diameter chamferin…

• 7, Safety Instructions 0 — 3 SAFETY INSTRUCTIONS In the service— and repair work of the engine there is al- ways the possibility of injury. Before starting the work read and understand the following safety instructions and remarks! Do not start a repair work that you do not fully handle. Make sure that the place of the repair and the surround- ing gives the possibility for safe working. Always be sure of the cleanness and the good order of the repairing place. Do not use faul…

• 71, Equipment and Feeding Table 1 4 — 2 FUEL SYSTEM Test equipment ISO 4008 Nozzle ISO 7440 207 bar EQUIPMENT AND FEEDING T ABLE Fluid ISO 4113 0,60 orifise plate Pipes ø 6 x 1,5 x 600 ISO 4093 645 Engine Application Pump spare part no Pump Injection advance˚ Boost rpm Feed rate RW mm Control rod Control rod Element Fuel adjustment card Governor Max. output r/min control mm 3 /stroke min. positio n Pressure valve Idling r/min press. —1 mm 4 mm Covernor spring Output …