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 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

• 68, 1 2 3 413— 25 Fuel System 13—12 6. Before asse mbling, all part s should be carefully cleaned in clean fuel or testing fluid. 7. Put the same thickness of shim back as were fitted earlier. Note possible adjustment of the opening pressure. Assemble the rest of the injector. Note the position of the spring guide andthevalvestopspacer. 8. Tighten the nozzle cap nut by hand and then t…

• 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……………………….…

• 56, Inlet and Exhaust System 12—3 E. Fitting intercooler 412— 4 1. Using a new gaskets, fit the intake manifold to the cylinder head. 2. Fit the cooler with thrust plates to the intake manifold. Note! A conventional gasket is not used but apply a continu- ous bead of silicone sealing to the sealing surface. Leak test pressure for the cooler: — W a t e r s i d e 2,9 bar — A…

• 38, 4 5 — 7 80 Nm 1 2 3 4 Crankshaft 5 — 2 D. Fitting crankshaft 1. Clean the oilways, bearing shells and bearing locations. Check that the crankshaft is clean. A B 4 5 — 4 2. Assembly the bearing with oilholes/groove (A)tothecylin- der block and the bearing with no hole (B) to the bearing cap. Ensure that the bearing shell clamping cl aws fit into their notches and th…

• 52, Cooling System 11—1 11. COOLING SYSTEM A. Quality requirements of coolant The coolant used must meet the standards ASTM D 3306 or BS 6580:1992. — Mixing proportion should be 40 —60 % of ethylene/propy- lene—glycol based coolant and the rest water. The best ratio is 50/50 %. — In warm climates the 30 % mixture ratio gives enough good protection against corrosion. —…

• 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 line…

• 22, 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 ci…

• 18, 4 0 — 4 Construction 0 — 1 4 CONSTRUCTION General 6 4 5 — e n g i n e i s l i q u i d c o o l e d , 6 — c y l i n d e r, 4 — s t r o k e , i n — l i n e diesel engine with direct injection. It is designed with wet, re- placeable, mid support cylinder liners, oil—cooled pistons and two separate cylinderheads. The engines have a rigid and ribbed cylinder …

• 20, 1 2 3 4 6 5 1 2 3 4 6 5 7 8 4 0 — 6 Construction 0 — 1 6 Timing gears There are two main types of a timing gear assemblies, so— called narrow— and broad timing gear casing. The timing gear train consists of hardened, helically cut gear wheels. The gears are encased by the timing gear casing which is fitt ed to t he front of the engine. The timing gear drives the camshaf…

• 54, Inlet and Exhaust System 12—1 12.INLETANDEXHAUSTSYS- TEM An engine that is equipped with a turbocharger is a great deal more sensitive to disturbances and impurities in the inlet and exhaust systems than a naturally aspirated engine. There fore special attentio n should be given to the whole inlet and ex- haust system. A. Checking air cleaner The engine performance and length of s…

• 9, Special Tools 0 — 5 1 2 3 4 6 7 8 9 10 5 11 12 13 14 15 16 17 18 19 21 22 23 24 26 25 29 27 30 31 20 28 39 38 37 4 0 — 3 32 33 34 35 36
  …

• 44, WARNING Timing Gear Assembly 8 — 1 8. TIMING GEAR ASSEMBLY A. Removing timing gear casing As the timing gear casing bottom face forms a part of the mat- ing face for the oil sump gasket, the casi ng cannot be re- moved without first removing the oil sump. 1. Remove the oil sump. 2. Remove the radiator, fan, belt,alternator and belt te nsioner assy. If the engine is equipped w…

• 50, 8363 36459 410— 9 8368 59108 60 Nm 410— 10 Lubrication System 10—3 F. Oil cooler Practically there are two different oil coolers, the difference being position of the oil filter, see picture. To r e m o v e 1. Open the coolant drain plug under the oil cooler and drain the co olant into a suitable container. Remove the pipe going into the thermostat housin…

• 29, 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. Clean the sealing surfaces between the cylinder block and the flywheel housing. 4 2 — 1 2. Apply silicone sealing a…

• 53, 411— 2 5294 01440 180 Nm 411— 3 40 Cooling System 11—2 C. Reconditioning the coolant pump 1. Drain the coolant. Disconnect the hose at the inlet connec- tion of the coolant pump. Loosen the coolant pipes from the coolant pump. 2. Release the three screws which retain the coolant pump to the cover of the timing case — from the rear. Remove the cool- ant pump. 3. Unscrew the gear fix…

• 57, 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 a…