AGCO POWER SISU Diesel Engines Workshop Repair Manual PDF: 645, 320, 420, 620, 634, Citius 44-84, Fortius, 4th & 5th Generation 168 AWF EEM4 - MAGCOSISUENG.zip
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PRODUCT DETAILS:
Total Pages: 1,821 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Sisu 645...1
Contents...2
TO THE USER...4
SAFETY INSTRUCTIONS...6
SPECIAL TOOLS...7
ENGINE SPECIFICATIONS...9
TECHNICAL DATA...10
TIGHTENING TORQUES...16
CONSTRUCTION...17
WORK INSTRUCTIONS...23
1. CYLINDER BLOCK...23
2. FLYWHEEL HOUSING...28
3. CYLINDER HEAD...30
4. VALVE MECHANISM...34
5. CRANKSHAFT...36
6. CONNECTING RODS ANDPISTONS...38
7. FLYWHEEL...42
8. TIMING GEAR ASSEMBLY...43
9. TENSIONING DEVICE...46
10. LUBRICATION SYSTEM...47
11. COOLING SYSTEM...51
12. INLET AND EXHAUST SYSTEM...53
13. FUEL SYSTEM...56
14. FUEL SYSTEM Test equipment...69
15. ELECTRICAL SYSTEM...71
Sisu 320, 420, 620, 634...1
Contents...2
TO THE USER...5
SAFETY INSTRUCTIONS...6
ENGINE SPECIFICATIONS...7
SPECIAL TOOLS...8
TECHNICAL DATA...10
TIGHTENING TORQUES...17
CONSTRUCTION...18
1. CYLINDER BLOCK...25
2. FLYWHEEL HOUSING...30
3. CYLINDER HEAD...32
4. VALVE MECHANISM...36
5. CRANKSHAFT...39
6. CONNECTING RODS ANDPISTONS...43
7. COUNTERBALANCE...47
8. FLYWHEEL...48
9. TIMING GEAR ASSEMBLY...49
10. LUBRICATION SYSTEM...54
11. COOLING SYSTEM...58
12. INLET AND EXHAUST SYSTEM...62
13. FUEL SYSTEM...64
14. FUEL SYSTEM EQUIPMENT AND FEEDING TABLE...93
15. ELECTRICAL SYSTEM...103
16. OPTIONAL EQUIPMENT...111
4th Generation Engine SISU Workshop Manual...1
TABLE OF CONTENTS...3
TO THE USER...8
SAFETY INSTRUCTIONS...9
ENGINE TYPE DESIGNATIONS LOCATION OF THE ENGINE SERIAL NO...11
LOCATION OF THE ENGINE SERIAL NO...11
MARKING OF THE EEM 4 CONTROL UNIT...12
LIFTING THE ENGINE...12
CONSTRUCTION...13
Technical Data...13
General...14
Cylinder Block...14
Flywheel Housing...14
Valve Mechanism...14
Cylinder Head...15
Crank Mechanism...15
Timing Gears...16
Lubricating System...17
Cooling System...18
Inlet and Exhaust System...19
TECHNICAL DATA...20
Cylinder Block...20
Cylinder Liners...20
Cylinder Head...21
Valves and Rockers...21
Tappets and Push Rods...22
Camshaft...22
Crankshaft...22
Flywheel...24
Balancing Unit...25
Timing Gears...25
Connecting Rod...25
Piston, Rings and Pin...26
Lubricating System...27
Oil Pump...27
Coolant Pump...28
Thermostat...29
Turbocharger...29
TIGHTENING TORQUES...30
SPECIAL TOOLS...31
Cylinder Block...31
Timing Gear and Flywheel Housing...32
Cylinder Head and Valve Mechanism...33
Crank Mechanism...34
Coolant Pump...35
Fuel System...36
WORK INSTRUCTIONS...38
1. CYLINDER BLOCK...38
1.1. Measuring Cylinder Liner Wear...38
1.2. Removing Cylinder Liner...38
1.3. Checking Cylinder Block...38
1.4. Changing Camshaft Bushing...39
1.5. Fitting Plug at Camshaft Rear End...40
1.6. Oversize Bushings for Camshaft...40
1.7. Fitting Plug at Camshaft Rear End (oversize bushings)...41
1.8. Fitting Cylinder Liner...41
2. FLYWHEEL HOUSING...44
2.1. Fitting Flywheel Housing...44
2.2. Changing Crankshaft Rear Oil Seal...44
3. CYLINDER HEAD...46
3.1. Removing Cylinder Head...46
3.2. Removing Valves...46
3.3. Checking Cylinder Head...47
3.4. Changing Valve Guides...47
3.5. Machining Valve Seat...48
3.6. Changing Valve Seat Rings...48
3.7. Grinding Valves...49
3.8. Fitting Valves...49
3.9. Fitting Cylinder Head...49
4. VALVE MECHANISM...51
4.1 Reconditioning Valve Mechanism...51
4.2 Changing Camshaft / Camshaft Gear...52
4.3 Adjusting Valves...53
5. CRANKSHAFT...55
5.1. Removing Crankshaft...55
5.2. Checking Crankshaft...55
5.3. Changing Crankshaft Gears...56
5.4. Fitting Crankshaft...56
5.5. Crankshaft Hub Piece...57
5.6. Checking Element of the Rubber Damper...58
5.7. Viscose Type Vibration Damper...58
6. CONNECTING RODS AND PISTONS...59
6.1. Removing Pistons Together with Connecting Rods...55
6.2. Changing Connecting Rod Bearings...59
6.3. Checking Connecting Rod...60
6.4. Changing Piston Rings...61
6.5. Checking Pistons...61
6.6. Fitting Piston Pin...62
6.7. Fitting Piston Together with Connecting Rod...62
7. COUNTERBALANCE (44and 49-Engines)...63
7.1. Removing and Disassembling Counterbalance Unit...63
7.2. Reconditioning Counterbalance Unit...63
7.3. Fitting Counterbalance Unit...64
7.4. Changing Crankshaft Gear Rim...64
8. FLYWHEEL...65
8.1. Changing Starter Ring Gear on Flywheel...63
8.2. Fitting Flywheel...65
9. TIMING GEAR ASSEMBLY...67
9.1 Removing Timing Gear Casing...67
9.2 Fitting Timing Gear Casing...68
9.3 Fitting the crankshaft hub, 98 engines...69
9.4 Power Take-off...70
9.5 Fan Drive Device...70
10. LUBRICATION SYSTEM...71
10.1 Oil Pressure Regulating Valve...71
10.2 Removing and Dismantling...71
10.3 Assembling and Fitting Lubricating Oil Pump...72
10.4 Piston Cooling Nozzles...72
10.5 Fitting Oil Sump Gasket...73
10.6 Lubricating Oil Cooler...73
10.7 Lubricating Oil Quality Requirements...74
10.8 Oil Capacities...75
10.9 Closed Crankcase Ventilation (CCV)...75
11. COOLING SYSTEM...77
11.1 Quality Requirements of Coolant...77
11.2 Thermostat...77
11.3 Reconditioning Coolant Pump...78
11.4 Coolant Pumps with Heavy Duty Bearings...80
11.5 Install the Cylinder Head Connection Part...82
12. INLET AND EXHAUST SYSTEM...83
12.1. Checking the Air Cleaner...83
12.2. Checking the Inlet and Exhaust Pipes...83
12.3. Checking the Turbocharger...84
12.4. Fitting the Turbocharger...85
12.5. Cooled EGR system...86
13. FUEL SYSTEM...89
13.1. Technical Data...90
13.2. Bleeding Fuel System...91
13.3. Measuring Fuel Feed Pressure...91
13.4. Inspecting Injectors...92
13.5. High-Pressure Pump...94
13.6. Rail...95
13.7. Fuel Quality Requirements...96
13.8. SCR system...97
14. EEM3 ENGINE CONTROL SYSTEM...101
14.1 Contstruction of the EEM4...101
14.2 EEM4 Engine Control System Desc...101
14.3 Service Tool of the EEM4 System...102
14.4 Changing the Control Unit (ECU)...103
14.5 Wiring Sets...104
14.6 Sensors of the Engine Control System...106
15. ELECTRICAL SYSTEM...109
15.1. Alternators...109
15.2. Starters...112
Sisu Fortius...1
CONTENTS...3
GENERAL...7
TO THE USER...7
SAFETY INSTRUCTIONS...8
ENGINE TYPE DESIGNATIONS...9
LOCATION OF THE ENGINE SERIAL NO...9
MARKING OF THE EEM 2 CONTROL UNIT...10
LIFTING THE ENGINE...10
CONSTRUCTION...11
Technical data...11
General...12
Cylinder block...12
Flywheel housing...12
Cylinder head...13
Valve mechanism...13
Crank mechanism...13
Timing gears...14
Lubricating system...15
Cooling system...16
Inlet and exhaust system...17
TECHNICAL DATA...18
Cylinder block...18
Cylinder block, 84-engines...18
Cylinder liners...18
Cylinder head...18
Valves, rockers and tappets...19
Camshaft...20
Crankshaft...20
Crankshaft, 84-engines...21
Flywheel...22
Balancing unit, 44-engines...22
Timing gears...22
Timing gears, 84-engines...23
Connecting rod...23
Piston, rings and pin...24
Piston, rings and pin, 84-engines...24
Lubricating system...25
Oil pump, 33- and 44-engines...25
Oil pump, 66-, 74- and 84-engines...26
Coolant pump, 33- and 44-engines...26
Coolant pump, 66- and 74-engines...26
Coolant pump, 84-engines...26
Thermostat...27
Turbocharger...27
TIGHTENING TORQUES...28
SPECIAL TOOLS...29
Cylinder block...29
Timing gear- and flywheel housing...30
Cylinder head and valve mechanism...31
Crank mechanism...32
Coolant pump...33
Fuel system...34
WORK INSTRUCTIONS...35
1. CYLINDER BLOCK...35
A. Measuring cylinder liner wear...35
B. Removing cylinder liner...35
C. Checking cylinder block...35
D. Changing camshaft bushing...35
E. Fitting plug at camshaft rear end...37
F. Oversize bushings for camshaft...37
G. Fitting plug at camshaft rear end (oversize bushings)...37
H. Fitting cylinder liner...38
2. FLYWHEEL HOUSING...41
A. Fitting flywheel housing...41
B. Changing crankshaft rear oil seal...41
3. CYLINDER HEAD...43
A. Removing cylinder head...43
B. Removing valves...43
C. Checking cylinder head...43
D. Changing valve guides...44
E. Machining valve seat...44
F. Changing valve seat rings...45
G. Grinding valves...45
H. Fitting valves...45
I. Fitting cylinder head...46
4. VALVE MECHANISM...47
A. Reconditioning valve mechanism...47
B. Changing camshaft / camshaft gear...47
C. Adjusting valves...48
5. CRANKSHAFT...51
A. Removing crankshaft...51
B. Checking crankshaft...51
C. Changing crankshaft gears...51