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Sisu Diesel 320 - User Manual

Sisu Diesel 320
116 pages
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WORKSHOP MANUAL
SISUDIESEL 320
420
620
8366 40634 634

Table of Contents

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Summary

TO THE USER

ENGINE TYPE DESIGNATIONS

Explains the coding system for identifying different Sisu Diesel engine types based on application.

SAFETY INSTRUCTIONS

ENGINE SPECIFICATIONS

LIFTING THE ENGINE

Provides guidance on the correct procedure for safely lifting the engine using a lifting device.

LOCATION OF THE ENGINE SERIAL NO.

Illustrates the positions where the engine serial number can be found on different engine models.

SPECIAL TOOLS

TECHNICAL DATA

Cylinder block

Details the dimensions and specifications for the engine's cylinder block.

Cylinder liners

Provides dimensional data for cylinder liners, including protrusion and diameters.

Cylinder head

Lists specifications for the cylinder head, including dimensions and valve guide details.

Valves, rockers and tappets

Contains technical data for valve train components like valves, rockers, and tappets.

Camshaft

Specifies dimensions and clearances for the camshaft and its bearings.

Crankshaft

Details crankshaft journal diameters, lengths, and clearances.

Flywheel

Lists specifications for the flywheel, including ring gear and unbalance limits.

Balancing unit (420-engines)

Provides technical data for the balancing unit specific to 420-series engines.

Timing gears

Contains specifications for timing gears, including tooth backlash and shaft dimensions.

Connecting rod

Details dimensions for connecting rods, including pin bushings and big end bearings.

Piston, rings and pin

Specifies dimensions for pistons, piston rings, and piston pins.

Lubricating system

Provides technical data for the lubrication system, including oil pressure and pump specifications.

Oil pump (320, 420-engines)

Lists dimensions and clearances for the oil pump used in 320 and 420 engines.

Oil pump (620;634-engines)

Provides specifications for the oil pump used in 620 and 634 engines.

Coolant pump (320, 420-engines)

Details specifications for the coolant pump used in 320 and 420 engines.

Coolant pump (with separate ball bearings 320 and 420-engines)

Provides specifications for coolant pumps with separate ball bearings for 320/420 engines.

Thermostat

Lists part numbers and opening temperatures for various thermostat types.

Turbocharger

Contains specifications for turbocharger shaft float and radial clearance.

TIGHTENING TORQUES

CONSTRUCTION

General

Provides a general overview of the Sisu Diesel 20/34 series engines.

Cylinder block

Describes the construction and features of the engine's cylinder block.

Flywheel housing

Explains the construction and mounting of the flywheel housing.

Crank mechanism

Details the construction of the crankshaft, including bearings and connecting rods.

Cylinder head

Describes the cylinder head construction, bolts, and valve guides.

Valve mechanism

Explains the operation and components of the valve mechanism.

Timing gears

Describes the construction of the timing gear train and its components.

Lubricating system

Explains the engine's pressure lubricating system and its components.

Cooling system

Describes the engine's cooling system, including the pump and thermostat.

Inlet and exhaust system

Details the construction of the inlet and exhaust systems, including the turbocharger.

Electronic Engine Management system (EEM)

Explains the Sisu Diesel EEM system, a microprocessor-based engine control system.

1. CYLINDER BLOCK

A. Measuring cylinder liner wear

Details the procedure for measuring cylinder liner wear using a dial gauge.

B. Removing cylinder liner

Describes how to remove cylinder liners using a specialized puller tool.

C. Checking cylinder block

Outlines steps for cleaning and checking the cylinder block for damage or wear.

D. Changing camshaft bushing

Explains the process of removing and installing camshaft bushings.

E. Oversize bushings for camshaft

F. Fitting plug at camshaft rear end

G. Fitting guide pipe for oil dipstick

H. Fitting cylinder liner

H. Fitting cylinder liner (continued)

2. FLYWHEEL HOUSING

A. Fitting flywheel housing

Details the procedure for fitting the flywheel housing, including sealant and bolts.

B. Changing crankshaft rear oil seal

Describes how to remove and replace the crankshaft rear oil seal.

3. CYLINDER HEAD

A. Removing cylinder head

Provides steps for removing the cylinder head and associated components.

B. Removing valves

Details the procedure for removing valves and valve train components.

C. Checking cylinder head

Explains how to clean and check the cylinder head for flatness and cracks.

D. Changing valve guides

E. Machining valve seat

F. Changing valve seat rings

G. Grinding valves

H. Fitting valves

I. Fitting cylinder head

4. VALVE MECHANISM

A. Reconditioning valve mechanism

Describes the process of reconditioning valve train components like tappets and rocker arms.

B. Changing camshaft;camshaft gear

C. Adjusting valves

5. CRANKSHAFT

A. Removing crankshaft

Details the procedure for removing the crankshaft from the engine.

B. Checking crankshaft

Explains how to clean and measure crankshaft journals for wear.

C. Changing crankshaft gears

Describes the process of removing and fitting crankshaft gears.

D. Changing crankshaft gear rim (420-engines only)

E. Fitting crankshaft

F. Crankshaft hub piece

G. Changing crankshaft pulley;vibration damper

H. Checking element of the rubber damper (620;420)

I. Viscose type vibration damper

6. CONNECTING RODS AND PISTONS

A. Removing pistons together with connecting rods

Details the procedure for removing pistons and connecting rods from the engine.

B. Changing connecting rod bearings

Explains how to change connecting rod big end bearings.

C. Checking connecting rod

Describes how to check connecting rods for damage or wear.

D. Changing piston rings

E. Checking pistons

F. Fitting piston pin

G. Fitting piston together with connecting rod

7. COUNTERBALANCE (420)

A. Removing and disassembling counterbalance unit

Details steps for removing and dismantling the counterbalance unit.

B. Reconditioning counterbalance unit

Explains how to check and recondition counterbalance unit components.

C. Fitting counterbalance unit

Describes the procedure for fitting the counterbalance unit.

8. FLYWHEEL

A. Changing starter ring gear on flywheel

Details how to change the starter ring gear on the flywheel.

B. Fitting flywheel

Explains the procedure for fitting the flywheel to the crankshaft.

9. TIMING GEAR ASSEMBLY

A. Removing timing gear casing

Provides steps for removing the timing gear casing and related components.

B. Reconditioning idler gear

Explains how to recondition the idler gear and its bushing.

C. Fitting timing gear casing

D. Idler gear with bevelled ball bearings

E. Power take-off

10. LUBRICATION SYSTEM

A. Reconditioning of oil relief valve for lubricating oil pressure

Details how to recondition the oil relief valve for lubricating oil pressure.

B. Removing and dismantling lubricating oil pump

Explains the procedure for removing and dismantling the lubricating oil pump.

C. Assembling and fitting lubricating oil pump

D. Fitting oil sump gasket

E. Lubricating oil cooler

F. Piston cooling nozzles (620;634)

G. Lubricating oil quality requirements

11. COOLING SYSTEM

A. Thermostat

Describes the thermostat's function and how to check its operation.

B. Reconditioning coolant pump (320, 420)

Details the process for reconditioning the coolant pump for 320 and 420 engines.

C. Reconditioning coolant pump (Separate ball bearings 320, 420, 620, 634)

D. Coolant pumps with heavy-duty bearings (620, 634)

E. Quality requirements of coolant

12. INLET AND EXHAUST SYSTEM

A. Checking air cleaner

Explains the importance of the air cleaner and how to check its condition.

B. Checking inlet and exhaust pipes

Highlights the significance of leak-free inlet and exhaust pipes for turbocharger performance.

C. Checking turbocharger

Provides a method for diagnosing potential faults in the turbocharger.

D. Fitting turbocharger

13. FUEL SYSTEM

IN-LINE FUEL INJECTION PUMP

Covers repair and service for the in-line fuel injection pump.

TECHNICAL DATA

Fuel feed pump

Details the type and construction of the fuel feed pump.

Injectors

Lists the type and sealing ring part number for injectors.

Tightening torques

Specifies tightening torques for various fuel system components.

Fuel system, description

Symptoms of dirty or faulty injectors

Bosch-P injection pump

Bosch-A injection pump

Injection pump with the boost control

The pump element consists of one plunger and one cylinder

Pressure valve

Governor

Fuel injection pump type plate

A. Bleeding fuel system

B. Bleeding Thermostart system

C. Measuring fuel feed pressure

D. Checking overflow valve

E. Changing fuel feed pump valves

F. Checking injection timing (dynamic)

G. Adjusting fuel injection timing

H. Removing fuel injection pump

I. Fitting fuel injection pump

I. Fitting fuel injection pump (Bosch-A injection pump)

I. Fitting fuel injection pump (Bosch-P injection pump)

J. Checking and changing pressure valve

K. Adjusting idling speed

L. Removing injectors

M. Inspecting injectors

N. Reconditioning injectors

O. Fitting injector in engine

P. Fitting delivery pipes

CAV DISTRIBUTOR PUMP

TECHNICAL DATA

Technical data for the CAV DPA type distributor pump.

Injection pump CAV

Lists types, injection order, and rotation direction for CAV pumps.

Fuel feed pump

Describes the construction and pressure specifications of the CAV fuel feed pump.

Injectors CAV

Specifies control pressure and sealing ring for CAV injectors.

Tightening torques

Lists tightening torques for CAV pump components.

A. Dismounting and mounting injection pump

B. Injection pump gear

C. Bleeding fuel system

Bleed the thermostart system

D. Feed pump

E. Injector

F. Adjusting low idling speed

G. Bleeding Thermostart system

H. Wiring diagram of electrical advance (CCA)

I. Checking injection timing (dynamic)

Trouble shooting

Fuel quality requirement

FUEL SYSTEM EQUIPMENT AND FEEDING TABLE

320

Equipment and feeding table data for 320 engine applications.

420

Equipment and feeding table data for 420 engine applications.

420 (continued)

Equipment and feeding table data for 420 engine applications.

420 (continued)

Equipment and feeding table data for 420 engine applications.

420 (continued)

Equipment and feeding table data for 420 engine applications.

420 (continued)

Equipment and feeding table data for 420 engine applications.

420 (continued)

Equipment and feeding table data for 420 engine applications.

620

Equipment and feeding table data for 620 engine applications.

620 (continued)

Equipment and feeding table data for 620 engine applications.

620 (continued)

Equipment and feeding table data for 620 engine applications.

634

Equipment and feeding table data for 634 engine applications.

634 (continued)

Equipment and feeding table data for 634 engine applications.

15. ELECTRICAL SYSTEM

A. Alternators

Details specifications for various Magneti Marelli and Bosch alternators.

A. Alternators (continued)

Provides further specifications for Magneti Marelli and Bosch alternators.

A. Alternators (continued)

Lists specifications for Iskra and Bosch alternators.

A. Alternators (continued)

Details specifications for Iskra alternators.

A. Alternators (continued)

Provides specifications for Iskra alternators.

A. Alternators (continued)

Details specifications for Iskra alternators.

C. Electric stop device

Explains the assembly and electrical connection of the electric stop device.

Checking the solenoid operation (Synchro start)

Describes methods to check the solenoid plunger operation for Synchro start.

Testing the external circuit of the solenoid

Explains how to test the external circuit of the solenoid.

Checking the solenoid operation (Elettrostart)

Describes how to check solenoid plunger operation for Elettrostart.

D. Installation of magnetic pick up

Details the installation procedure for the magnetic pick-up sensor.

E. Temperature sensor

Provides specifications and resistance values for the temperature sensor.

16. OPTIONAL EQUIPMENT

A. Compressor (Bendix)

Details the inspection and disassembly of the Bendix compressor.

DISASSEMBLY

Step-by-step instructions for disassembling the Bendix compressor.

B. Compressor (Knorr)

Provides inspection and reassembly instructions for the Knorr compressor.

C. Industrial clutch (A.P. Borg & Beck)

Details the service and adjustment procedures for the industrial clutch.

SERVICE

Service notes for the industrial clutch, emphasizing safety.

ADJUSTMENT

Describes the adjustment procedure for the industrial clutch engagement load.

Sisu Diesel 320 Specifications

General IconGeneral
BrandSisu Diesel
Model320
CategoryEngine
LanguageEnglish

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