Sisu Diesel 420DW - User Manual

WORKSHOP MANUAL
SISUDIESEL 320
420
620
8366 40634 634

Summary

SAFETY INSTRUCTIONS

TECHNICAL DATA

Cylinder liners

Lubricating system

Technical data for the lubrication system.

TIGHTENING TORQUES

CONSTRUCTION

Cylinder block

Cylinder head

Crank mechanism

Description of the crankshaft and connecting rod assembly.

Lubricating system

Description of the engine's lubricating system.

Cooling system

Description of the engine's cooling system.

Inlet and exhaust system

Description of the inlet and exhaust systems.

Electronic Engine Management system (EEM)

WORK INSTRUCTIONS

1. CYLINDER BLOCK

Work instructions for the cylinder block.

2. FLYWHEEL HOUSING

Work instructions for the flywheel housing.

3. CYLINDER HEAD

Work instructions for the cylinder head.

2. FLYWHEEL HOUSING

A. Fitting flywheel housing

B. Changing crankshaft rear oil seal

Procedure for replacing the crankshaft rear oil seal.

3. CYLINDER HEAD

A. Removing cylinder head

Procedure for removing the cylinder head.

B. Removing valves

C. Checking cylinder head

Procedure for inspecting the cylinder head.

D. Changing valve guides

E. Machining valve seat

F. Changing valve seat rings

G. Grinding valves

H. Fitting valves

I. Fitting cylinder head

Procedure for fitting the cylinder head.

4. VALVE MECHANISM

A. Reconditioning valve mechanism

B. Changing camshaft;camshaft gear

Procedure for changing the camshaft and its gear.

C. Adjusting valves

Procedure for adjusting valve clearances.

5. CRANKSHAFT

A. Removing crankshaft

Procedure for removing the crankshaft.

B. Checking crankshaft

Procedure for checking the crankshaft.

C. Changing crankshaft gears

Procedure for changing crankshaft gears.

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

E. Fitting crankshaft

Procedure for fitting the crankshaft.

G. Changing crankshaft pulley;vibration damper

6. CONNECTING RODS AND PISTONS

A. Removing pistons together with connecting rods

Procedure for removing pistons and connecting rods.

B. Changing connecting rod bearings

Procedure for changing connecting rod bearings.

C. Checking connecting rod

D. Changing piston rings

Procedure for changing piston rings.

E. Checking pistons

F. Fitting piston pin

G. Fitting piston together with connecting rod

Procedure for fitting piston and connecting rod.

9. TIMING GEAR ASSEMBLY

A. Removing timing gear casing

Procedure for removing the timing gear casing.

B. Reconditioning idler gear

C. Fitting timing gear casing

Procedure for fitting the timing gear casing.

10. LUBRICATION SYSTEM

A. Reconditioning of oil relief valve for lubricating oil pressure

Procedure for reconditioning the oil pressure relief valve.

B. Removing and dismantling lubricating oil pump

Procedure for removing and dismantling the oil pump.

C. Assembling and fitting lubricating oil pump

Procedure for assembling and fitting the oil pump.

11. COOLING SYSTEM

B. Reconditioning coolant pump (320, 420)

Procedure for reconditioning coolant pumps on 320/420 engines.

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

Procedure for reconditioning coolant pumps with separate bearings.

12. INLET AND EXHAUST SYSTEM

A. Checking air cleaner

B. Checking inlet and exhaust pipes

Procedure for checking inlet and exhaust pipes for leaks.

C. Checking turbocharger

Procedure for checking the turbocharger for faults.

D. Fitting turbocharger

Procedure for fitting the turbocharger.

13. FUEL SYSTEM

IN-LINE FUEL INJECTION PUMP

Details on the in-line fuel injection pump.

Fuel system, description

Description of the fuel system components and operation.

Bosch-P injection pump

Details and specifications for the Bosch-P injection pump.

Bosch-A injection pump

Details and specifications for the Bosch-A injection pump.

Two-hole pump element (maximum feed)

Governor

Description and function of the engine governor.

A. Bleeding fuel system

Procedure for bleeding the 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)

Procedure for dynamically checking injection timing.

G. Adjusting fuel injection timing

Procedure for adjusting engine injection timing.

H. Removing fuel injection pump

Procedure for removing the fuel injection pump.

I. Fitting fuel injection pump

Procedure for fitting the fuel injection pump.

J. Checking and changing pressure valve

Procedure for checking and changing the pressure valve.

K. Adjusting idling speed

Procedure for adjusting engine idling speed.

L. Removing injectors

Procedure for removing fuel injectors.

M. Inspecting injectors

N. Reconditioning injectors

O. Fitting injector in engine

P. Fitting delivery pipes

CAV DISTRIBUTOR PUMP

Details on the CAV distributor fuel pump.

A. Dismounting and mounting injection pump

B. Injection pump gear

E. Injector

STANADYNE DISTRIBUTOR PUMP

Details on the Stanadyne distributor fuel pump.

TECHNICAL DATA

Technical data for the Stanadyne distributor pump.

Fuel system with distributor pump

Stanadyne-distributor pump

Detailed components of the Stanadyne distributor pump.

Eventual injector pump equipment (e.g. E-engines)

Construction

Function

A. Removing pump

B. Fitting injection pump and adjusting injection timing

Procedure for fitting and timing the Stanadyne pump.

C. Bleeding fuel system

E. Injectors

F. Adjusting low idling speed

G. Bleeding Thermostart system

I. Checking injection timing (dynamic)

Procedure for dynamically checking injection timing.

FUEL SYSTEM EQUIPMENT AND FEEDING TABLE

320

420

FUEL SYSTEM INJECTOR

15. ELECTRICAL SYSTEM

A. Alternators

Bosch N1 28 V 10;80 A

Bosch N1 28 V 0;100 A

Iskra AAK 5118 14 V 95 A

Bosch NC 14 V 70-120 A

Bosch NC 14 V 150 A

B. Starters

Iskra AZJ3234 12 V 3,1 kW z11

Iskra AZJ3247 12 V 3,6 kW z11

Iskra AZJ3319 12 V 3 kW z10

Iskra AZJ3256 24 V 4 kW z11 2-pole

C. Electric stop device

D. Installation of magnetic pick up

Sisu Diesel 420DW Specifications

General

Brand	Sisu Diesel
Model	420DW
Category	Engine
Language	English