836640359
Sisudiesel
Sisudiesel320,420,620,634
engines
Operator’sManual
0102
FIN–37240Linnavuori,FinlandTelephone:+35833417111
E–mail:info.sisudiesel@sisudiesel.com
www.sisudiesel.com
DieselEngines,AfterSalesTelefax:+35833417333
SisuDieselInc.
SisuDieselInc.takesnoresponsibilityforanydamagescaused
becauseofincorrectinformationinthismanual
Contents2CONTENTS
TOTHEUSER......................................................---enginetypedesignations..........................................---locationoftheengineserialno......................................---markingoftheinjectionpump......................................---safetyinstructions.................................................---liftingtheengine..................................................CONSTRUCTION...................................................---technicaldata....................................................---general..........................................................---airintakesystem..................................................---fuelsystem.......................................................---lubricationsystem.................................................---coolingsystem...................................................---electricalsystem..................................................OPERATIONANDDRIVING.........................................---dailypre---startcheck..............................................---starting..........................................................---coldstart.........................................................---attentionduringoperation..........................................---stopping.........................................................---couplingadditionalequipmenttotheengine..........................SERVICE..........................................................---periodicalmaintenance............................................---servicechart.....................................................---basicserviceafterthefirst50...100hoursofoperation.................---servicestobemadedailyorat10hoursintervals.....................---servicestobemadeweeklyorat50hoursintervals...................---servicestobemadeat300hoursintervals...........................---servicestobemadeat600hoursintervals...........................---servicestobemadeat1200hoursintervals..........................---servicestobemadeat2400hoursintervals..........................---servicestobemadeat4800hoursintervals..........................---servicestobemadeeverytwoyears................................ADDITIONALSERVICEANDADJUSTINGINSTRUCTION..............---bleedfuelsystem(Bosch)..........................................---checkandadjustinjectiontiming(Bosch)............................---adjustidlingspeed(Bosch)........................................---bleedfuelsystem(Stanadyne)......................................---checkandadjustinjectiontiming(Stanadyne)........................---adjustlowidlingspeed(Stanadyne).................................---fitcylinderhead...................................................---inspectionofthezincplug.........................................---checkoftherubberelementvibrationdamper........................---beforethecoldseason............................................---tighteningtorques.................................................---lubricatingoilqualityrequirements..................................---coolantqualityrequirements........................................---fuelqualityrequirements...........................................---biodiesel.........................................................---troubleshooting..................................................---storingtheengine.................................................---after---storageattention............................................
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Contents3TOTHEUSER
ThepurposeofthismanualistofamiliariseyouwiththeuseandmaintenanceofyourSisudieselengineandgiveyouthebasictechnicaldataandsettingsrelatingtoitsconstruction.Beforeusingtheenginecarefullyreadtheoperating,serviceandsafetyinstructionstoensureyourenginerunsinthemostecon-omicway.
WhencontactingtheServiceOrganisation,pleasestatetheenginetypeandtheserialnumber.Wereservetherighttochangetheadjustmentsettings,equipmentandalsotheserviceandrepairin-structionsoftheengineswithoutfurthernotice.Unlessotherwisestated,theinstructionsandsettingsapplytoallvariantsof320,420,620and634engines.
ENGINETYPEDESIGNATIONS
420DSRIELApplication
A=vehicleengine
G=generatingsetengineL=combineharvesterengineM=marineengineP=pumpsetengine
E=emissiontestedengine(certified)foroff---roadC=emissiontestedengine(certified)foron---roadEquippedwithintercoolerA=airtoairI=airtowater
Rotaryfuelinjectionpump(B,ifequippedwithBoschP---typeinjectionpump)
Turbochargedengine(W,ifequippedwithby---passturbo)Basictype(E,ifequippedwithelectronicenginecontrol)Numberofcylinders(3,4or6)
TotheUserLOCATIONOFTHEENGINESERIALNO.Theengineserialnumberisalwaysstampedonthecylinderblockasthepictureshows.Iftheenginehasatypeplate,theserialnumberisalsoonit.42---1NOTE!Becauseofvariousenginemountingstheengineserialno.mayalsobelocatedontheleftsideoftheengine.MARKINGOFTHEINJECTIONPUMP2---42---5Thetypeplateoftheinjectionpumpindicatesthesymbolletteroftheapplicationortheordernumber.Insometypesofrotarypumpstherecanbebothorderno.andsymbolletter.Thisletter/orderno.mustbestatedwhenorderinganinjectionpumporaskingforadjustingsettings.
TotheUser5SAFETYINSTRUCTIONSIntheuseandserviceoftheenginethereisal-waysthepossibilityofinjury.Beforestartingtheservicereadandunderstandthefollowingsafetyinstructionsandremarks!
Whenyouareoperatingtheengineorworkingnearit,usehearingprotectorstoavoidnoisein-juries.Ifyoustarttheengineindoors,besureyouhaveproperventilation.
NeveruseaerosoltypeofstartingaidwhileoperatingtheThermostartdevice(riskforexplosion).Starttheengineonlybyusingthestartingswitchinthecabin.Stoptheenginealwaysbeforeservice---orrepairwork.
Openfire,smokingandsparksshouldnotbeallowednearthefuelsystemandbatteries.(Speciallywhenloadingbatteries,explosive.)
Opentheradiatorcapwithcarewhentheengineishotasthecoolingsystemispressurised.Thecoolingliquidandlubricationoilofahotenginecausesinjurieswhentouchingtheskin.
Avoidtouchingtheexhaustmanifold,turbochargerandtheotherhotpartsoftheengine.tem.Alwaysdisconnecttheminus(---)wireofthebatterywhendoingserviceorrepairoftheelectricsys-
Whencheckingfuelinjectorsdonotletthejetofhighpressurefuelcontactyourskin.Thefuelpen-etratestheskincausingsevereinjuries.Contactyourdoctorimmediately!
Keeptheenginesurfacescleaninordertoavoidtheriskoffire.
Attemperaturesonexcessof300˚C,e.g.iftheengineisburntbyafire,thevitonsealsoftheengine(e.g.theundermosto---ringoftheoilpressureregulatingvalve)produceveryhighlycorrosivehydrofluo-ricacid.Donottouchwithbarehands,vitonsealssubjectedtoabnormallyhightemperatures.Alwaysuseneoprenerubberorheavydutyglovesandsafetyglasseswhendecontaminating.Washthesealsandthecontaminatedareawitha10%calciumhydroxideorotheralkalisolution.Putallremovedma-terialinsealedplasticbagsanddeliverthemtothepointstatedbytheAuthoritiesconcerned.NOTE!Neverdestroyviton---sealsbyburning!
Thefuel,lubricatingoilandcoolantcauseirritationinskincontactforlongtime.
Donotletoilandotherliquidsdropintothesoilwhenservicingtheengine.Takethemtoasuitabledisposalpoint.
Avoidunnecessaryidlingoftheengine.
Allthegasketsoftheengineareofnon---asbestosmaterial.
Becarefulwhenwashingtheenginewithahighpressurewashingmachine.Donotusehighpres-suretowashe.g.theelectricandfuelequipmentortheradiatorbecausetheycaneasilybedamaged.
TotheUserLIFTINGTHEENGINE
Safeliftingoftheengineisdonewithaliftingdevicewheretheliftingforceeffectstheliftingearsvertically.6WARNINGAA2---6
2---7
A=Engineliftingears
Engineweightkg(withoutflywheelandelectricalequipment).
320D320DS
=275=280
420D=335420DS/DW=340420DWI=345
620D
620DS634DS
=500=510=515
Construction7CONSTRUCTION
TECHNICALDATA
PRINCIPALDIMENSIONSANDDATANumberofcylindersDisplacement(ltr)Cylinderbore(mm)Stroke(mm)CombustionCompressionratioInjectiontiming(B.T.D.C.)Valveclearance,intakeandexhaust(mm)Directionofrotationfromtheenginefront32033,31081204206206344664,46,67,4108108108120120134Directinjection16,5/18,5:1Markedonthecrankshaftpulley0,35ClockwiseFUELSYSTEMInjectionpumpFuelFeedpressure,in---linepump---overflowvalveopeningpressure---staticFeedpressure,rotarytypepump---static---min.pressureInjectionorderInjectorOpeningpressureofthenozzleAdjustingpressureofthenozzleFuelfilter320420620634Bosch,in---linetype/Stanadyne,rotarytypeGasoil,seepage470,6---1,0bar2,7bar0,48bar0,20bar/max.rpm1---2---3Five---holenozzleSee20/34---seriesWorkshopManualSee20/34---seriesWorkshopManualBosch/CAV1---2---4---31---5---3---6---2---4LUBRICATIONSYSTEMOilpressureinhotengineatrunningspeedOilpressureatidlespeed,min.Oilcapacity(ltr)withoutfilterandoilcooler11)
32042062063472,5---4,0bar1,0bar122424Differentoilsumpsofmanyenginevariantshavenotthesameoilcapacity.Capacitiesshownabove
areforstandardoilsumps.
Construction812345L678151413420DWRIE--engineviewedfromtheleft1.2.3.4.5.6.7.8.
ThermostatInjectorIntercooler
ThermostartdeviceBreatherpipeFuelfilter
CoolantdrainplugOilcooler
9.10.11.12.13.14.15.
12111092---8Oilfilter
Coolantdrainplug(oilcooler)OilpressureregulatingvalveOildipstickInjectionpumpTimingindicatorCoolantpump
L=mountingpointforpreheatingdevice
Construction912876542---9
3420DWRIE--engineviewedfromtheright1.2.3.4.5.6.7.8.
OilfillerplugCompressorAlternator
AirconditionercompressorPrefilterStarter
FuelfeedpumpTurbocharger
Crosssection
Construction101152L341314571211620/634DS--engineviewedfromtheleft1.2.3.4.5.6.7.8.
ThermostartdeviceBreatherpipeIntakemanifoldFuelfiltersOilfilter
OilpressureregulatingvalveCoolantdrainplugOilfillerplug
9.10.11.12.13.14.15.
OildipstickInjectionpumpTimingindicatorVibrationdamperStopsolenoidThermostatInjector
109862---10L=mountingpointforpreheatingdevice
Construction111237654620/634DS--engineviewedfromtheright1.2.3.4.5.6.7.
TurbochargerOilfillerplug
SensorforcoolanttemperatureAlternator
OilpressuresensorStarter
Exhaustmanifold
2---11
ConstructionGENERAL
12Sisudieselengine---seriesconsistsofwater---cooledin---linedieselengineswiththree,fourandsixcylin-ders.Theenginesareequippedwithwet,changeablecylinderlinersandconsiderationwasmadeinthebasicdesignoftheenginesforturbocharging.Tomakethespare---partserviceeasierandmoreflex-ible,themajorityofpartsarecommontoallenginesintherange.
AIRINTAKESYSTEM
Theairintakesystemincludesthepre---filter(orcyclone,ifinstalled),airfilter,turbocharger(DS/DW---en-gines),intercooler(coolingofinletair,DSI/DWI---engines),inletmanifoldandairpipes.Amechanicalorelectricsensorcanbefittedtoindicatetheservicepointoftheairfilter.Iftheengineisoperatinginverydustyconditions(forexamplespreadinglime)itmustbeequippedwithaspecialpre---filterandoilbathairfilter.
Turbocharger(DS/DW--engines)
AA=By---passchannelINLETAIREXHAUSTGASES
2---12LUBEOIL
Theturbochargerisaturbo---compressordrivenbyexhaustgas.Thecompactdesignoftheturbo-chargerisfasttoreactevenduringlowrevolutions.Theturbochargerislubricatedandcooledbythelubricationsystemoftheengine.DW/DWI---engineisequippedwithaby---passturbochargerwhereex-cessiveairpressureisadjustedbyaso---calledby---passchannel(A).Coolingofinletair(DSI/DWI--engines)
Thecompressedairiscooledontheairtowaterbasis.Theaircomingfromtheturbochargerhasatem-peratureabt.150˚Cwhichiscooledbythecoolingwateroftheenginedowntoabt.95˚C.Thecoolingcellisinstalledontheintakemanifoldandconnectedtotheenginecoolingsystem.Thecoolingofthecompressedairstabilisesthecombustion,irrespectiveofthetemperature,andminimisesthethermalandmechanicalloadoftheenginethusloweringnitricoxides(NOx).
ConstructionFUELSYSTEM7a7b6138945132---132Fuelsystem(Bosch---Pinjectionpump)1.Fueltank2.Prefilter3.Feedpump4.Fuelfilter
5.Injectionpump
6.Injector
7a.Thermostartfuelreservoir7b.Solenoidvalve8.Glowplug9.Overflowvalve
TheSisudieselenginesareequippedwithBosch---A/Pin---lineinjectionpumporwithStanadynerotaryinjectionpump.
Thefuelflowsfromthetankviaaprefiltertothefeedpumpandthroughthefiltertotheinjectionpump.Theinjectionpumpforcesthefuelintotheinjectorthatfeedsfuelintothecombustionspaceinafinespray.
ThefuelsystemisoftenequippedwiththeThermostartdevicetobeusedincoldconditions.TheglowplugreceivesfuelfromaseparatereservoiroftheThermostartdeviceorfromtheoverflowvalveoftheinjectionpumpregulatedbythemagneticvalve.
Thefuelisgasoilthatmustbecleanandfreefromwater(seepage47,qualityrequirementsofthefuel).
ConstructionNOTE!Useofanti---freezesolutionisnotusefulandnotatallrecommended!
14Waterisremovedfromthesystembydrainingthewatertrapperiodicallyandbycleaningthefueltankbeforefrostseason(seealsoactionsbeforewinter,page45).
Bosch--Ainjectionpump
Theinjectionpumpisanin---linepumpandthebasicconstructionisthesameinallenginesirre-spectiveofthecylindernumber.
18Injectionpump
1.Oilfillerplug2.Speedlever3.Handpump
4.Lubeoilintotheinjectionpump5.O---ringseal
6a.Returnoflubeoiltoengine6b.Alternativeoilreturntoengine
(e.g.aggregateapplication)7.Drivegear
8.Identificationplate
726b6a3542---14Thefuelinjectionpumpisflangemountedandsealedbyoneo---ring(5)inthetiminggearhousing.Theinjectionpumpisdrivenfromthecrankshaftthroughanidlergear.Theinjectionpumpisconnectedtotheengineforce---feedlubricationsystemthroughanexternalpipe(4).Lubricatingoilreturnstotheengineviathehole(6a)atthefrontendoftheinjectionpump.Insomeversions,speciallylocallyinstalledengines,thereturnoftheoilisleadthroughahose(6b)fromtheregulatorcovertothecrankcase.
1Injectionpumpwiththeboostcontrol1.Boostcontrol
2.Coldstartsolenoid
3.Indicatorplugforadjustinginjectiontiming
322---15
ConstructionStanadynerotaryinjectionpump
15In20/34---seriesR---engineshaveStanadynerotaryinjectionpump.Thepumpisdrivenbytheidlergearandinstalledonthetiminggearhousing.Thepumpisequippedwithanelectricstopsolenoid(ignitionswitchstop)andwithanautomaticbleedingsystem.Stanadynepumpinternallubricationhappenswithaidoffuel.Aseparatefuelfeedpumpisofamembranetypeanditisdrivenbytheenginecamshaft.
Stanadynerotaryinjectionpump1.2.3.4.5.6.7.8.9.10.
TypeplatewithpumpordernumberTimingmarksunderthecoverFuelinlet
Returnfuel/overflowvalveRevolutionlever
ConnectorforwiretoelectricstopsolenoidAneroidcontrolBoostpressure
Timingsensor(E---engine)Interruptedscrew(E---engine)108654793122---16Injector
Theinjectorhasafive---holenozzle.Inthebodyoftheinjectorthereisanin---builtslottednozzlethatisservicefree.Theexcessfuellubricatingtheinjectorneedlereturnsintothefueltankthroughtheoverflowpipe.
1
2
Injector
1.Fuelinlet
2.Leak---offpipeconnection3.Adjustingshim4.Pressurespring5.Pressurepin6.Nozzlebody
7.Pressurechamber8.Injectorneedle9.Nozzlehole
2---17
3456789
ConstructionLUBRICATIONSYSTEM
16Theenginehasapressurelubricationsystemwiththegearoilpumpfittedtothelowestleveloftheen-gine.Theoilpumpisdrivenbythegearatthefrontendofthecrankshaft.
Nearlyallthelubricationpointsandauxiliaryequipmentareconnectedtothepressurisedlubricationsystembyoilgalleriesorpipes.Thelubricationofthegearsinthegearhousing,theupperendoftheconnectingrodsandthepistonsismainlyeffectedbysplashlubrication.
Theundersidesofthepistonsofthe620/634DSengineswithhighoutputarealwayscooledbytheoilspraywhentheoilpressureismorethan3bar.
47356212---18
Lubricationsystem
1.Oilpump
2.Oilpressureregulatingvalve3.Oilfilter
4.Turbocharger
5.Mainoilbore
6.Pistoncoolingnozzle7.Oilpressuresensor
Itisveryimportantthatyouusethelubricationoilthatcorrespondstoambienttemperaturesandloadsplaceontheengine(seelubricatingoilchart,page46).Alwayschangetheoilandoilfilteraccordingtotheservicechart.
ConstructionOilpressureregulatingvalve
17Oilpressure
2---19Theoilpressureregulatingvalveislocatedundertheoilfilterontheleftsideoftheengine.Theregulatingvalvekeepstheoilpressureconstantindependentoftheenginespeed.
Atworkingspeedtheoilpressureis2,5to4bardependingonthetemperatureandthequalityoflubricat-ingoil.Atidlingthepressureis1,0barminimum.Oilfilterandoilcooler
Theoilfilterisofmainflowtype.Ithasareplaceablecartridgemountedontheleftsideoftheengine.Atthebottomoftheoilfiltercartridgethereisaby---passvalveforcoldstartorpossiblecloggingofthefilter.Thefilterisalsoequippedwithabafflethatpreventsthefilterfromemptyingwhentheengineisnotuse.
Someenginetypesareequippedwithalubeoilcoolerlocatedbetweenthecylinderblockandtheoilfilter.Alltheoilthatcirculatesthroughthefilteralsogoesthroughthecoolerandiscooledbytheenginecoolantcirculatingintheoilcooler.
COOLANTLUBEOIL211.Oilfilter2.Oilcooler
2---20
ConstructionCOOLINGSYSTEM
18Thecoolantpumpisattachedtothefrontfaceofthecylinderblockandthethermostathousingismountedaboveit.Thesystemhastheinternalliquidcirculationviatheby---passpipe.Thecirculationisregulatedbythe2---waythermostat.Thisarrangementensuresasteadywarming---upoftheengineunderallconditions.
5236142---21Coolingsystem1.Coolantpump2.Thermostat3.By---passpipe
4.Radiator
5.Expansiontank6.Oilcooler
NOTE!Neveruseonlywaterasacoolantbutamixtureof40--60%ofwaterandantifreeze(seepage46,qualityrequirementsofthecoolant).Installingtheengineheater
Installthepre---heaterofthecoolantaccordingtotheinstructionsofthemanufacturer.
MostenginesofSisudiesel20/34---serieshavethecoolantheaterasstandardequipment.Thepointswheretoinstalltheheateraretobeseeninthepicturesthatareinthebeginningofthechapter”Con-struction”.
ThethreadoftheconnectionpointsoftheexternalheaterisM18x1,5.
ConstructionRawwatersysteminmarineenginesInthefrontoftheenginethereisaheatexchangerthatactsasacoolingwatertank.Therawwater(seawater)flowsthroughthetubesoftheheatex-changerandcoolsthefreshwater(enginecool-ant)whichflowsoutsidethetubes.Therawwaterpumpwithrubberimpellerismountedonthegearhousingandisgeardriven.Thepumpsucksthewaterevenatstartingspeed.Theexhaustmanifoldiscooledbythefreshwater.Thusthetemperaturesoftheexhaustmanifoldandtheexhaustgasesarelowered.Thisminimisestheriskofaccidentsandfire.NOTE!Iftheenginerunwithoutrawwater,therubberimpellermustbetakenoutoftherawwaterpump.1.Heatexchanger2.Rawwaterpump3.Watercooledexhaustmanifold231912---22ELECTRICALSYSTEMThevoltageoftheelectricalsystemiseither12Vor24V.Theenginemayhavea1---poleor2---polesystemdependingontheenginetype.NOTE!---Faultyconnections(especiallythoseofthebatteryorthealternator)willcausealternatordamage.---Neveropenthechargingcircuitwhiletheengineisrunning.---Disconnectthealternatorandbatterywiresbeforeundertakinganyelectricalwelding.---Disconnectthebatterywiresbeforechargingthebattery.StartingwithanauxiliarybatteryThefollowingshouldbenotedwhenusinganauxiliarybatterytostarttheengine:---Checkthattheauxiliarybatteryhasthesamevoltageasthestandardbattery.---Openthebatteryplugstoavoidriskofexplosion.---Connectthepositivepole(+)oftheauxiliarybatterytothepositivepoleofthestarterortothepositivepoleofthedischargedbattery.---Connectthenegativepole(---)oftheauxiliarybatteryforexampletothefasteningscrewofthestarterortotheenginebody.---Whentheenginestarts,firstremovethenegativecablebetweentheauxiliarybatteryandtheenginebody.Thenremovethepositivecable.Neverconnectthecabletothenegativepoleofthedischargedbattery.Riskofexplosion!WARNINGOperationandDriving20OPERATIONANDDRIVING
DAILYPRE---STARTCHECK
(Beforeusingtheengine,carefullyreadtheSAFETYINSTRUCTIONS,page5.)
Beforestartingtheengine,checkthefollowingpoints:---Checkthefuelquantity
---Checkthelubricationoillevel---Checkthecoolantlevel
---Checkthatthelubricationoilsystemandcoolantsystemoftheenginearenotleaking---Cleanthecycloneoftheairfilter
STARTING
---Checkthatthestopleverisindriveposition.---Turnthespeedlevertohalfspeedposition.---Switchthecurrenton.
---Starttheengineandadjustthespeedwiththespeedlevertopreventtheenginefromracing.---Watchtheoilpressure.Toensuresufficientlubrication,thepressuregaugehastobewithinnormalrangein3...4secondsafterstarting.NOTE!Thisisparticularlyimportantforthelubricationoftheturbocharger(DS/DW---engines).
---Alwaysacceleratetheengineatanevenrate,neverbyracing.
NOTE!Iftheenginehasnotbeenusedforoveramonth,cranktheenginewiththestarteruntiloilpres-surerisesordismountthepressureoilpipeoftheturbocharger(DS/DW---engines)andpourcleanlu-bricationoil(abt.0,2ltr)intothebearinghousingoftheturbocharger.
COLDSTART
(Seealsoactionsbeforewinter,page45)
---Checkthatthestopleverisindriveposition.
---Releasetheengineofallextraload(movethegeartoneutralposition,depresstheclutchpedal,donotturnthesteeringwheeletc.).
---Movethespeedcontrollevertohalfspeedposition.---Switchthecurrenton.
---Switchontheglowcurrentfor20to25seconds.
---Cranktheenginetillallcylindersarefiring.Continueglowingfor30secondsaftertheengineisfiringonallcylinders.
---Iftheenginefailstostartin10seconds,stopcrankingandcontinueglowingforabt.15seconds.Thenstartaccordingtotheforegoinginstruction.
---Watchtheoilpressure.Donotracethecoldenginebecausethelubricationisnotsufficientwhiletheoiliscold.
OperationandDriving21NOTE!(Theengineswithouttheelectricalstopdevice,Boschinjectionpump)
Afteroperatingleavestopleverindriveposition.Thusensuringexcessfuelfeed.(Theinjectionpumphastheexcessfueldevicealwaysswitchedonwhenstartingandtheinjectionpumpgivesanextraamountoffuel.Atthesametimetheinjectionisretarded,whichalsohelpsthecoldstarting).Alwaysuse,ifpossible,thecoolantheaterwhenthetemperatureisbelow0˚C.Useofaerosoltypestartingaid
If,underverydifficultstartingconditions,itisnecessarytouseanaerosoltypeofstartingaid,removetheairfiltercartridgesbeforestartingtospraytheaerosoltopreventthecartridgesfromcatchingfire.Spraytheaerosolintotheintakemanifoldonlywhentheenginerotates.Whentheaerosolisproperlyused(i.e.insmallquantities),itisanefficientstartingaid.Excessiveusemayleadtoenginedamageandthewarrantydoesnotcoversuchdamage!ToavoidtheriskoffireneverusestartingaerosolandtheThermostartdevicesimulta-neously.Disconnectthecablefromtheglowplugandisolatethecableconnector.WARNINGWarminguptheengine
Sincetheenginewearisgreatestwhentheengineisrunningcold,warmuptheenginequicklywithalightloadforacoupleofminutesafterstarting.However,youmustnotloadtheengineheavilyandtherotationspeedmustnotexceed2000rpmwhentheenginetemperatureisbelow50˚C.
876INST.LIGHTSSTOP1C20100005,02ENGINEHOURS10121416volt530402barminx100---1431.Coolanttemperaturegauge2.Oilpressuregauge
3.Tachometer/hourcounter4.Ignitionkey
2---23
5.Voltagegauge6.Stopbutton
7.Chargingindicator
8.Switchforinstrumentslight
OperationandDrivingATTENTIONDURINGOPERATION
2,5---4bar
22---Checktheengineoilpressure·runningspeed2,5...4bar·idlingspeedmin.1bar12345bar75---90C---Checkthecoolanttemperature·normalrunningtemp.75...90˚C40100120C2---24---Watchtheammeterreading/warninglightNOTE!---Iftheengineisoverheated,coolitslowlydownbyidlingforafewminutes.Neverpourcoldcoolantintoahotengine!Neverremovethe2---waythermostattoreducethetemperature.Inthatcaseagreaterquantityofthecoolantiscirculatingviatheby---passpipeandthetemperatureisgettinghigherthanbefore.Itisdangeroustoopenthecapofthepressurisedhotradiator.WARNINGNOTE!Avoidlongperiodsofidlingbecausethenthetemperatureofcombustionisreduced.Thiscausesincompletecombustionandcarbonformationwhichmayseizethenozzlesandclogthevalvesandpistonrings.
STOPPING
---Movethespeedleverintoidlingposition.
---Neverstoptheengineimmediatelyafterheavydriving.Letitidleforafewminutestoequalizethetemperatures.Thisappliesespeciallytoaturbochargedengine.---Turnthestopleverintostoppingpositionorpushthestopbutton.
---Switchthecurrentoff.Donotswitchthecurrentoffwhiletheengineisrunning.
---Inwintermovethestopleverintodrivepositionimmediatelyaftertheengineisstopped(toensurethefunctionoftheautomaticcoldstartdeviceoftheengineswithouttheelectricalstopdevice).
OperationandDrivingTheenginestopssuddenlywhilerunning(enginesequippedwithelectricalstopdevice)
123232---25
Electricalstopdevice
1.Solenoid2.Plunger
3.Regulatingrodoftheinjectionpump
Iftheenginestopswhenyouarerunningit,thereasonforthismaybethedamageofthesolenoid.Takesolenoidawayfromtheinjectionpumpandalsoremovetheplungerinsidethesolenoid.Adjustthesole-noidtoitsplace.Iftheenginestartsnow,thesolenoidisdefective.Youmaycarryonrunningtheenginebutitmustbestoppedbythestopleverbehindtheinjectionpump.Installthenewsolenoidassoonaspossible.
NOTE!Checkthefuseofthesolenoidfirst.
Othereventualrunningtroubles,seecartinpage49.
COUPLINGADDITIONALEQUIPMENTTOTHEENGINE
Variousdevicescanbecoupledtotheengine.Besurethattheydonotapplyconstantaxialloadtothecrankshaftorotherdriveaxles.
NOTE!Afterassemblingtheclutchorthegearchecktheaxialplayofthecrankshaftwhichshouldbe0,10...0,35mm.
Service24SERVICE
PERIODICALMAINTENANCE
Oneofthemostessentialpreconditionsforsecureoperationofyourengineispropermaintenanceatregularintervals.Maintenancecostsarelowcomparedtocostscausedbynegligence.MaintenanceworkAlwaysstoptheenginebeforeservice.Cleantheengineanditssurroundingsbeforeyoustartservicework.WARNINGSERVICECHART
MAINTENANCEWORK1.2.3.4.CheckengineoillevelCheckcoolantlevelCheckforoil,fuelorcoolantleakagesCleanairfiltercycloneSERVICEINTERVAL/RUNNINGHOURS105030060012002400xxxxxxxxxxx2x2x2x2xxAT4800hINTERVALSEVERYTWOYEARS5.Drainwatertrap6.Clean/changeairfilter7.Cleancoolingsystem(fromoutside)8.Changeengineoilandoilfilter9.Checkfanbelttightness110.Checkbatteryfluidlevel11.12.13.14.ChangefuelfiltercartridgeChangeprefilter(Stanadyne)DrainwateroutoffueltankGreasecoolantpump15.Adjustvalves16.Checkandcleaninjectors17.Turbochargerandintercoolerinspectioninanauthorisedworkshop18.Changecoolant1)
greasespringloadedbelttensioner2)oronceayear(intheautumn)
ServiceBASICSERVICEAFTERTHEFIRST50...100HOURSOFOPERATION
1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.
Checkbatteryfluidlevel.
Checkforfuel,lubricationoilandcoolantleaks.Checktightnessofscrewandnuts.Testrun.
Checkoilpressure/charging.Checkidlingspeed.
Checkmax.runningspeed.Checkturbochargeroperation.Checkthermometeroperation.Checkstopdeviceoperation.Changeengineoilandoilfilter.Adjustvalveclearances.Cleanairfilter.Drainwatertrap.Changefuelprefilter
25SERVICESTOBEMADEDAILYORAT10HOURSINTERVALS
1.Checkengineoillevel
MAXMIN2---26
Stoptheengineandwaitforafewminutesbeforechecking.Theoillevelshouldbebetweenthemax.andmin.linesonthedipstick.Whenaddingoil,topuptothemax.line.2.Checkcoolantlevel
Opentheradiatorcapcarefully.Ifthecoolantishot,thereisanoverpressureinthesystem.Thecoolantlevelshouldbeslightlyabovetheradiatorcore.
ThecoolantlevelshouldbebetweentheMAXandMINlinesifthesystemisprovidedwithanexpansiontank.
WARNINGServiceCheckthefreezingpointofthecoolantbeforethecoldseason.
26NOTE!Neveruseonlywaterascoolant.Thehotenginecanbedamagedifyoupourcoldcoolantintoit.
3.Checkforleakages(fuel,oil,coolant)
Findanyleakagepointsandeliminatethenassoonaspossible.Thecoolantpumpisprovidedwithadrainingholeontheunderside.Thisholemustnotbeblocked.Ifcoolantdripsoutofthehole,thecool-antpumpmustimmediatelyberepaired.Theremaybeaslightleakageonanewpumpbeforeithasbeenrunin.
4.Cleanairfiltercyclone
Alwaysstoptheenginebeforecleaning.Undothelockingclamporthenutonthecyclone,emptyandcleantheglassbowl.Refittheglassbowl.
MAXAUPBC2---27
ServiceSERVICESTOBEMADEWEEKLYORAT50HOURSINTERVALS
5.Checkthewatertrap
27OFFONWatertrap(CAV)Fuelfilter/Watertrap(Bosch)Prefilter/Watertrap(Stanadyne)2---28Openthedrainpluganddrainanywaterwhichmaybecollectedinthewatertrap/prefilter.Wipeoffanyfuelwhichmayhaverundown.6.Clean/changetheairfilter
Alwaysstoptheenginebeforecleaning/changing.
Unscrewthenutattheendoftheaircleanerorundothelockingclampsandtakeoutthefilterelement.Iftheairfilterisequippedwithasafetyfilterelementdonottakeitoutbutchangeitat1200hintervals.
2---29
Cleanthefilterelementwithcompressedairwithamax.pressureof5barwhichshouldbedirectedobliquelyfromthemiddleofthefilterandoutwards.
Service28Holdthefilteragainstthelight,orloweranelectriclightdownthroughthefilterandcheckthattherearenoholesorcracks.Iffaulty,thefilterelementmustbechanged.
Whenyoufitthefilterelement,checkthatitisproperlylocated,thesealsareingoodconditionandthesealingsurfacesareclean.Donottightenthenutattheendoftheaircleanertoohard.EnginewarrantyisvalidonlywhenoriginalSisudieselairfilterelementsareused.
ELECTRICALMECHANICAL
2---30
Theairintakepipemaybefittedwithamechanicalorelectricalserviceindicatortoindicatewhenfiltercleaningisdue.Withtheelectricalserviceindicatoralampintheinstrumentpanelwillshowwhenser-viceisneeded.Whenthemechanicalserviceindicatorturnsredthefilterelementmustbecleanedorreplaced.Youcanresettheindicatorbypushingthebuttonattheendofthevacuumindicator.7.Cleanthecoolingsystem
Checkandcleantheoutsideoftheradiatorfromtimetotime.Usecompressedairorwaterspraytoremovedirtandimpurities.Avoidtoohighapressure.
ServiceSERVICESTOBEMADEAT300HOURSINTERVALS
8.Changeengineoilandoilfilter
292---31Runtheengineuntilwarm.Stoptheengine.Removethedrainingpluganddraintheoilintoasuitablecontainer.Whentheoilsumpisempty,refittheplug.Taketheoldoiltoasuitabledisposalpoint.Theenginemaybeequippedwithanoildrainingpump(e.g.marineengines),sousethepumptogettheoilsumpempty.
Fillnewoiltotheprescribedlevel(uppermarklineondipstick)throughthefillerhole.Notethecapacityoftheoilfilter,abt.0,7ltr.
Regardingoilgrade,seeLubricationOilChart,page46.Changeoilfilter
Beforeremovingtheoilfiltercleanthesurroundingsofit.Usethelooptooltounscrewtheoldfilter.Lubri-cateslightlytherubbergasketofthenewfilterandcleanthesealingfaces.Tightenthenewfilterbyhand.Wipeoffanyoilwhichhasrunontothechassis.Starttheengine.Donotrace.Ensurethatnooilisleak-ingfromthefilter.Taketheoldfiltertoasuitabledisposalpoint.
EnginewarrantyisvalidonlywhenoriginalSisudieseloilfiltersareused.Thebreatherpipe
Alwayscheckthatthebreatherpipeiscleananduncloggedatthesametimeaschangingtheoil.
Service9.Checkfanbelttension
30Thebeltiscorrectlytensioned,ifitdeflectsabt.15...20mmbetweenthebeltpulleyswithreasonablyhardthumbpressure.Aslack,wornoroilybeltmustbereplaced.Alwayskeepasparefanbeltavailable.
15...20mmTensioning2---32
Slackentheattachingscrewsandmovethealternatoroutwardsuntilthebeltissufficientlytight.Tightenthescrews.
Iftheengineisequippedwithaspringloadedbelttensioner,pressthespring(e.g.withasuitablescrew+nut)sothatthetensionerdoesnotpressthebelts.Preformthetensioningasbeforeshown.Releasethespringloadedtensioner.Iftheengineisequippedwithanaircompressor,thecompressorfanistensionedbyaseparatetighteningpulley.
Lubricatethegreasenipple.
10.Checkbatteryfluidlevel
2---33
Thefluidshouldstandabt.5...10mmabovethecellplatesinthebattery.
Topupwithdistilledwaterifrequired.Duringthecoldseasonitisimportantthattheengineisallowedtorunforawhileaftertoppingupwithdistilledwater.Thisistoavoidthefreezingofthewaterbeforeithashadtimetomixwiththebatteryacid.
Keepthebatterycleananddryontheoutside.Ensurepropermountingofthebattery.Cleanandprotectthepolestudsandthecableterminalswithbatterygrease.
Neveruseanakedflamenearthebatterytocheckthefluidlevel.WARNINGServiceSERVICESTOBEMADEAT600HOURSINTERVALS
31(oronceayear,intheautumn)
11.ChangefuelfilterBosch---Cleanremovethethefilteroldandfilter.thesurroundingareaand---Lubricatefilter.thegasketonthenewfilterandcomeTurninto3/4contactofaturnwithafterthesealingthegasketface.hasfitthe---Pumpfull.fuelwiththehandpumpuntilthefilteris---Bleedthefuelsystem,seepage37/40.A=Bleedscrew
11.ChangefuelfilterCAV
---Cleanthefilterandthesurroundingarea.---Emptybottomthenotontoshield.fuelfilterbyopeningthepluginthethesoil.Letthefueldropintocontainer,---UnscrewAtthesamethetimescrewsupportonthethetopfilterofthebottom.fuelfilter.---Cleantheglassbowlandthebottomshield.---Fitthenewsealsandreassemblethefilter.---Pumpfull.fuelwiththehandpumpuntilthefilteris---Bleedthefuelsystem,seepage37/40.A=Bleedscrew
Taketheoldfiltertoasuitabledisposalpoint.
A2---34A2---35
Service32NOTE!Useofspiritsasantifreezeisnotusefulorrecommendedatall.Itmakesthefuelsolidifyandweakensthelubricatingqualitiesofthefuelandincreasesthepossibilityofcorrosion.EnginewarrantyisvalidonlywhenoriginalSisudieselfuelfilterelementsareused.
12.ChangeprefilterStanadyne---Cleantheprefilterandsurroundingarea.---Openthequickchangeringandtakeoutthefilterelement.
---Fitthenewelement.NOTE!Theelementwillonlygoononeway.
---TurnthequickchangeringtoONpositionuntilaudible“click”willbeheard.
---Pumpfuelwiththehandpumpuntiltheprefilterisfull.
---Bleedthefuelsystem,seepage37/40.Taketheoldfilterelementtoasuitabledis-posalpoint.
UNLOCKLOCK
2---36
13.Drainfueltank
Thefueltankshouldbecleanedbeforethewinter.Thusyouavoidtroublescausedbythewaterinthefuelsystem.Thebestwaytopreventcondensationistoalwayskeepthefueltankasfullaspossible.---Emptythefueltankandrinseitwithpurefuel.---Fillthefueltankwithfuelforwinterconditions.14.Greasecoolantpump
(Thepumpsfittedwithagreasenipple)
Alwaysuseheatresistantballbearinggrease(NLG2)aslubricant.Donotgreasethebearingstoomuchasexcessivegreaseisforcedoutfromthebearingspaceandmaydamagetheseals.Topresstwicewithagreasegunisenough.
ServiceSERVICESTOBEMADEAT1200HOURSINTERVALS
15.Adjustvalveclearances
33Thenominalclearanceofbothinletandexhaustvalvesis0,35mm.Thevalveclearancescanbecheckedregardlessofwhethertheengineiscoldorhot.Thevalveclearancesofacertaincylindercanbeadjustedwhenthepistonisatitscompressionstroketopdeadcentre.
Enginefrontend
I
INLET
PEXHAUST
IPIPIPIPIPIPIP
320,620,634420
2---37
320--engines
Checkthevalveclearancesintheinjectionorderoftheengine.Injectionorderis1---2---3.
---Checkvalvesinthe1stcylinder,whentheexhaustvalveofno.3cylinderiscompletelyopen(valveno.6).
---Checkvalvesinthe2ndcylinder,whentheexhaustvalveofno.1cylinderiscompletelyopen(valveno.2).
---Checkvalvesinthe3rdcylinder,whentheexhaustvalveofno.2cylinderiscompletelyopen(valveno.4).420--engines
---Rotatethecrankshaftintherunningdirectionuntilthevalvesinthe4thcylinderarerocking(exhaustcloses,inletopens).Checkthevalveclearanceofthe1stcylinder.
---Rotatethecrankshaftby1/2ofaturnintherunningdirectionsothatvalvesinthe3rdcylinderarerocking.Checkvalvesinthe2ndcylinder.---Continueaccordingtotheorderofinjection:InjectionorderValvesrockincyl.no12434312620/634--engines
---Rotatethecrankshaftintherunningdirectionuntilthevalvesinthe6thcylinderarerocking(exhaustcloses,inletopens).Checkthevalveclearanceofthe1stcylinder.
---Rotatethecrankshaftby1/3ofaturnintherunningdirectionsothatvalvesinthe2ndcylinderarerocking.Checkvalvesinthe5thcylinder.---Continueaccordingtotheorderofinjection:InjectionorderValvesrockincyl.no153624624153ServiceAdjusting
340,352---39
---Slackenthelocknutontheadjustingscrewontherockerarm.
---Checktheclearancewithafeelergaugeandadjusttothecorrectclearancebyturningtheadjustingscrew.
---Tightenthelocknutandagaincheckthattheclearanceiscorrect.
SERVICESTOBEMADEAT2400HOURSINTERVALS
16.Checkandcleaninjectors
Inordertoensuretrouble---freeengineoperationtheinjectorsmustbekeptinfirstclasscondition.Im-perfectoperationofaninjectorcausesforexample,lowerengineoutput,greaterconsumptionoffuel,engineknockingandsmokeinnaturallyaspiratedengines.Removeinjectors
---Cleantheinjectors,theirpipesandsurroundings.---Detachtheinjectionpipesandtheleak---offpipes.
---Detachthenutsfrominjectorsandremovetheinjectors.Ifyoucannotremovetheinjectorbyhand,usetheextractorno.905171300.Coveralltheconnectionpointsoftheinjector.
---Alsoremovetheinjectorsealingringfromthecylinderhead,ifnotremovewiththeinjector.Specialmeasuringtoolsareneededfortheinjectorcheck.PreferablyletSisudieselServiceOrganiz-ationcheck,adjustandcleantheinjectors.
ServiceFittinginjectors
35---Ensurethattheinjectorseatonthecylinderheadisclean.Installthewasherandtherubberringaroundtheinjector.Replacetheoldsealingringonthelowerendwithanewone.
---Installtheinjectortothecylinderhead.Thentightenthenutsscrewingthembyturns,alittleatatimecheckingthatthetorquesofbothnutsareequalallthetime.Continuetighteninguntilthefinaltighteningtorque,15Nmisreached.
---Attachedtheinjectorpipesandtheleak---offpipes.
12Fittingtheinjector1.Washer
2.Protectiverubber3.Sealwasher
32---40
SERVICESTOBEMADEAT4800HOURSINTERVALS
17.Checkturbochargerplayandcheckthattheintercoolercellisclean(DS/DSI/DW/DWI---engines)
TheturbochargerandtheintercoolercellservicemustbeentrustedtoanexperttechnicianatSisudieselService.
Itisessentialtocarryoutregularengineservicestokeeptheturbochargeringoodcondition.Specialattentionmustbepaidtothecleanlinessoftheairfiltercartridgeandtotheengineoilandoilfilterchangeatrecommendedintervals.Checkregularlythattheturbochargerisproperlyfittedtotheexhaustmani-foldaswellasthetightnessoftheinletandexhaustmanifoldjointings.Correctadjustmentoftheinjec-tionequipmentisessentialfortheoperationoftheturbocharger.
Whenanewturbochargerisinstalled,pourabt.0,2ltrofpureengineoilintothebearinghousingbeforeattachingthepressureoilpipe.Ensurethatnoimpuritiesareenteringtheturbochargerwiththeoil.
ServiceSERVICESTOBEMADEEVERYTWOYEARS
18.Changecoolant
36Changethecoolanteverytwoyears.Thisensuresthattheanti---corrosiveisalwaysactive.Seepage46forthequalityrequirementsofthecoolant.
Atthesametimecheckthetightnessandconditionofrubberhosesofthecoolingsystem.Renewbrokenordamagedhosesbeforefillingthesystem.
1.Drainplugonradiator
2.Drainplugoncylinderblock3.Drainplugonoilcooler
4.Drainplugonchargeaircooler5.Bleedplug6.Joint
2---41
Draincoolantsystem
---Removethefillercap
---Removethedrainingplugsontheradiatorandontheleftsideofthecylinderblock.
---Iftheengineisequippedwithanoilcoolerandanintercooler(DSI/DWI),alsoremovethedrainingplugsonthem.
---Makesureallcoolantisdrainedoutandnoimpuritiesareblockingthedraininghole.
---Theengineassemblymayalsohaveotherdrainingplugs(e.g.ontheengineheaterpiping).Alsoremovetheseplugswhenyouchangethecoolant.Drainingcoolingsystemofmarineengine
Ifyoustoptheengineinthecoldseasonforsolongatimethatthereisariskoffreezing,alwayscom-pletelydraintherawwatersystem.Ensurealsothatthereisenoughantifreezeinthefreshwatersystem.------------Drainthefreshwatersystemuntiltheheatexchangerisempty.
Openthecoversoftheheatexchangerandblowthecelltubesempty.Opentheplatecoveroftherawwaterpump.
Alsodraintherawwateroutoftheoilcooler/oilcoolercelltubesofthemarinegearbox.
Fillcoolingsystem
Fillthecoolingsystemwithamixtureofantifreezeandcoolantuntilthecoolantlevelcomesabovetheradiatorcore.Bleedthecoolingsystembyremovingtheplug/thethermometerfeeleronthethermostatbody.Pourcoolantuntilthecoolantlevelreachestheplug.Screwtheplugandfillrestofthesystem.InDSI/DWI---enginesopenalsotheupperjointfortheintercoolercoolantpipe.NOTE!Neveruseonlywaterascoolant.
AdditionalServiceandAdjusting37ADDITIONALSERVICEANDADJUSTINGINSTRUCTION
(tobecarriedoutwhenrequired)
BLEEDFUELSYSTEM(Boschin---lineinjectionpump)
2---43
2---42---Pumpfuelwiththehandpumponthefeedpump.
---Unscrewthebleedscrewonthetopofthefuelfilter.Pumpwiththehandpumpuntilthefuelrunningoutofthebleedscrewisfreeofairbubbles.Closethebleedscrew.
---Iftheenginefailstostart,opentheinjectorpumpoverflowvalveandcontinuepumpinguntilthefuelrunningoutisfreeofairbubbles.Closetheoverflowvalve.---Cleantheengineofleakedfuel.BleedtheThermostartsystem
Alwaysbleedthefuelpipeoftheglowplug,ifthepipeorthefuelcontainerisemptye.g.afterservice.Damagetotheglowplugcanoccurduetothelackoffuelwhenstartingtheengine.Systemwithmagneticvalve
---Disconnecttheglowplugwireandopenthepipeadapter.
---Switchthecurrentonthemagneticvalveandturnthecrankshaftuntilfuelisrunningoutofthepipejointing.
---Tightenthepipeadapterandconnectthewire.
2---44
AdditionalServiceandAdjustingSystemwithfuelcontainer
---Ifthecontainerhasbecomeempty,fillitwithadripcanthroughthebreatherholeonthecover.---Opentheglowplugpipeadapterandletfueldropthroughthepipe.Tightentheadapter.
38CHECKANDADJUSTINJECTIONTIMING(Boschin---lineinjectionpump)
Injectionofthe1stcylinderstartswhenthemarkofthecrankshaftpulleyshowstowardsthetimingindi-catorwhichiseitherontherightorleftsideofthepulleydependingontheenginetype.Thetractoren-ginesmayhavethetimingmarklocatedontheflywheel.
NOTE!Ifyouremovethehubofthepulley,markitslocation.Afterwardswhenassemblingthepulleyyoumustensurethatthemarksonthehubandonthecrankshaftcoincidewitheachother.Check
Theinjectionpumpisequippedwithanautomaticexcessfeed.Thereforemovethecontrolrodtotherunningpositionbeforecheckingtheinjectiontiming.Withoutthisactioninjectiontimingerrorswillre-sult!
---Cleantheinjectionpumpanditssurroundingsthoroughly.
---Turnthecrankshafttoapositionwherethe1stcylinderreachesitscompressionstroketopdeadcentre.Thenturnthecrankshaftbackwardsuntilthemarkonthepulleypassesthetimingindicator.
9025990002---45---Removethecontrolrodcover/thestopmagnetfromtheinjectionpump.Movethecontrolrodtodrivepositionwithtool902599000.
---Removethe1stcylinderinjectionpipe.
---Blowtheconicalpartofthepressurevalveholderfreeoffuel.Turnthecrankshaftslowlyuntilthefuelsurfaceinthepressurevalveholderstirsbutdoesnotyetrise.
---Iftheinjectiontimemarkingonthepulleyisinlinewiththetipofthetimingindicator,theinjectiontimingiscorrect.Otherwiseadjustthetiming.
---Aftercheckingandeventualadjustmentreplacetheinjectionpipeandthecontrolrodcover.Lettheenginerunforafewminutesandre---check.Thusyoucanbesurethatthereisnoairinthefuelsystemasthismightaffectthetiming.
AdditionalServiceandAdjusting39NOTE!Insometypesofinjectionpumpstheinjectionstartingpointinthe1stcylinderhasbeenposi-tionedwithaidofanindicatorpininthepumpgovernorhousing.Dotheinspectionofinjectiontimingasfollows:
---Turnthecrankshafttoapositionwherethe1stcylinderpistonreachesitscompressionstroketopdeadcentre.Thenturnthecrankshaftbackwardsuntilthemarkonthepulleypassesthetimingindica-tor.Afterthatrotatethecrankshaftslowlytorunningdirectionuntilthemarkonthepulleyisatthepointofthetimingindicator.
2---46---Unscrewtheplugonthesideoftheinjectionpump.Takeouttheindicatorpin.
---Turntheindicatorpinandpushitintotheholesothatthegrooveattheendofthepinpointstowardsthepump.
---Ifthepingroovefitsonthebossonthegovernorweightassembly,theinjectiontimingiscorrect.Otherwise,turnthepumptoapositionwherethebossandthepingroovealign.
NOTE!Donotrotatethecrankshaftwhenthegrooveendofthepinisinsidethepump,sincethepinenddamageseasilyandplasticpiecesremaininthegovernorhousing.
---Whentheadjustmentiscorrect,turntheindicatorpinsothatthegroovepointsoutwards(runningposition)andpushthepinintothehole.Refittheplug.InjectiontimingadjustmentAR2---47---Loosentheretainingnutsoftheinjectionpumpandtheconnectionnutsoftheinjectionpipes.---Iftheinjectiontimingisretarded,turntheinjectionpumpanti---clockwise,direction“A”(viewedfromthefrontendofthepump).Ifthetimingisadvanced,turnthepumpclockwise,direction“R”.---Checktheinjectiontimingandturnthepumpagain,ifnecessary.
---Whentheinjectiontimingiscorrecttightentheretainingnutsofthepumpandtheconnectingnutsoftheinjectionpipes.
AdditionalServiceandAdjustingADJUSTIDLINGSPEED(Boschin---lineinjectionpump)
Iftheengineidlingspeeddiffersfromtherating,adjustasfollows:
401
2
2---482---49---Opentheprotectioncap(1)oftheidlingspeedadjustingscrewandtheprotectioncap(2)oftheadjustingscrewoftheadditionalspringforidling.
---Ensurethatthethrottleleverisinidlingpositionandtheengineisatrunningtemperature.
---Starttheengineandopentheadjustingscrew(2)oftheadditionalspringsothatitdoesnotaffecttheidlingspeed.
---Adjusttheidlingspeedbytheadjustingscrew(1)atabt20--30rpmbelowtherating.---Racetheengineafewtimesandensurethattheidlingspeedremainsasset.
---Tightentheadjustingscrew(2)oftheadditionalspringuntiltheidlingspeedrisestotheratedvalue.Locktheadjustingscrewinthisposition.
---Fixtheprotectioncapsoftheadjustingscrews.
BLEEDFUELSYSTEM(Stanadynerotaryinjectionpump)
NOTE!Thisfuelsystemremovesautomaticallysmallamountsofairbubblesfromthefilterandthepumpwhentheengineisrunning.However,bleedthesystemalways,whenthesystemhasbeenopenedorfuelhasbeenexhaustedduringdrivingoranewsparepumphasbeenfitted(toavoidlongstartingtime).
2---50---Pumpbyhandthefuelfeedpumplever.Ifthepumpingseemstobeineffective,turntheenginealittlesothatthecamshaftcamisnotatthefeedpumplifter.
AdditionalServiceandAdjustingA41B2---51
---Loosenthebleedingscrew(A)onthefilter.Pumpwiththehandpumpuntilnoairbubblesflowsoutofthebleedingscrewhole.Tightenthebleedingscrew.
---Pumpfurtherwiththehandpumpandloosenthefuelinletconnection(B)onthepump,untilthefuelcomingoutisfreefromairbubbles.Tightentheconnection.---Starttheengineandassure,thatnoleaksexist.
NOTE!Whenthebleedingisdoneinthisway,fuelflowsimmediatelyintotheinternaltransferpumpwhenthestartermotorisrotatingandthedistributorpumphousingisfilledquicklywithfuel.Inthepumphousingthereisastopsolenoid,whichmustnotbeswitchedonforlongerperiodswhenthepumphousingisemptyoffuel.
CHECKANDADJUSTINJECTIONTIMING(Stanadynerotaryinjectionpump)
2---52---Turnthecrankshafttoapositionwherethe1stcylinderpistonreachesitscompressionstroketopdeadcentre.Thenturnthecrankshaftbackwardsuntilthemarkonthepulleypassesthetimingindica-tor.Afterthatrotatethecrankshaftslowlytorunningdirectionuntilthemarkonthepulleyisatthepointofthetimingindicator.
AdditionalServiceandAdjusting422---53
---Removethesmallcoverplateonthesideoftheinjectionpump.Ifthepumptimingmarksareagainsteachother,thetimingiscorrect.
---Ifthepumptimingmarksarenotagainsteachother,loosentheretainingnutsofthepumpandthedeliverypipes.Rotatethepumptoapositionwherethetimingmarksareagainsteachother.Tightentheinjectionpumpintopositionwherethetimingmarksontheengineandontheinjectionpumpareagainsteachother.Tightentheconnectingnutsofthedeliverypipes.
NOTE!TheE---enginetimingcheckandadjustmentisdonewithspecialgauges.ContactyourSisudie-seldealer.
ADJUSTLOWIDLINGSPEED(Stanadynerotaryinjectionpump)
2131.Lowidlingspeed2.Revolutionlever3.Max.revs
2---54Thelowidlingspeedcanbeadjustedwithalimitingscrewinfrontoftherevolutionlever.Theadjustingscrewformax.revshasbeensealed.Thisadjustmenthasbeendoneinthefactory,andadjustmentofmax.revsafterwardsisprohibited.
AdditionalServiceandAdjustingFITCYLINDERHEAD
max.14243max.188,52---55
---Measurethescrewlengthwhichshouldbewithinthelimitsshowninfigure.Ifanyscrewdiffersinlengthfromthemeasuresgiven,replacethescrew.---Fitthecylinderheadinitsposition.
1416103
751
9151721
22191012624117
1417162
128
6
411
1320
18
8315
913
15320,620,634
420
2---56
---Picturesaboveshowthecorrecttighteningorderofthecylinderheadbolts.Theorderhasalsobeenmarkedonthecylinderheads.
---Tightenthecylinderheadboltsprogressivelyasfollows:1.Firsttighteningto80Nm2.Tighteningof90˚
3.Tighteningagainof90˚.---Adjustthevalveclearances.
---Runtheenginewithalightloadtothenormalrunningtemp.(~75˚C).---Tightenthebolts60˚andadjustthevalveclearances.NOTE!Afterthisthecylinderheaddoesnotneedretightening.
AdditionalServiceandAdjusting44INSPECTIONOFTHEZINCPLUG
(620/634marineengines)
Checkzincthezincplugatleastoncebependsmadeplugmoreisbadlycorroded,theinspectioneveryyear.mustIftheingthroughonthethechemicaloften.Thesystem.
contentsextentofofthecorrosionwaterflow-de-zinc---Emptytherawwatersystemandloosenthe-of-----Cleanplug.
Changethezincplugbyscraping.
inpicture.anewplug,theplugifithaswornmorethantohalfSparecomparepartnowith8450dimensions85699.
shownCHECKVIBRATIONOFTHEDAMPER
RUBBERELEMENT(620/420--engines)
Theonitstheinertiacrankshaftmemberfrontofrubbervibrationdamperhours.hubinthecourseendofhundredsmayturninofrelationtoofcanthebevibrationTherearenoticed.
damper,indexlineswhereonthepossiblefrontrunningsurfaceturningment,---Iflines(A)aremorethan1,5mmoutofalign-one.
changethevibrationdamperforanewpieces---Checkmemberofalsoorisrubbertheconditionofrubberelement.Ifmorethanare3,5missing,mmbeloworifthethesurface,rubberring)ifforwarddampercanforbemovementanewdetected,ofone.
changeinertiamemberthevibration(outerNOTE!every4000Vibrationrunningdamperhours!
shouldbereplaced20142---57A1,52---582---59AdditionalServiceandAdjustingBEFORETHECOLDSEASON
45---Drainwateroutofthefueltank.---Drainwateroutofthewatertrap.
---Replacethefuelfilterandprefilter(Stanadyne).
---Ensurethatthefuelinthefueltankisofwinterquality.---Changetheengineoil(winterquality).---Checkthebatterycondition.
---Movethecontrolrodtotherunningpositionaftertheenginehasbeenstopped(engineswithoutelectricalstopdevice).
---EnsurethatthefuelinThermostartfuelcontainerandinthefuelpipebetweenthecontainerandtheglowplugisofwinterquality.Ifthereisfuelofsummerquality,itbecomessolidandtheglowplugisglowingwithoutfuel.Theresultisthattheenginefailstostartandtheglowspiralisburntoff.TheeasiestwaytochangethefuelintheThermostartcontainer:Removethefuelpipeattheglowplugendandletthecontainerdripempty.Afterthisreplacethefuelpipeandfillthecontainere.g.withadripcanthroughthebleedholeonthecontainer.Removethefuelpipecarefullytoensurethattheglowpluggetsfuel.Thusalsothefuelpipebecomesairfree.
---Checkexternallybyhandtheglowplugfunctionwhentheglowplugisfittedandtheglowingcurrentisswitchedon.Iftheglowplugisworking,itiswarmonthetop.---Checkthefunctionoftheenginepre---heater.
TIGHTENINGTORQUES
Object
Nm
Cylinderheadbolts............................................80Nm+90˚+90˚Cylinderheadstudstocylinderblock................................30Mainbearingbolts...............................................200
Connectingrodbolts..........................................40Nm+90˚Crankshaftnut:
---320/420.......................................................600---620/634......................................................1000Crankshaftpulleybolts.............................................30Flywheelbolts...................................................140Flywheelhousingbolts:
---outerringM12.................................................110---innerringM10.................................................60Idlergearbolts:
---M10...........................................................60---M14..........................................................200Idlergearretainingscrews(withballbearing):
---thebiggerbolt.................................................180---theboltsforholdingthebearing..................................22Balancingweights(420)............................................60Pistoncoolingvalve(620/634)......................................30Oilpumpretainingscrews..........................................60Oilcoolerconnectingpiece.........................................60Coolantpumppulleynut..........................................120Exhaustmanifoldbolts.............................................50Intakemanifoldbolts..............................................30Injectionpumppressurevalveholder................................45Injectionpumpgearretainingnut...................................90Injectionpumpgearretainingnut(Bosch---P)........................200Injectorattachingnuts(onstuds)....................................15Injectornozzlesleeve..............................................60Compressorpulleynut(Knorr)......................................80
AdditionalServiceandAdjustingLUBRICATINGOILQUALITYREQUIREMENTS
---Naturallyaspiratedandturbochargedengines---Lowemission(E)engines
APICF--4,CG--4,CH--4APICG--4,CH--4
ACEAE2/E3--96,E4--98,E5--99ACEAE3--96,E4--98,E5--99
46TEMPERATURE˚C
---40---30---20---100+10+20+30+40SAE---GRADE5W---305W---4010W---3010W---4015W---4020W---2020W---40302---60
Lubricatingoilishazardoustohealth.Avoidprolongedcontactwiththeskin.Theoilmistisdangeroustoinhale.WARNINGCOOLANTQUALITYREQUIREMENTS
ThecoolantwhichisusedmustsatisfythedemandsofstandardASTMD3306orBS6580:1992.---Thecoolingmixturemustconsist40...60%ofethylene/propylene---glycolbasedantifreezeandwater.Thebestproportionis50%ofantifreezeliquidand50%ofwater.
---Thewaterusedmustbemechanicallycleanandnottooacid(e.g.swampwater)ortoohard(calciferouswellwater).
---Checkperiodicallytheproportion(thefrostproof)ofthecoolant.Changethecoolanteverytwoyears.NOTE!Neveruseonlywaterascoolant!
Antifreezeishazardoustohealth.Avoidcontactwiththeeyesandskin.WARNINGAdditionalServiceandAdjustingFUELQUALITYREQUIREMENTS
Requirement
Density,+15˚CViskosity,+40˚CSulphurcontentCetaneindexWatercontent
0,82...0,86kg/dm31,2...4,5mm2/smax.0,2%m/mmin.45max.200mg/kg
47Testmethod
ASTMD4052,ENISO12185ASTMD445,ISO3104ASTMD4294,ISO8754ASTMD4737ASTMD1744
ThefuelshouldbeaccordingtonormEN590.EngineoutputdependingonfuelqualityDifferentfuelqualitiesliketemperature,densityandviscosityaffecttheactualoutputoftheen-gine.Ouroutputratesusefuelwithadensityof0.84kg/dm3andspecificheatrateof42,7Mj/kgatafueltemperatureof+15˚C.
Thecorrectionin%causedbythechangeoffuelqualitiesisseenintheattachedfigures.
OUTPUT%+5OUTPUT%+5B0
---50,800,840,900,85DENSITYkg/dm3
AFIG.B.Engineoutputdependenceonfuelden-sity.Normalvalueis0,84kg/dm3at+15˚C.
OUTPUT%+50
C---510203035405060
FUELTEMPERATURE˚C
0---22345786VISCOSITYcSt
FIG.A.Engineoutputdependenceonfueltem-perature.+35˚Cisthereferencetemp(correc-tion0%).
Thefueltemperatureisnotonlyafunctionofambientconditionsbutalsovariesaccordingtothefuelsystemoftheapplication(tanksizeandlocation,returnflowetc.).
FIG.C.Engineoutputdependenceonfuelvis-cosity.Normalvalueis3cStat+20˚C.
AdditionalServiceandAdjustingNotefig.BandConlyifthefuelqualityischanged.
48Infig.Athereareallthequalitydependenciescausedbythechangeofthetemperature.Thefueldensityandviscositycanbeseenintheproducedeclarationgivenbythemanufacturer.
Theoutputcorrectionismadeasfollows:CorrectionpercentagesfromfiguresA,BandCaresummedup.Thegivenratedpoweristhencorrectedwiththeresultingpercentage.
BIODIESELFUEL
IntheSisudiesel---enginesitisacceptedtouseesterifiedrapeoilasbiodieselfuel---orRME(rapeoilesterifiedwithmetanol)withouttechnicalmodificationsontheengine.Therequirementfortheaccept-anceisthatthebiodieselthatisusedisverypureandthatisfillstheAustrian“Ö1190”biodieselnormdemandsofpureness.Practicallyitmeansthattheamountofpurecarbon,hydrogenandoxygencon-tenttogetherinthebiodieselismorethan99%.Thewarrantyformsarethesame.
Intheserviceinstructionsthereisonethingchanging:checkingcleaningofnozzlesevery1000hours.
AdditionalServiceandAdjustingTROUBLESHOOTING
49Alwayslistentoenginenoiseandpayattentiontohowitoperates.Eliminatingaslightfaultoftenpre-ventsamoreseriousone.TroublesandtheircausesA.ENGINECANNOTBECRANKED1.2.LooseBatteryorduetoadischarged.brokenwire.
slackenedThismaybe3.alternatororbrokenStarterdefective.belt.B.ENGINEFAILSTOSTART
1.Fueltankempty.Fillthe2.theFuelfueltankandbleednotsystem.
fluidenoughincoldweather3.(summer4.Airininjectionquality).
pump,pipesor5.Leak6.CloggedinfuelFaultyinjectorsfuelinletfilterordeliverypipe.injectors.1orpipe.7.Feedpumpinoperative.
18.9.RetardedLowa)compressioninjection.1.
timing.b)leakyc)cylinderpistonvalves
ringsheadsticking
gasketdamaged10.11.Coldd)brokenvalvespring12.Leak-start-devicedefective.13.StopFaultylever-offvalvestopnotsolenoid.
indefective.
driveposition.C.ASHORTENGINEWHILESTARTSBUTSTOPSAFTER1.2.AirFuelininjectionpump,pipesorinjectors.3.4.Cloggedstrainer5.Cloggedfuelinfilterfuelortankairpipeclogged.6.
FeedFaultypumpwaterseparator.pipe.stopsolenoid.
defective1.Troublesandtheircauses
D.ENGINEDOESNOTRUNSMOOTHLY1.2.AirCloggedininjectionpump,pipesorinjectors.3.4.Leak5.Injectorsinfuelfuelinletfilterorordeliverypipe.
pipe.6.LowFeedcompressiondefective1(see.
B9a---d)17.
Injectionpumppumpdefective1orgovernor.
.defective1.
E.ENGINEDOESNOTDEVELOPFULLPOWER1.2.AirSpeedfiltercontrolclogged.
linkageincorrectlyadjusted.3.Loose4.AirCloggedinfuellinkage.fuelsystem.
filter,prefilter,5.orwaterseparator6.Injectorsfuelpipe.
7.Leakinfueldefective1inletor.
deliverypipe.8.Incorrect9.FeedLowcompressionpumpinjectiondefectivetiming.1(see.
B9a---d)110.11.InjectionTurbochargerpumpdefectiveorgovernor.1
defective1.12.(turbocharged13.Leak-Stop-engine).lever-offvalvenotproperlydefective.
indriveposition.F.ENGINEKNOCKING1.2.Incorrect3.InjectorsAdvanceddefectivefuel.
14.5.
Lowcompressioninjection.
(seetiming.
B9a---d)1Excessivebearingclearance1.
.1)Consultanexperttechnician
AdditionalServiceandAdjusting50Troublesandtheircauses
G.SMOKEORSOOTINEXHAUSTGASES1.2.Engine3.EnginerunningAirhasbeentoocold.
4.5.Incorrectfilterclogged.idlingfortoolong.6.Engine7.Leakoilfuel.
leveltoohigh.Cloggedinfuelpipes.
8.separatorfuelfilter,waterInjectorsorfuelpipe.10.9.Incorrectdefective1.
11.Low12.
Injectioncompressioninjectiontiming.
Turbochargerpumpdefectiveorgovernor(seeB9a---d)1.1.
defective1.H.ENGINEOVERHEATS
1.2.SlackCoolingorsystembrokennotfancompletelybelt.
filled.3.SystemThermostatclogged.
4.(double---actingdefectivethermostat).orremoved5.Thermostatupsidedown.
6.RadiatorOverloading.
fillercapnotpressuretight.Troublesandtheircauses
I.MAINTAINENGINETENDSITSSTANDARDTORACESPEEDORFAILSTO1.Governordefective1.J.OILPRESSURETOOLOW
1.2.Engine3.Impuritieshasrunshortofoil.4.Incorrect5.OilSAEincontrolgradevalve.ofoil.6.Excessivetoohot.
bearingclearance17.
Idling.Sensorspeedforoiltoolow.
8.lampOilpressuredefective.
pressuregaugeorindicatorgaugeshowsincorrect10.9.OilOilfilterdilutedclogged.reading.byfuel.
1)Consultanexperttechnician
AdditionalServiceandAdjustingSTORINGTHEENGINE
51Iftheengineistobestoredforthewinterperiodorisleftunusedforalongtime,takethefollowingmeasures:1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.
Cleantheengineexternally.
Cleanthefueltankandwaterseparator.
Replacethefuelfilterandprefilter(Stanadyne).Replace(orclean)theairfilter.
Addabout5ltroffuelintothefueltankandbleedthefuelsystem.Runtheengineuntilitreachesitsnormalrunningtemperature.Replacetheoilfilter.Changetheengineoil.
Ensurethatcoolant---antifreezemixtureisstrongenough(addantifreeze,ifnecessary).Draintherawwater(=seawater)coolingsysteminmarineenginesasdescribedearlier.Removetheinjectorsandchecktheircondition.
Pourequalquantitiesofpureengineoilintothecylindersthroughtheinjectorholes(useabout0,05ltrforeachcylinder)andcranktheengineafewrevolutionswiththestopleverengaged.Theoilwillnowspreadonthecylinderwalls.
Attachtheinjectorsagain.Fitnewsealrings.
Disconnectthebatteryandensurethatitgetsproperattention(storage).
Cleanthecablelugsandcoattheexposedsurfaceswithprotectiveoil(withCRCorwithgrease).Removethev---beltsandapplygreasetothepulleysandotherenginepartswhichmightrust.Protecttheaircleanerandexhaustpipeopeningsaswellastheelectricalequipmentandtheinstrumentpanelwithplastic.Fillthefueltankwithgasoil.
AFTER---STORAGEATTENTION
1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.
Cleantheenginetoremoveprotectivegrease.Removetheplasticcovers.
Carefullyturnthefanbackandforthtoreleasethecoolantpumpseal(ifstuck).Fitthev---beltsandadjusttheirtension.Checkthecoolantlevel.
Removetherockercoverandlubricatethevalvemechanismwithengineoil.Checktheengineoillevel.
Openslightlythedrainingplugofthefueltankanddraincondensedwaterifpresent.Bleedthefuelsystem.
Checkallelectricalwiresandmakeanynecessaryrepairs.Cleantheterminals.
Pourabout0,2ltrofpureengineoilintotheturbochargerbearinghousing(turbochargedengines).Connectthebattery,fullycharged,inplace.Starttheengine.
Watchtheoilpressureandalternatorwarninglights.
Checkforanycoolant,oilorfuelleaksandmakerepairsasnecessary.
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