Sisu Diesel Fortius Series Engines Workshop Manual

Sisu Fortius

Sisu Diesel Fortius Series Engines Workshop Manual PDF. This Workshop Manual is intended to facilitate workshop operations and repair work. Fortius series engines (types 33, 44, 66, 74 and 84) are mainly the same in construction, so the same repair instructions usually apply to different engine types. The differences between the various engine types which affect repair work have been mentioned in 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 the repair work read the safety instructions in the beginning of this book. Make sure that you have all necessary tools, parts and accessories at your disposal. 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 work. An engine which has undergone repairs must be run in just like a new one.

Should the engine require measures 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
– application or equipment
– hours operated or kilometres driven.

In this Workshop Manual the regular service procedure is not handled as this is explained in the Fortius series Instruction Manual.

CONTENTS

GENERAL
TO THE USER
SAFETY INSTRUCTIONS
ENGINE TYPE DESIGNATIONS
LOCATION OF THE ENGINE SERIAL NO
MARKING OF THE EEM 2 CONTROL UNIT
LIFTING THE ENGINE
CONSTRUCTION
Technical data
General
Cylinder block
Flywheel housing
Cylinder head
Valve mechanism
Crank mechanism
Timing gears
Lubricating system
Cooling system
Inlet and exhaust system
TECHNICAL DATA
Cylinder block
Cylinder block, 84-engines
Cylinder liners
Cylinder head
Valves, rockers and tappets
Camshaft
Crankshaft
Crankshaft, 84-engines
Flywheel
Balancing unit, 44-engines
Timing gears
Timing gears, 84-engines
Connecting rod
Piston, rings and pin
Piston, rings and pin, 84-engines
Lubricating system
Oil pump, 33- and 44-engines
Oil pump, 66-, 74- and 84-engines
Coolant pump, 33- and 44-engines
Coolant pump, 66- and 74-engines
Coolant pump, 84-engines
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
A. Measuring cylinder liner wear
B. Removing cylinder liner
C. Checking cylinder block
D. Changing camshaft bushing
E. Fitting plug at camshaft rear end
F. Oversize bushings for camshaft
G. Fitting plug at camshaft rear end (oversize bushings)
H. Fitting cylinder liner
2. FLYWHEEL HOUSING
A. Fitting flywheel housing
B. Changing crankshaft rear oil seal
3. CYLINDER HEAD
A. Removing cylinder head
B. Removing valves
C. Checking 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
4. VALVE MECHANISM
A. Reconditioning valve mechanism
B. Changing camshaft / camshaft gear
C. Adjusting valves
5. CRANKSHAFT
A. Removing crankshaft
B. Checking crankshaft
C. Changing crankshaft gears
D. Fitting crankshaft
E. Crankshaft hub piece
F. Checking element of the rubber damper
G. Viscose type vibration damper
H. Changing crankshaft pulley / vibration damper
6. CONNECTING RODS AND PISTONS
A. Removing pistons together with connecting rods
B. Changing connecting rod bearings
C. Checking connecting rod
D. Changing piston rings
E. Checking pistons
F. Fitting piston pin
G. Fitting piston together with connecting rod
7. COUNTERBALANCE (44-engines)
A. Removing and disassembling counterbalance unit
B. Reconditioning counterbalance unit
C. Fitting counterbalance unit
D. Changing crankshaft gear rim
8. FLYWHEEL
A. Changing starter ring gear on flywheel
B. Fitting flywheel
9. TIMING GEAR ASSEMBLY
A. Removing timing gear casing
B. Reconditioning idler gear
C. Fitting timing gear casing
D. Idler gear with bevelled ball bearings
E. Power take-off
9. TIMING GEAR ASSEMBLY
A. Removing timing gear casing
B. Fitting timing gear casing
C. Fan drive device
10. LUBRICATION SYSTEM
A. Oil pressure regulating valve
B. Removing and dismantling lubricating oil pump
C. Assembling and fitting lubricating oil pump
D. Piston cooling nozzles
E. Fitting oil sump gasket
F. Lubricating oil cooler
G. Lubricating oil quality requirements
H. Oil capacities
11. COOLING SYSTEM
A. Quality requirements of coolant
B. Thermostat
C. Reconditioning coolant pump
D. Coolant pumps with heavy duty bearings
E. Reconditioning the coolant pump
12. INLET AND EXHAUST SYSTEM
A. Checking air cleaner
B. Checking inlet and exhaust pipes
C. Checking turbocharger
D. Fitting turbocharger
13. FUEL SYSTEM
Injectors
A. Removing injectors
B. Inspecting injectors
C. Reconditioning injectors
D. Fitting injector in engine
E. Fitting delivery pipes
Bosch VE rotary pump
Technical data
Fuel system, description
A. Bleeding the fuel system
B. Measuring the fuel feed pressure
C. Removing the fuel injection pump
D. Fitting the fuel injection pump
Bosch VP 30 and VP 44 rotary pump
Technical data
Fuel system, description
A. Bleeding fuel system
B. Measuring fuel feed pressure
C. Removing fuel injection pump
D. Fitting fuel injection pump
E. Fuel quality requirements
14. ENGINE CONTROL SYSTEM EEM 2
Construction of the EEM 2
EEM 2 Engine Control System, description
Service tool of EEM 2 system
A. Changing of Control Unit (ECU)
B. Sensors of Engine Control System
15. ELECTRICAL SYSTEM
A. Alternators
B. Starters
16. OPTIONAL EQUIPMENT
A. Compressor (Bendix)
B. Compressor (Knorr)

Language: English
Format: PDF
Pages: 104

Sisu Diesel Fortius Series Engines Workshop Manual