AGCO Sisu Power 4th Generation Engines Workshop Manual 837079492 – PDF DOWNLOAD
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AGCO Sisu Power 4th Generation Engines Workshop Manual 837079492 – PDF DOWNLOAD
GENERAL
ТОТНЕ USER
This Workshop Manual is intended to assist with workshop operations and repair work. 4th Generation engines (types 33, 44, 49, 66, 7 4, 84 and 98) are generally of the same construction, so the same repair instructions will usually apply to various engine types. The differences between the various engine types, which affect repair work, are mentioned in the technical data and repair instructions.
- AII measurements are in millimetres and valid when the temperature of the parts is +20° С, unless otherwise stated. Before starting any repair work, please read the safety instructions at the beginning of this book. Make sure that you have all the necessary tools, parts and accessories to hand.
- 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 the work. An engine which has undergone repairs must Ье run in just like а new one. Should the engine require work not described in this manual, please consult your local agent or the Service Department of AGCO SISU POWER lnc., Linnavuori, Finland. То facilitate consulting, find out the following facts about the engine before contacting us:
– engine type
– engine number
– model or equipment
– hours operated or kilometres driven.
This Workshop Manual does not cover the regular service procedure as this is explained in the 4th Generation
series lnstruction Manual.
As AGCO SISU POWER lnc. is continuously developing its products, all rights are reserved to alter the specifications, accessories and the service and repair procedure without separate notice.
TABLE OF CONTENTS:
AGCO Sisu Power 4th Generation Engines Workshop Manual 837079492 – PDF DOWNLOAD
GENERAL
ТО ТНЕ USER 1
SAFEТY INSTRUCTIONS 2
ENGINE ТУРЕ DESIGNATIONS 4
LOCATION OF ТНЕ ENGINE SERIAL NO 4
MARKING OF ТНЕ ЕЕМ 4 CONTROL UNIT 5
LIFTING ТНЕ ENGINE 5
CONSTRUCTION
Technical Data 6
General 7
Cylinder Block 7
Flywheel Housing 7
Valve Mechanism 7
Cylinder Head 8
Crank Mechanism 8
Timing Gears 9
Lubricating System 1 О
Cooling System 1 1
lnlet and Exhaust System 12
TECHNICAL DATA
Cylinder Block 1 3
Cylinder Liners 1 З
Cylinder Head 1 4
Valves and Rockers 1 4
Т appets and Push Rods 1 5
Camshaft 1 5
Crankshaft 1 5
Flywheel 1 7
Balancing Unit 1 8
Timing Gears 1 8
Connecting Rod 1 8
Piston, Rings and Pin 1 9
Lubricating System 20
Oil Pump 20
Coolant Pump 21
Thermostat 2 2
Turbocharger 2 2
TIGHTENING TORQUES 2 3
SPECIAL TOOLS
Cylinder Block 2 4
Timing Gear and Flywheel Housing 2 5
Cylinder Head and Valve Mechanism 26
Crank Mechanism 27
Coolant Pump 28
Fuel System 29
WORK INSTRUCTIONS
1 CYLINDER BLOCK
1 1 Measuring cylinder liner wear 3 1
1 2 Removing cylinder liner 31
1 3 Checking cylinder Ыосk 31
1 4 Changing camshaft bushing 32
1 5 Fitting plug at camshaft rear end 33
1 6 Oversize bushings for camshaft 33
1 7 Fitting plug at camshaft rear end (oversize bushings) 34
1 8 Fitting cylinder liner 34
2 FL YWHEEL HOUSING
2 1 Fitting flywheel housing 37
2 2 Changing crankshaft rear oil seal 37
3 CYLINDER HEAD
3 1 Removing cylinder head 39
3 2 Removing valves 39
3 3 Checking cylinder head 40
3 4 Changing valve guides 40
3 5 Machining valve seat 41
3 6 Changing valve seat rings 41
3 7 Grinding valves 42
3 8 Fitting valves 42
3 9 Fitting cylinder head 42
4 VALVE MECHANISM
4 1 Reconditioning valve mechanism 45
4 2 Changing camshaft / camshaft gear 46
4 3 Adjusting valves 47
5 CRANKSHAFT
5 1 Removing crankshaft 49
5 2 Checking crankshaft 49
5 3 Changing crankshaft gears 50
5 4 Fitting crankshaft 50
5 5 Crankshaft hub piece 51
5 6 Checking element of the rubber damper 52
5 7 Viscose type Vibration Damper 52
6 CONNECTING RODS AND PISTONS
6 1 Removing Pistons Together with Connecting Rods 53
6 2 Changing Connecting Rod Bearings 53
6 3 Checking Connecting Rod 54
6 4 Changing Piston Rings 55
6 5 Checking Pistons 55
6 6 Fitting Piston Pin 56
6 7 Fitting Piston Together with Connecting Rod 5 6
7 COUNTERBALANCE (44- and 49-Engines)
7 1 Removing and DisassemЫing Counterbalance Unit 57
7 2 Reconditioning Counterbalance Unit 57
7 3 Fitting Counterbalance Unit 58
7 4 Changing Crankshaft Gear Rim 58
8 FLYWHEEL
8 1 Changing Starter Ring Gear оп Flywheel 59
8 2 Fitting Flywheel 59
9 TIMING GEAR ASSEMBL У
9 1 Removing Timing Gear Casing 6 1
9 2 Fitting Timing Gear Casing 62
9 3 Fitting the Crankshaft Hub, 98 63
9 4 Power Take-off 64
9 5 Fan Drive Device 64
10 LUBRICATION SYSTEM
10 1 Oil Pressure Regulating Valve 65
10 2 Removing and Dismantling Lubricating Oil Pump 6 5
10 3 AssemЫing and Fitting Lubricating Oil Pump 6 6
10 4 Piston Cooling Nozzles 6 6
10 5 Fitting Oil Sump Gasket 6 7
10 6 Lubricating Oil Cooler 6 7
10 7 Lubricating Oil Quality Requirements 6 8
10 8 Oil Capacities 6 9
10 8 Closed Crankcase Ventilation (CCV) 6 9
11 COOLING SYSTEM
11 1 Quality Requirements of Coolant 7 1
11 2 Thermostat 7 1
11 3 Reconditioning Coolant Pump 7 2
11 4 Coolant Pumps with Heavy Duty Bearings 7 4
11 5 lnstalling the Cylinder Head Connection Part 7 6
1 2 INLET AND EXHAUST SYSTEM
12 1 Checking the Air Cleaner 7 7
12 2 Checking the lnlet and Exhaust Pipes 7 7
12 3 Checking the Turbocharger 7 8
12 4 Fitting the Turbocharger 7 9
12 5 EGR System 8 0
1 3 FUEL SYSTEM
13 1 Тe chnical Data 8 4
13 2 Bleeding Fuel System 8 5
13 3 Measuring Fuel Feed Pressure 8 5
13 4 lnspecting lnjectors 8 6
13 5 High-Pressure Pump 8 8
13 6 Rail 8 9
13 7 Fuel Quality Requirements 9 0
13 8 SCR System 9 1
1 4 ЕЕМ4 ENGINE CONTROL SYSTEM
14 1 Construction of the ЕЕМ4 9 5
14 2 ЕЕМ4 Engine Control System, Description 9 6
14 3 Service Tool of the ЕЕМ4 System 9 6
14 4 Changing the Control Unit (ECU) 9 7
14 5 Wiring Sets 9 8
1 4 6 Sensors of the Engine Control System 100
1 5 ELECTRICAL SYSTEM
1 5 1 Alternators 1 03
1 5 2 Starters 1 06
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