Sisu Diesel 645 Series Workshop Manual Download

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Technical Data

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TECHNICAL DATA

Cylinder block

Holes for guide pins

13,250...13,320 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main bearing housing diameter

96,000...96,025 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder liner location, diameter:

--- upper end

125,014...125,054 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- lower end

121,000...121,040 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inner diameter of camshaft bushings (fitted)

50,010...50,070 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height of cylinder block

468,900...469,100 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder liners

Protrusion of cylinder liner above cylinder block top face

0,030...0,080 mm

. . . . . . . . . . . . . . . . . . . . . . . . . .

Max. permissible height difference between liners (under same head)

0,02 mm

. . . . . . . . . . . . . .

Outer diameter of cylinder liner guide:

--- at upper end of liner

124,975...125,000 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- at lower end of liner

120,961...120,986 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liner bore

111,000...111,022 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height of cylinder liner flange

9,03...9,05 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height of cylinder liner flange, 1st oversize, part no 8368 59581

9,08...9,10 mm

. . . . . . . . . . . . . . . . . . . .

Height of cylinder liner flange, 2nd oversize, part no 8368 59582

9,13...9,15 mm

. . . . . . . . . . . . . . . . . . .

Height of cylinder liner flange, 3rd oversize, part no 8368 59583

9,23...9,25 mm

. . . . . . . . . . . . . . . . . . .

Outer diameter of cylinder liner flange

131,700...131,800 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder head

Height of cylinder head

104,800...105,000 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height of cylinder head after repair grinding (minimum)

104,000 mm

. . . . . . . . . . . . . . . . . . . . . . . . . .

Inside diameter of valve guide (not fitted)

9,000...9,015 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outside diameter of valve guide

16,028...16,039 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of valve guide bore in cylinder head

16,000...16,018 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Position of valve guide top above cylinder head surface

21 mm

. . . . . . . . . . . . . . . . . . . . . . . . . .

Depth of valve head face below cylinder head surface:

--- inlet valve

0,7±0,05 mm (max 2,20 mm)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- exhaust valve

0,6±0,05 mm (max 2,20 mm)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Angle of valve seat:

--- inlet valve

+20’

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- exhaust valve

+20’

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width of valve seat:

--- inlet valve

2,9...3,7 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- exhaust valve

1,3...2,3 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of exhaust valve seat ring

44,070...44,132 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of exhaust valve seat rings recess

44,000...44,025 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of exhaust valve seat ring (overhaul part 8366 52269)

44,270...44,332 mm

. . . . . . . . . . . . . . . . . . . .

Diameter of exhaust valve seal ring recess (overhaul part 8366 52269)

44,200...44,225 mm

. . . . . . . . . . . . . .

Diameter of inlet valve seat ring

48,570...48,632 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of inlet valve seat ring recess

48,500...48,525 mm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of inlet valve seat ring (overhaul part 8368 55347)

48,770...48,832 mm

. . . . . . . . . . . . . . . . . . . . . . .

Diameter of inlet valve seat ring recess (overhaul part 8368 55347)

48,700...48,725 mm

. . . . . . . . . . . . . . . . .

Summary of Contents for 645 Series

Page 1: ...WORKSHOP MANUAL SISUDIESEL 645 8368 41000 ...

Page 2: ...N 37240 Nokia Finland Telephone 358 3 341 7111 E mail info sisudiesel sisudiesel com www sisudiesel com Diesel Engines After Sales Telefax 358 3 341 7333 Sisu Diesel Inc takes no responsibility for any damages caused because of incorrect information in this manual ...

Page 3: ... gears 0 16 Lubricating system 0 17 Cooling system 0 18 Inlet and exhaust system 0 19 WORK INSTRUCTIONS 1 CYLINDER BLOCK A Measuring cylinder liner wear 1 1 B Removing cylinder liner 1 1 C Checking cylinder block 1 1 D Changing camshaft bushing 1 1 E Fitting plug at camshaft rear end 1 2 F Oversize bushings for camshaft 1 3 G Fitting plug at camshaft rear end oversize bushings 1 3 H Fitting cylind...

Page 4: ...ng nozzles 10 2 E Oil cooler 10 3 G Lubrication oil quality requirements 10 4 11 COOLING SYSTEM A Quality requirements of coolant 11 1 B Thermostat 11 1 C Reconditioning coolant pump 11 2 12 INLET AND EXHAUST SYSTEM A Checking air cleaner 12 1 B Checking inlet and exhaust pipes 12 1 C Checking turbocharger 12 1 D Fitting turbocharger 12 2 E Fitting intercooler 12 3 13 FUEL SYSTEM IN LINE FUEL INJE...

Page 5: ...e 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...

Page 6: ...ing the engine Safe lifting of the engine is done with a lifting device where the lifting force effects the lifting ears vertically A Engine lifting ears Engine weight dry without flywheel and electrical equipment self carrying and casted oil sump 826 kg normal oil sump 690 kg ...

Page 7: ... noise injuries Stop the engine always before service or repair work Avoid touching the exhaust manifold turbocharger and the other hot parts of the engine Open the radiator cap with care when the engine is hot as the cooling system is pressurised The cooling liquid and lubrication oil of a hot engine causes injuries when touching the skin Open fire smoking and sparks should not be allowed near th...

Page 8: ...1 66200 Lever for compressing valve spring 19 9052 47200 Counter nut for lever above 20 9101 66000 Milling tool for injector seat 21 9052 46660 Drift for 36 mm cup plug 22 9101 65800 Drift for removing valve guide 23 9101 65900 Drift for fitting valve guide 24 9024 55800 Spanner for crankshaft nut 25 9103 94700 Drift for fitting crankshaft gears 26 9103 41300 Drift for fitting coolant pump bearing...

Page 9: ...Special Tools 0 5 1 2 3 4 6 7 8 9 10 5 11 12 13 14 15 16 17 18 19 21 22 23 24 26 25 29 27 30 31 20 28 39 38 37 40 3 32 33 34 35 36 ...

Page 10: ...g temperature and starting revs Max permitted difference between cylinders 3 0 bar FUELSYSTEM Injection pump Bosch in line type Fuel Gas oil see page 13 13 Feed pressure overflow valve opening pressure 0 6 1 0 bar static 2 7 bar Injection order 1 5 3 6 2 4 Injector Four five hole nozzle Opening pressure of the nozzle See page 14 3 Adjusting pressure of the nozzle See page 14 3 Fuel filter CAV LUBR...

Page 11: ...700 131 800 mm Cylinder head Height of cylinder head 104 800 105 000 mm Height of cylinder head after repair grinding minimum 104 000 mm Inside diameter of valve guide not fitted 9 000 9 015 mm Outside diameter of valve guide 16 028 16 039 mm Diameter of valve guide bore in cylinder head 16 000 16 018 mm Position of valve guide top above cylinder head surface 21 mm Depth of valve head face below c...

Page 12: ...r head 16 000 16 018 mm Protrusion of valve guide top above cylinder head surface 21 mm Depth of valve face below cylinder head surface inlet valve 0 7 0 05 mm max 2 20 mm exhaust valve 0 6 0 05 mm max 2 20 mm Valve spring free length 69 8 mm Spring pressure when spring compressed to a length of 48 6 mm 327 17 N 37 4 mm 500 23 N Rocker arm shaft diameter 22 970 22 990 Diameter of rocker arm bore 2...

Page 13: ...ard 2 955 2 965 mm 1st undersize 0 25 mm 3 080 3 090 mm 2nd undersize 0 50 mm 3 205 3 215 mm 3rd undersize 1 00 mm 3 455 3 465 mm 4th undersize 1 50 mm 3 705 3 715 mm Main bearing clearance 0 050 0 127 mm Length of thrust bearing journal journal nearest to flywheel standard 2 standard thrust plates 45 000 45 080 mm 1st oversize one std and one 0 1 mm overthick thrust plate 45 100 45 180 mm 2nd ove...

Page 14: ... 040 mm Outside diameter of piston pin bush std 48 080 48 120 mm Outside diameter of piston pin bush oversize 8363 38606 48 580 48 620 mm Interference fit connecting rod small end bushing connecting rod 0 057 0 120 mm Connecting rod small end bore 48 000 48 025 mm Connecting rod small end bore oversize bush 48 500 48 525 mm Connecting rod big end bore 76 730 76 749 mm Big end bearing shell thickne...

Page 15: ... Lubricating system Oil pressure at normal running temperature at idling speed min 1 0 bar at running speed 2 5 5 0 bar Free length of oil pressure valve spring 71 mm Spring pressure when valve spring is compressed to a length of 52 mm 74 5 N Diameter of oil pressure valve plunger 19 602 19 635 mm Diameter of oil pressure valve cylinder 19 700 19 752 mm Oil filter by pass valve opens at a pressure...

Page 16: ...er Type Opening Fully Max stroke begins at open at mm 8360 15156 ø54 79 C 79 2 C 94 C 7 5 8363 31590 ø67 83 C 83 2 C 95 C 8 Turbocharger Schwitzer S2B Max axial end play 0 14 mm Max radial play1 0 95 mm Turbine housing attaching bolts 17 Nm Nut on end of shaft 15 6 Nm 1 Measured at nut on end of shaft Schwitzer S300 Min axial end play 0 05 mm Max axial end play 0 12 mm Max radial play turbine end ...

Page 17: ...gger bolt M14 180 the bolts for holding the bearing M8 22 Piston cooling valve 30 Oil pump retaining bolts 60 Coolant pump gear nut 180 Exhaust manifold nuts 50 Intake manifold bolts 30 Injection pump gear nut 200 Injector attaching nuts on studs 15 Injector nozzle sleeve 60 Always use the torque values listed in the following tables when specific torque values are not available M8 M10 Cast iron 3...

Page 18: ...ed in grooves in the cylinder block The upper part is sealed by the cylinder head gasket The camshaft is located in the cylinder block 645 engines have separate bearing sleeves in all camshaft bearing loca tions The drilling for the camshaft rear end is covered with a plug There are spaces on both sides of the rear main bearing for guide bearing shims the crankshaft thrust bearings Flywheel housin...

Page 19: ...ted at the front end of the crankshaft They are a press fit and drive the idler wheel and oil pump In addition the front end of the crank shaft has splines for the hub of the ribbed V belt pulley An oil deflector ring is fitted between the hub and gear wheel The crankshaft is supported on the cylinder block by main bearings which are placed on both sides of each cylinder Thus there is one main bea...

Page 20: ...coolant pump If the engine is equipped with the broad timing gear casing there is a separate drive unit for a hydraulic pump or a com pressor The drive unit is driven via a small idler gear The idler gear is supported with a bevelled ball bearing on the shaft on the front face of the cylinder block Narrow timing gear casing 1 Camshaft gear 2 Idler gear 3 Injection pump gear 4 Coolant pump gear 5 C...

Page 21: ...s is the bottom of the piston cooled with oil spray always when the oil pressure is higher than 3 bar The oil pressure regulating valve is located on the right hand side of the engine The valve regulates the lubricating oil pres sure so that it is kept constant regardless of the engine speed Oil pressure is about 2 5 5 bar depending on revs oil quality and temperature and at engine idling speed th...

Page 22: ...p has separate ball bearings In 645 engines there are two separate thermostats where one of them is steering the by pass of coolant liquid The thermostats differ in types and opening temperatures When the coolant temperature is below the thermostat opening temperature the coolant A circulates through the by pass hole into the coolant pump The smaller single acting ther mostat 1 opens first at 79 C...

Page 23: ...turbocharger and the turbo charger and the intake manifold The exhaust manifold is attached to the cylinder head with elongated stud bolts without a separate gasket Retightening of the manifold bolts is unnecessary The turbocharger is turbo compressor driven by exhaust gas The compact design of the turbocharger is sensitive to react even during low revolutions The turbocharger is lubri cated and c...

Page 24: ...uller 9104 51500 C Checking cylinder block 1 Clean the cylinder block and all oil ways 2 Check the cooling channels and remove the scale and sediment to ensure engine cooling 3 Check the tightness of the cup plugs and threaded plugs in the cylinder block as well as the condition of the cylinder block and sealing faces 4 Measure the wear of the camshaft bearing points com pare with rated Note If it...

Page 25: ...e oil groove on the outside the groove was earlier on the cam shaft As spare part the earlier bushing always be replaced with the new one Fit the hole of the new bushing in 30 angle from horizontal level as picture shows The bushing is after assembly in its correct measures no need for machining Order no Hole diameter 1 8363 22610 55 62 55 65 2 8368 52460 55 42 55 45 3 8368 52459 55 22 55 25 4 836...

Page 26: ...r diam eters Note the position of the oil hole It is unnecessary to ream the bushing because it has a correct inner diameter when it is fitted in place G Fitting plug at camshaft rear end oversize bearing bushings 41 7 The camshaft rear end plug is replaced with plug 8363 24391 and o ring 6146 05125 after machining Use plate 8361 24210 in those engines where the flywheel housing is not covering th...

Page 27: ...sure the cylinder liner height with a dial gauge and holder 9025 79200 Zero the dial gauge against a flat surface for example the cylinder block face Measure each liner in four places The height of the liner above the cyl inder block face should be 0 03 0 08 mm The height differ ence between cylinder liners under the same cylinder head must not exceed 0 02 mm nor must an intermediate cylinder line...

Page 28: ...s into the grooves in the cylinder block and lubricate them with a liquid soap not with engine oil 41 12 9 Press the cylinder liners into the cylinder block It should be easy to press them fully home Make sure that the liners do not rise up after fitting ...

Page 29: ... in the holes A and E 9104 52700 42 3 4 Centre the housing with centring tool 9104 52700 Note This is important of the engines with a turbine clutch Fit the tension pins with drift 9025 98700 5 Tighten the fixing bolts the inner ring socket head bolts to 60 Nm and outer ring hexagonal bolts to 110 Nm B Changing crankshaft rear oil seal 1 Lift out the engine Remove the clutch assembly and poss ible...

Page 30: ... DRY NOT OILED T O 42 5 O Sleeve T Seal Put the sleeve against the crankshaft rear end so that the sleeve is on the shaft bevelling Push the seal over the sleeve on the shaft and further against the flywheel housing 9104 52600 42 6 Remove the sleeve and hit the seal into position with the fit ting tool 9104 52600 ...

Page 31: ...urn and then remove them Remove the cylinder head B Removing valves Ensure that valves which are to be re used are marked so that they are fitted in their original locations 9052 47200 43 1 9101 66200 1 Install the counter screw 9052 47200 for the valve spring installing tool in the rocker arm cover bolt For the valves in the middle use a bolt of suitable length 2 Compress the valve springs using ...

Page 32: ... drift 9101 65800 Clean the valve guide locations 2 Lubricate the outside of the new guides and fit them using drift 9101 65900 which ensures the correct fitting height 21 mm over the spring face 21 mm 9101 65900 43 6 3 The guides are the same for the inlet and exhaust valves Ensure that the steepest chamfer on the guide faces the valve head Check that the valves do not bind in the guides E Machin...

Page 33: ... a difference in the sealing surface angles Thus there is a very narrow sealing surface which seals effec tively even after prolonged running A B 43 9 C A B C Inlet 35 20 35 20 0 7 0 05 mm max 2 20 mm Exhaust 45 20 45 20 0 6 0 05 mm max 2 20 mm 1 Grind the damaged valve disc with a valve refacer Adjust angles to 45 20 for exhaust valves and 35 20 for inlet valves 2 If the edge of the valve head is...

Page 34: ...ead bolts the exhaust manifold can damage if the heads are not parallel Clean and lubricate and fit the bolts 43 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 Picture above show the correct tightening order of the cylin der head bolts The order has also been marked on the cylin der heads 5 Tighten the cylinder head bolts progressively as follows 1 First tightening to 80 Nm 2 Tightening of 90 3 Ti...

Page 35: ...rder Note the correct position of the shaft and the bearing brackets The split side of the bracket and the shaft oil holes must be turned to the valve side see figures above Fit the other end plug B Changing camshaft camshaft gear 1 Remove the inlet pipe between the turbocharger and the intake manifold Remove the valve cover and the breather pipe Remove the rocker arm mechanism 2 Remove the radiat...

Page 36: ...l drilling which is not at the same place as the oil drilling of the cylinder block 30 angle upwards from the hori zontal level C Adjusting valves 0 35 44 6 The valve clearance which can be adjusted on a hot or cold engine is 0 35 mm for both inlet and exhaust valves The clearance is adjusted when the respective piston is at T D C in the compression stroke The valves for the different cylin ders a...

Page 37: ...re the I D with a dial gauge which has been zeroed to the dimensions obtained in point 2 With this method the indicator shows the actual bearing clear ance Measure in several points in case the worn bearing housing is not round 45 2 4 If the bearing clearance exceeds 0 18 mm for main bear ings or 0 14 mm for connecting rod big end bearings with new bearing shells the bearing journals on the cranks...

Page 38: ...ing a dial gauge The correct end float is 0 10 0 38 mm If the end float is too large oversize thrust bearings should be fitted Note Bearing shells should never be reamed or machined in any other way nor should the sides of the bearing caps be filed E Checking vibration damper 1 Housing 2 Damper mass 3 Liquid cavity 4 Bushing In the 645 engines the crankshaft front end incorporates a torsional vibr...

Page 39: ...ting rods from engine number L 1110 The bushing 8368 64288 has a Æ 4 mm oil hole therefore nodril ling after assembly is needed Scrape the bushing to correct dimension Note The connecting rod can if needed be fitted with a 0 5 mm oversize bushing 8363 38606 See technical data point connecting rod Big end bearing 1 Fit the bearing shells together and tighten the screws 2 Measure the I D using a cyl...

Page 40: ...070 g J 8363 52756 3071 3090 g K 8363 52757 3091 3110 g L 8363 52758 3111 3130 g M 8363 52759 3131 3150 g N 8363 52760 3151 3170 g 0 8363 52761 3171 3190 g P 8363 52762 3191 3210 g R 8363 52763 3211 3230 g S 8363 52764 3231 3250 g T 8363 52765 3251 3270 g U 8363 52766 3271 3290 g V 8363 52767 3291 3310 g X 8363 52768 3311 3330 g Y 8363 52769 3331 3350 g Z 8363 52770 3351 3370 g New connecting rod ...

Page 41: ...ring gap by pushing one piston ring at a time into the cylinder bore The piston ring gap must not exceed 1 mm on 1 and 3 piston rings and 1 3 mm on 2 pis ton ring 4 Fit the piston rings on the piston using the piston ring pliers Ensure that the rings are fitted in the correct groove and that TOP or the manufacturer s designation faces upwards 46 11 E Checking pistons Check the condition of the pis...

Page 42: ... rod and bearing cap Note the position of the bearing shells 2 Lubricate piston rings and cylinder bore Ensure that the piston ring gaps are spread around the piston 46 14 9105 18700 3 Use a piston ring strap or preferably a fitting tool 9105 18700 Fit the piston with the marking on the connecting rod weight class facing the camshaft an arrow on the piston must point forward 4 Lubricate the big en...

Page 43: ...cal 3 Tighten the flywheel retaining screws evenly to a torque of 200 Nm Note Flywheel delivered as spare parts do not have injection timing mark Make the marking on the new flywheel in con nection with installation 4 Rotate the crankshaft until the piston of the 1st cylinder re aches its top dead centre Drop cyl no 1 inlet valve down against the piston head Set the dial gauge on top of the valve ...

Page 44: ...pump can remain in place In which case disconnect all leads and pipes from the pump and loosen bottom mounting from the pump 7 Unscrew the idler gear bolts and remove the idler gear broad timing gear casing 8 Extract the camshaft Note If the cylinder head and valve mechanism have not been removed the tappets must be prevented from falling down see instruction point 4 B 9 Remove the timing gear cas...

Page 45: ...ver apply sealing compound to the thread and fit the cover Hit in the tension pins Note If the crankshaft oil throwing ring is removed fit it drift 9103 94900 before fitting the cover 6 Tighten the cover bolts Remove the guide pin fit the idler gear shim and tighten the bolt 180 Nm 9103 94600 48 6 7 Fit the protective plate into the bottom of the seal position and fit the crankshaft front seal wit...

Page 46: ...les and housing holes Tighten the idler gear bolts through the guide unit holes tighten 180 Nm Remove the guide unit 48 10 6 Check the tooth backlash which should be 0 05 0 25 mm 7 Fit the drive unit shaft and camshaft axial controller in the front cover apply sealing compound to the thread Fit the cover and hit in the tension pins Observe the idler gear shaft bolt seals Fit the drive unit rear be...

Page 47: ...bbed belt that the starting position of the tensioner is determined by the mounting hole place B Fan drive device 49 3 350 Nm 1 Assemble the drive device as the picture shows Fit inner bearing and circlip Fill the bearing housing partially with heat resistant ball bearing grease NLGI 2 Fit the intermediate sleeve outer bearing and circlip Note the position of the outer bearing as assembling 2 Pres...

Page 48: ... the spring housing and bolt should be turned downwards Note From engine number J 14016 The engines are equipped a new type of oil pressure valve In the construction of the new valve the hydraulic vibrations are damped it is more reliable and it gives the best optimised pressure level 410 2 Loctite 638 B Removing and dismantling lubri cating oil pump 1 Drain the engine oil and remove the oil sump ...

Page 49: ...h shims between the pump body and the cylinder block shim 0 2 mm order no 8360 07871 One shim increases decreases the backlash about 0 07 mm Note When measuring the tooth backlash the engine should be the correct way up as the crankshaft bearing clear ance affects the tooth backlash 5 Connect suction and pressure pipes together with new seals Fit the oil sump and fill in the lubrication oil D Fitt...

Page 50: ...to a container 3 Remove the oil cooler from the engine Open the cooler housing and remove the guide plate Unscrew the cell bolts and remove cell from the body Clean the all parts Fitting oil cooler 1 Assemble the oil cooler using new gaskets Fit the cell to the body The oil side can be pressure tested before fitting the housing Test pressure is 5 1 bar 2 Push the guide plate between the cell and t...

Page 51: ...C 410 12 D Lubrication System 10 4 G Lubricating oil quality requirements Turbocharged engines API CF 4 CG 4 CH 4 ACEA E2 E3 96 E4 98 E5 99 Low emission E engines API CG 4 CH 4 ACEA E3 96 E4 98 E5 99 H Oil capacities A min 20 5 max 24 5 ltr B min 25 0 max 29 5 ltr C min 42 0 max 46 5 ltr D min 17 0 max 21 0 ltr ...

Page 52: ...at 83 C In 645 engines there are no separate winter thermostats To remove 1 Drain the cooling system so that the coolant level is below the thermostats position and disconnect the top hose from the water outlet cover 2 Remove the outlet cover and the thermostats Clean the sealing surfaces Check the function of the thermostat as follows Lower the thermostat into a vessel of boiling water so that th...

Page 53: ... also contains all seals see Parts Catalogue 6 Tap the new shaft seal in the body using a drift 9103 41000 Grease bearings with heat resistant ball bearing grease NLGI 2 Press in the bearings and fit the circlip 7 Fit the shaft in such a way that the pressing force is not transmitted by the bearing balls 8 Hit the water seal into its position with tool 9103 41100 Press the impeller to its position...

Page 54: ...scratches machine or renew the intake manifold Ensure that the cylinder heads are parallel 3 Fit a new gasket and fasten the intake manifold Tighten the manifold fixing screws to a torque of 30 Nm Fasten the air pipes carefully 4 Check that the exhaust manifold is air tight Tighten the nuts to 50 Nm and inspect for any damage cracks deforma tion corrosion etc Check also the connection between the ...

Page 55: ...e injection pump critically affects the function of the turbocharger The injection pump should be adjusted according to the manufacturers instructions 1 Check the tightness of the intake and exhaust manifolds and that they are securely fastened Ensure that there are no loose carbon or rust particles or other foreign objects in the manifolds 2 Connect the turbocharger to the exhaust manifold and ti...

Page 56: ... cooler with thrust plates to the intake manifold Note A conventional gasket is not used but apply a continu ous bead of silicone sealing to the sealing surface Leak test pressure for the cooler Water side 2 9 bar Air side 3 5 bar 3 Attach the boost air pipe to the cooler housing and coolant pipes to the cooler Fill the cooling system ...

Page 57: ...der 1 5 3 6 2 4 Direction of rotation clockwise Diameter of pump piston 3000 series 12 mm 7100 series 12 mm Stroke 3000 series 11 mm 7100 series 12 mm Injection advance see injection pump adjusting values Fuel feed pump Type Bosch FP KG24P307 Construction piston pump separate hand pump Fuel feed pressure overflow valve opening pressure 0 6 1 0 bar Pressure from fuel feed pump without overflow valv...

Page 58: ...e reservoir of the thermostart device or from the overflow valve of the injection pump regulated by the magnet ic valve 7 6 Injector 7 Solenoid valve 8 Glow plug 9 Overflow valve Symptoms of dirty or faulty injectors are Knocking is an indication that one of the injectors is faulty When a cold engine ticks over a certain amount of knocking is unavoidable If the engine knocks after it has reached n...

Page 59: ...essure which fills the high pressure pump el ements with fuel is created by a piston pump which is at tached to the side of the fuel injection pump The piston pump is driven from an eccentric on the camshaft of the injection pump The fuel feed pump supplies more fuel than the injec tion pump needs The excess fuel flows through the overflow valve back to the fuel tank The fuel cools the injection p...

Page 60: ...pprox 8 This should be borne in mind when checking the fuel in jection timing This groove improves the cold starting prop erties of the engine It works fully automatically When the en gine has stopped the control rod in the injection pump turns the plungers so that the starting groove faces towards the re lease passage When the engine has started and when the in jection pump has reached a certain ...

Page 61: ...the spring rests against the threaded guide sleeve 2 The spring tension can thus be changed in certain limits adjusted in factory With thread equipped pin 1 is attached to the membrane The lower end of the pin transmits movement of the mem brane via an angle piece to the injection pump control rod 3 When increased boost pressure presses the membrane downwards also the pin moves downwards against t...

Page 62: ...when the pipe or reservoir has been emptied during repair work etc This prevents damages to the glow plug caused by lack of fuel during starting System with the magnetic valve 413 10 1 Disconnect the electrical wire from the glow plug and the fuel pipe 2 Connect electricity to the magnetic valve and rotate the en gine until fuel comes out from the fuel pipe connection 3 Tighten the pipe connection...

Page 63: ...alves 1 Clean the feed pump Disconnect fuel pipes to the feed pump Remove the feed pump 413 12 2 Secure the pump in a vice provided with soft jaws Loosen the tappet body from the pump and remove the piston seal rings suction valve and the spring 3 Detach from the pump body the outlet side threaded con nector in which is placed the pressure valve 4 Rinse the valves with clean fuel and check the fun...

Page 64: ...on and push the pin into the hole Refit the plug 8 Take out the locator from the flywheel hole Usage of the electrical inspection device Bosch KDEP 1601 0 986 612 174 Also in electrical device can be used to check the timing 1 Turn the crankshaft to a position where the 1 st cylinder pis ton reaches its compression stroke top dead centre Then turn the crankshaft backwards until the mark hole on th...

Page 65: ...and that the engine is at normal operating temperature 3 Start the engine and loosen the adjusting screw of the addi tional spring so that it does not affect the idling speed 413 18 4 Adjust the idling speed using the adjusting screw to about 20 30 rpm below rated speed and lock the adjusting screw 5 Run the engine a few times and ensure that the idling speed remains as set 6 Tighten the adjusting...

Page 66: ... Connect the supply and return fuel lines Connect the lubri cating oil line Use new sealing washers Fit the delivery pipes 6 Bleed the fuel system see instruction 13 A 7 Fit the coolant pump and fill the cooling system K Removing injectors 1 Clean the injectors and the area around them Disconnect the delivery pipes and the leak off pipes 9104 53700 413 21 2 Remove the injector attaching nuts and r...

Page 67: ... nozzles are the test results reliable With used nozzles there is no chattering creaking sound when the tester is pumped at a certain rate This has to do with the de sign of the nozzles However with a rapid pumping on the tester handle it should be possible to hear the chattering creaking sound or and see a mist of the fuel jetting out Tightness of nozzle Press down the tester pump lever until the...

Page 68: ... on purpose It is therefore important that the injector is fitted correctly in the cylinder head The connection for the leak off line should be facing the valve mechanism 3 Fit the attaching clamp and tighten the nuts evenly to 15 Nm 4 Connect the leak off line together with new sealing washers and connect the delivery pipes Note The screw studs in the cylinder head for the injectors should only b...

Page 69: ...perature of 15 C The correction in caused by the change of fuel qualities is seen in the attached figures FIG A Engine output dependence on fuel temperature 35 C is the reference temp correction 0 The fuel temperature is not only a function of ambient condi tions but also varies according to the fuel system of the ap plication tank size and location return flow etc FIG B Engine output dependence o...

Page 70: ... 14 2 P1A 678 0 0 500 150 152 10 7 0 0 550 12 14 3 8 4 2 645 DSBIE MF 8280 8363 54708 PES 6P 120A 14 1 2 1100 172 174 11 8 12 2 1120 1180 1200 8363 54638 MF 8180 8 002 320RS 3382 2200 1 2 950 180 182 12 2 12 6 8363 30239 950 1 2 750 181 183 12 2 12 6 RSV 200 LDA 0 75 0 80 500 11 9 0 0 500 110 113 8 7 9 1 0 0 475 7 10 5 5 645 DSBIE MF 8170 8363 54740 PES 6P 120B 14 1 2 1100 157 159 10 5 10 9 1120 1...

Page 71: ... rpm 645 DSBIEL MF 7274 8368 54811 PES 6P 120A 12 2 0 1000 230 232 13 2 13 6 1020 1065 1085 8 009 320RS 7437 2000 2 0 500 222 224 13 2 13 6 A 1100 LDA RSV 550 1000 234 1 2 500 212 214 13 3 P1A 678 0 0 500 150 152 10 7 0 0 550 12 14 3 8 4 2 645 DSIM BONI 8368 54775 PES 6P 120A 12 1 8 1000 242 244 14 1 14 5 1010 1080 1100 8 005 320RS 7437 2000 1 8 800 14 0 14 4 C 850 LDA RSV 295 1 2 500 212 214 13 0...

Page 72: ...Opening pressure bar Setting pressure bar 1 Adjusting plate no 1 00 2 00 mm Code C 8363 54615 Bosch P 8363 54611 4 250 8 258 8363 40907 8363 40925 8368 54929 Stanadyne M 8368 54930 5 270 8 278 8368 62000 8368 62020 234 1 Value to be used when adjusting the opening pressure of a new or used injector ...

Page 73: ...127 45 A 0 25 ohm A 127 65 A 0 18 ohm Rotor resistance 2 9 ohm Regulating voltage 13 6 14 4 V Tightening torques 1 Shaft nut 60 Nm 2 Assembling screws 5 5 Nm 3 Phase connection M5 4 0 Nm 4 Regulator screws 2 5 Nm 5 Main connection 4 0 Nm 1 2 3 4 5 2 1 A 127 45 A 65 A AC 5 RS 415 1 CAV AC 5 RS 24 V 55 A Sisu Diesel no 8353 39422 Nominal voltage 24 V Output 2000 r min 27 A 3000 r min 42 5 A 4000 r m...

Page 74: ...5 Joint W M5 2 7 3 8 Nm 6 Joint D M4 1 6 2 3 Nm 7 Joint B M8 7 5 8 0 Nm 1 2 3 4 6 5 7 1 4 5 6 2 7 3 415 2 100 A 80 A Bosch N1 28 V 0 100 A Sisu Diesel no 8353 40374 Nominal voltage 24 V Output warm generator testing voltage 26 V 2000 r min 26 A 3500 r min 72 A 7000 r min 94 A Min slip ring diameter 26 8 mm Brush length when new 19 mm Min brush length 5 mm Rotor resistance 7 5 8 2 ohm Stator resist...

Page 75: ... 2 7 3 8 Nm 4 Joint W M 5 2 7 3 8 Nm 1 2 3 4 415 3 Bosch NC 14 V 70 120 A Sisu Diesel no 8368 40939 Nominal voltage 12 V Output 13 5 V 2000 r min 79 A 4000 r min 111 A 6000 r min 120 A Charge begins 1200 r min Max allowed speed 12 000 r min Min slip ring diameter 14 9 mm Brush length when new 12 5 mm Min brush length 5 mm Tightening torques see figure above 1 Shaft nut 60 70 Nm 2 Joint B M8 10 Nm ...

Page 76: ...V Min slip ring diameter 31 5 mm Brush length when new 12 mm Min brush length 5 mm Tightening torques 1 Shaft nut 70 Nm 2 Assembling screws 4 1 5 5 Nm 3 Regulator screws 1 6 2 3 Nm 4 Joint B M6 4 8 6 8 Nm 5 Joint W M5 2 7 3 8 Nm 6 Joint D M4 1 4 2 0 Nm 7 Joint B M8 7 5 8 0 Nm 1 4 5 6 2 7 3 415 3 1 ...

Page 77: ...commutator diameter 38 mm Tightening torques 1 Solenoid battery jointing 12 Nm 2 Solenoid retaining screws 6 Nm 3 Fork link nut 20 Nm 4 Assembling screws 11 Nm 5 Earth joint 8 Nm 0 14 1 14 1 2 3 4 5 415 4 Magneti Marelli Bosch JF R 24 V 4 kW Sisu Diesel no 8353 30965 Bosch JF R 24 V 4 kW 2 pole Sisu Diesel no 8361 30388 Values unloaded Running speed 7000 r min Amperage 85 A Voltage 23 V Values wit...

Page 78: ...n engagement lever 12 Nm Contact screws on solenoid switch M8 8 5 Nm Contact screws on solenoid switch M10 13 Nm Iskra AZJ3247 12 V 3 6 kW z11 Sisu Diesel no 8366 40940 Values unloaded Running speed 10 000 r min Amperage 140 A Voltage 11 V Values with armature locked Running speed 0 r min max Amperage 1756 A Voltage 5 3 V Torque 47 Nm Brush length new 23 mm Min brush length 13 mm Brush spring tens...

Page 79: ...agement lever 12 Nm Contact screws on solenoid switch M8 8 5 Nm Contact screws on solenoid switch M10 13 Nm Iskra AZJ3256 24 V 4 kW z11 2 pole Sisu Diesel no 8366 64355 Values unloaded Running speed 10 000 r min Amperage 80 A Values with armature locked Running speed 0 r min max Amperage 1200 A Torque 70 Nm Brush length new 23 mm Min brush length 13 mm Brush spring tension 30 35 N Tightening torqu...

Page 80: ...the solenoid through a battery with suitable voltage and keep it energized during installation D Installation of magnetic pick up 1 Rotate the flywheel to a position so that one of the flywheel ring gears teeth are in front of the pick up installation hole 0 75 415 6 2 Turn the pick up in until it comes in contact with the tooth 3 Turn the pick up out turn and tighten the lock nut This way the pic...

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Sisu Diesel 645 Series, Workshop Manual

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